Tech Downloads & Articles - daemon4x4.org

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Subject: E.G.R Removal
Description: Complete removal of the E.G.R system, (2LT-E).

In this picture:

http://daemon4x4.org/portal/uploads/articles/aue9h_vacuum_hoses_reroute.jpg

the green and red encircled areas designate how the hoses should be rerouted. Both ports on the butterfly valve, (encircled red), are connected to the outlet port on the blue V.S.V bolted to the top of the inlet manifold. (The V.S.V outlet port is encircled red).

The inlet port of the V.S.V, (encircled green), is connected directly to the vacuum feed pipe from the alternator which comes via the small metal crossover pipe, (encircled green), attached to the front of the E.F.I crossover tube.

The following picture shows how the hoses will be connected once done.

http://daemon4x4.org/portal/uploads/articles/awbfu_vacuum_hoses_rerouted.jpg

The E.G.R pipe/hose assembly, (encircled blue), will then be disconnected from the system completely. The metal pipes circled in blue are routed below the inlet manifold to two more, larger, V.S.V's, which are also located below the inlet manifold. These valves will also be removed. The following picture shows the parts once they have been removed from the engine bay.

http://daemon4x4.org/portal/uploads/articles/wh7ab_vacuum_valves.jpg

The hose/pipe portion circled in blue is the same one visible, (encircled blue), in the first picture. The pipe circled in red is where the hose which connects to the E.G.R valve is connected. The electrical connectors for those V.S.V's in the engine bay should be completely sealed once the valves are removed, to prevent corrosion incase the assembly ever needs to be refitted.

Now the E.G.R assembly itself can be removed. The pictures below show where the E.G.R assembly is normally located and the complete assembly once removed.

http://daemon4x4.org/portal/uploads/articles/hbpyx_egr_location.jpg
http://daemon4x4.org/portal/uploads/articles/jbkvk_egr_assembly.jpg

The end circled in purple is the part which bolts to the exhaust manifold, just below and to the left of where the exhaust downpipe bolts to the turbo. There are two 12mm nuts securing the flange in place, (which are not easy to access or remove), so some patience will be required for that part. When the exhaust end is removed, make sure you keep the multi-layer steel gasket which you will find there safe, as that will be needed again when the blanking plate is added.

The end circled in green is the part which connects to the inlet manifold. The pipe on the top of the assembly circled in red is where the hose is connected from the pipe on the valve hose assembly in picture three.

Two blanking plates will need to be made to blank off the outlet in the exhaust manifold and the inlet on the inlet manifold. Use the flanges on the E.G.R assembly as templates for cutting those plates and for the location of the plate bolt holes. The plates can be made from mild steel plate, preferably a few millimetres or more in thickness. Once you have made those plates, fit them, (remembering to refit the metal gasket underneath the blanking plate on the exhaust manifold), and you now have an E.G.R free system.

Date added or last updated: 06-10-2009 Return to previous page  
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