Pajero EGR Modification

Pajero EGR Modification
By members of the Pajero Owners Club
www.pocuk.com

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Hi all, in reference to the latest posts regarding blocking the EGR valve I'd like to thank our
wise fellow members for their feedback and advice
... I (eventually) had ago myself and did
this simple task... (simple when you know how
).
*Warning: Where I am using my Pajero, blocking the EGR valve and its effect does not fail the MOT!

If you plan to have ago yourself, first read the wise words of our fellow members further on
(the photos below show the EGR valve in a 2.5TD engine! shouldn't be much
different in a 2.8TD):

Here it goes:
Before you start, it makes it easier if you remove the small pipe going into the top of the EGR
valve and the AutoTrans. dipstick out of the way

1- unbolt the two bolts (size 12) facing the auto trans dipstick (Photo 1)
2- Once loose use one hand to completely unbolt, ... use the other hand to stop the metal
gasket falling of behind the EGR valve! (Photo 2)
3- Once the long bolts are out, remove (slide) the metal gasket out and give it a clean (Photo
3)
* If you want to remove the valve completely and give it a good clean, then you need to
unbolt two more bolts below the valve... not impossible but it takes more time (which I didn't
have) so I left those untouched... there is enough gap between the EGR valve and the inlet to
do the job!
4- Have a drink (mine was Pepsi
)... using the metal gasket outlines on a piece of paper,
creat your blocking metal sheet (Photos 4 & 5)
5- Wrap a clean cloth around a long thin screwdriver and give the "gap" between the valve
and the inlet a good clean... lots of black tar there!
6- Place the blocking metal and the original gasket in the gap! (Photo 6)
7- Bolt and place the autotrans dipstick & valve pipe back!

Have a spin....


I did and defintely the black smoke has reduced marginally... the Pajero pulls better... but I
am yet to judge the long term effects...


Photo 1:

Photo 2:

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Photo 3:

Photo 4:

Photo 5:

Photo 6:

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Photo 7

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Author
Message
yokozuna
Posted: Thu Jun 05, 2003 6:24 pm Post subject: EGR Valve again
*


Got sick of doing 'sink the bismark' type smoke trails so decided to block off the
Joined: 04 Jun 2003
pipe to the egr, 'no smoke' and spins the inside wheel when puulling out from a
Posts: 11
Location: lancashire
junction with the same amount of throttle, amazing.
Just looking for reassurance that I,m not hurting my motor by doing it,
Traced one end back to the solenoid looking thing on the bulkhead, has any body
traced the other pipe? what does that control?
Also does blocking it off make any difference at service time its being given a full
service next week I,ve only drained off the Japanese oil and changed the fiter up
to now.
Regards
Berni
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ower to the people, free Leigh from Wigan
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JayCee
Posted: Thu Jun 05, 2003 8:57 pm Post subject:
***


Are you saying you got a performance increase just by blocking the ERG pipe..

Joined: 22 Feb 2003
Posts: 248

Location: Portlaoise ,
If so I'll be outside in 5 min's time rain or not..

Ireland


Joe
_________________
96 Pajero 2.8GLS LWB..

Inside every tiny problem,
is
a huge one waiting to get out..!
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Trig
Posted: Thu Jun 05, 2003 9:56 pm Post subject:
******
Yokozuna,... go on, tell us how you blocked the little bugger STEP by STEP
PLEEEEEEZ

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Cheers... Trig


T
rig's toy is a 1992 Mk2 2.5TD LWB Pajero Auto Exceed... Gold-Green-Gold.
Joined: 24 Nov 2002
Posts: 807
Location: N. Cyprus
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yokozuna
Posted: Fri Jun 06, 2003 8:36 am Post subject:
*

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JOE
Joined: 04 Jun 2003
I dont know if I got a performance increase or not but before the car felt as if it
Posts: 11
Location: lancashire
was 'holding back' a little particularily between second and third as if it couldnt
make up its mind to change gear, and making big smoke plumes. now it pulls
strongly and apart from a little black on full throttle which I believe to be right
makes no smoke! now I dont mind waiting in a stream of traffic to turn right when
plods behind me before I was feathering the throttle to try to reduce the smoke.
Trig
As to how I did it
Step one find a golf tee
step two pull off the rubber pipe from the agr vacuum canister
step three push golf tee into end of pipe
thats all I,ve done! make sure the pipe cant dangle down near to the Turbo I zip
tied mine up.
I hope I,ve not done anything stupid but its been two days and 200 clicks now and
everything seems fine.
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ower to the people, free Leigh from Wigan
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Trig
Posted: Fri Jun 06, 2003 8:55 am Post subject:
******
Yokozuna, I had a look THIS morning at the EGR... and was thinking what to block
it with.... I thought of a metal screw!! But the golf tee idea is quite handy


I also asked around about the EGR... and what I understood (correct if wrong


please!) is that when the Turbo is pushed hard, the valve releases some of the
Joined: 24 Nov 2002
Turbo output to the exhuast!! If you block it then you don't loose that extra bit of
Posts: 807
Turbo output...
Location: N. Cyprus

The question is why have it there in the first place? ... also if you block it what's
the WORST thing to happen?... can you blow the Turbo up?

_________________
Cheers... Trig

T
rig's toy is a 1992 Mk2 2.5TD LWB Pajero Auto Exceed... Gold-Green-Gold.
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nigel fegan
Posted: Fri Jun 06, 2003 9:18 am Post subject:
*


having read this I'm also now thinking about doing the same, '96 2.8 LWB with
Joined: 09 Jan 2003
o
nly 39,000mls but very smokie, love to hear some more info first though!
Posts: 10
Location: Wicklow, Ireland
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jimmy
Posted: Fri Jun 06, 2003 9:41 am Post subject: EGR why....
*


The EGR valve or Exhaust Gas Recirculation Valve allows exhaust gas into the air
Joined: 10 Oct 2002
intake. The reason for doing this is that it reduces the temperature of combustion
Posts: 17
and the level of NOx (oxides of nitrogen) that are output. NOx is a cause of acid
rain and so lower levels are a good thing (especially if your a tree). However in our
Pajeros the EGR valve usually due to being sooted up and not functioning correctly

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causes a lot of smoke which is made up of soot particulates and aggravate
respiratory problems like asma, so blocking it off to stop this is also a good
thing....

My understanding of the MOT for our Diesels is that they look at the smoke out
put and not the NOx levels so blocking it may help pass the MOT (mine is blocked
and sails through it's MOT).

As an aside I would block the EGR valve by replacing the gasket where the
exhaust enters it with a solid plate. Only blocking the vacuum tube will mean if
your EGR valve is faulty ie not closing properly) you will still have gases
recirculating and I also noticed that the valve vents to the atmosphere spreadign
soot around your engine bay if you bock the output from the valve to the intake
manifold....

Hope this is all clear

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Don't Panic.




O
K PANIC
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yokozuna
Posted: Fri Jun 06, 2003 9:49 am Post subject:
*


Trig
Joined: 04 Jun 2003
Dosnt the turbo wastegate dump excess pressure? I think I heard mine working
Posts: 11
Location: lancashire
sounded like somebody drumming their fingers on the bonnet, its the first time
thats happened as well since I,ve been running the car.
Jimmy
I,m thinking of cutting a gasket from a coke can (one of the other threads
mentioned it) but the bolts look a bugger to get at on the exhaust side of the
valve and doing it that way, I cant see any soot around the thing at the moment
and I,ve been booting it quite a lot just to enjoy the rear view.
Anyway you can only try it it worked for me.
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ower to the people, free Leigh from Wigan
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Ivor Green
Posted: Fri Jun 06, 2003 10:26 pm Post subject:
***
Just a quickie Be carefull blocking these EGR valves We dont but there are the odd
hot head young MOT testers who look for EGR opperation on the test, they wach
to see if it pulsates when raising the engine speed , on what basis they could fail it
I dont quite know, but a comment to one of our local competitors and I was told

they always check it opperation where possible to do so . and just as a foot note ,

Joined: 07 Mar 2003
I hope you are checking those Cam belts they take a fair old hammering on the
Posts: 152
MOT smoke test , and the testers take no prisoners when they floor the pedal to
Location: Coventry
the metal . if any doubt about there condition , Change them . and dont forget the
ballancer belt at the same time , can make a nasty mess when that one breaks .
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W
hat's that smell.<><

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yokozuna
Posted: Sat Jun 07, 2003 1:01 pm Post subject:
*


Cheers Ivor I,ll watch out for them,although my Garage seem really more
Joined: 04 Jun 2003
interested in seeing if they can get the T.V. and satnav system to speak English.
Posts: 11
Location: lancashire

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ower to the people, free Leigh from Wigan
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nigel fegan
Posted: Sun Jun 08, 2003 2:36 pm Post subject:
*


I have carried out the above mentioned mod. to the EGR valve and there's
Joined: 09 Jan 2003
definatly considerably less smoke but didn't notice any power increase.
Posts: 10
Location: Wicklow, Ireland would it be better to block up the EGR valve or would there be any difference?
what happens to all the black smoke that was there?
Quote:
'96 2.8td LWB

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NewRSoul
Posted: Sun Jun 08, 2003 11:39 pm Post subject:
**
Had a go at this on Sat morning, I had been thinking of doing it for a while, on my
2.8 I unbolted the 2 12mm bolts from the EGR tube (to the exhaust manifold) and
the 2 12mm bolts into the inlet manifold, then very easily peeled the metal gasket
from the inlet, drunk a can of pepsi, stanley knifed a replica of the gasket from the


empty can (slightls smaller so it couldn't be seen by some tester) placed the
Joined: 04 Mar 2003
blanking piece (pepsi) against the inlet, the real gasket on top (so it doesn't look
Posts: 123
any different) and rebolted the unit on.
Location: Blackburn, East

Lancashire
After a test drive I must admit it seems smoother, the EGR valve was bery sooty,
and may even have been leaking past, but now it can't.

The car is producing less smoke also, although this is subjective.

I'm happy with mod, it took all of 20mins to do, including drinking the pepsi!

With the ease it took doing this it may be worth others doing this as a tester, if
there not happy then just remove it. The problem with blocking the vacuum pipe is
that if the value is faulty, and leaking then it doesn't work, this way it's definate.

Hope this helps.
_________________
Regards

Peter

9
3 LWB 2.8TD Auto Super Exceed
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Trig
Posted: Mon Jun 09, 2003 4:07 pm Post subject: Last question in picture??????
******
Just a last question (in picture) to confirm what has been described above...
(NewRSoul... 20 mintues including having the drink
)



RED marks:
Joined: 24 Nov 2002
Part 1: the EGR tube the can also be blocked with a golf ball tee!
Posts: 807
Location: N. Cyprus
Part 2: the two bolts that need to come out to block the whole thing! Is it
ok to block this end after unbolting?... can't show part 3 which must be
the other two bolts near the inlet!

Just curious! What are the parts marked with Green & Blue !? The part marked in
blue has a top that rotates freely!





_________________
Cheers... Trig

T
rig's toy is a 1992 Mk2 2.5TD LWB Pajero Auto Exceed... Gold-Green-Gold.
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NewRSoul
Posted: Mon Jun 09, 2003 7:16 pm Post subject:
**
Trig,

Mine's a 2.8, see the below for a photo, the layout seems somewhat different on
the 2.5.



Joined: 04 Mar 2003
http://www.photobox.co.uk/album/album_photo.html?c_photo=3321226
Posts: 123

Location: Blackburn, East
I don't think you'd do much with a golf tee in the EGR pipe, it must be an inch
Lancashire
round! I think most people put it in the vacuum pipe to stop activation of the
diaphram.

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But from your photo it would seem similar enough to it a try, I think there must be
more that 2 bolts though, becasue it must be fastened to to inlet and exhaust
manifolds?
_________________
Regards

Peter

9
3 LWB 2.8TD Auto Super Exceed
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Trig
Posted: Mon Jun 09, 2003 7:46 pm Post subject:
******
NewRSoul, thanks for the detailed photo
There is a different layout indeed... but
as you said they are still similar. The 2.8 EGR valve is rotated, the 2.5's faces

upwards... I think I will also give it a try... the two bolts I show in my photo see to

be the only bolts holding the valve... !
Joined: 24 Nov 2002
PLan is... unbolt those two... remove the valve... clean it (while drinking my cold
Posts: 807
Location: N. Cyprus
beer
)... cut a sheet of the beer can... fit and put back together... Will have a go
asap... and post results

_________________
Cheers... Trig

T
rig's toy is a 1992 Mk2 2.5TD LWB Pajero Auto Exceed... Gold-Green-Gold.
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