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2003 D4D Egr Clean


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#1 Rossi46

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Posted 28 August 2010 - 01:30 PM

I decided to tackle my 2003 D4D EGR valve today, after my MPG has dropped from 55MPG to about 45MPG over the last month or so.

I wouldn't say i've noticed a drop in power, as there's never really been any to start with.

After trying a few remedies (checking tyre pressures, new air filter, fuel system cleaner) I decided to go for it as nothing made a difference, after reading a few posts on here.
There are a few posts about the EGR, and one is very good but is for the later engine (mine is the gutless 116BHP 2.0 D)

I decided to try and sort it today and it's much more fiddly than the newer EGR valve location.

Anyway, I hope the piccies are of some help to someone, they would have helped me.
The 1st pic shows the EGR valve location when viewed from the passenger side, with the engine cover and airbox removed.
Posted Image

This 2nd pic is with the plastic engine cover removed and airbox hose, cover and filter removed. By taking the airbox out access was possible.
After taking the air filter cover and air filter out, 3 bolts are exposed (12mm Heads) undo these and remove the airbox.
Posted Image

To remove the EGR itself, there are two 12mm nuts and one 12mm bolt holding it on. There are also 2 coolant pipes which I removed (held on by hose clips) which just seem to be for cooling the EGR valve, as one is an input to the housing and the other is the output. Some water came out, so try and keep the hose as high as you can or bung the hose.
The 2 retaining nuts are either side of the EGR valve and the bolt is at the bottom and you'll have to feel for it, as it's not visible from above.
There is also an electrical connector, which operates the valve.
I've pictured the EGR valve removed and the hole it left, for clarity.
Posted Image
Posted Image

To be honest, although it was fairly dirty inside, it wasn't as bad as I thought it would be but (seeing as the car now has 136000 miles on it) I cleaned the EGR using brake cleaner and a toothbrush and manually exercised the valve.
Posted Image

I put it all back together and whilst I was at it decided to clean the MAF sensor with alchohol cleaner spray.
Posted Image

Anyway i've got a few more pictures if anyone needs any more detail.

I'll report back when i've drove the car next week, to see if it's any better.
If anything i've written doesn't make sense, please feel free to correct me.
Sorry to go on but hopefully this will help someone, as there doesn't seem to be much info about the earlier D4d EGR valves.

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#2 Rossi46

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Posted 01 September 2010 - 08:03 AM

Just an update...

My car is now averaging 54.5 MPG and rising over the last 400 miles (on the display), where previously 43-45 was about the most I had been getting.

I'm happy and i'm going to do an oil change soon, which will hopefully give me a few more MPG back.

It feels much sharper and cleaner, which makes it easier to make good progress.

Result :thumbsup:

#3 t-spiritpete

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Posted 01 September 2010 - 07:50 PM

Just an update...

My car is now averaging 54.5 MPG and rising over the last 400 miles (on the display), where previously 43-45 was about the most I had been getting.

I'm happy and i'm going to do an oil change soon, which will hopefully give me a few more MPG back.

It feels much sharper and cleaner, which makes it easier to make good progress.

Result :thumbsup:

Job was worth doing so well done mate and the photos were good, they should help someone out in the future.

Regards Pete.;)

#4 peanutome

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Posted 01 September 2010 - 10:19 PM

Many thanks for the info as have been thinking about doing mine for ages but have not due to lack of info!

That is now remedied thanks to these pics!

Cheers

David

#5 Rossi46

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Posted 02 September 2010 - 01:13 PM

Just an update...

My car is now averaging 54.5 MPG and rising over the last 400 miles (on the display), where previously 43-45 was about the most I had been getting.

I'm happy and i'm going to do an oil change soon, which will hopefully give me a few more MPG back.

It feels much sharper and cleaner, which makes it easier to make good progress.

Result :thumbsup:



Cheers Pete

That's why I did it, hopefully someone will be able to save some cash and the piccies should make the job less daunting.

Regards, Adz

#6 Rossi46

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Posted 02 September 2010 - 01:23 PM

Many thanks for the info as have been thinking about doing mine for ages but have not due to lack of info!

That is now remedied thanks to these pics!

Cheers

David



Good stuff

Hope it works for you David

Cheers

Adz

#7 LEIGH T180

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Posted 02 September 2010 - 08:35 PM

In the second from last photo, the section of that part nearest your hand looks cracked...?

Is it?

#8 Rossi46

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Posted 03 September 2010 - 06:59 AM

In the second from last photo, the section of that part nearest your hand looks cracked...?

Is it?



No, it's a bit of frayed material from the fleece I was wearing .

Good spot though :thumbsup:

#9 acetip

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Posted 03 September 2010 - 09:22 AM


In the second from last photo, the section of that part nearest your hand looks cracked...?

Is it?



No, it's a bit of frayed material from the fleece I was wearing .

Good spot though :thumbsup:

some crack.

#10 Mistermena

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Posted 26 November 2010 - 05:09 AM

I decided to tackle my 2003 D4D EGR valve today, after my MPG has dropped from 55MPG to about 45MPG over the last month or so.

I wouldn't say i've noticed a drop in power, as there's never really been any to start with.

After trying a few remedies (checking tyre pressures, new air filter, fuel system cleaner) I decided to go for it as nothing made a difference, after reading a few posts on here.
There are a few posts about the EGR, and one is very good but is for the later engine (mine is the gutless 116BHP 2.0 D)

I decided to try and sort it today and it's much more fiddly than the newer EGR valve location.

Anyway, I hope the piccies are of some help to someone, they would have helped me.
The 1st pic shows the EGR valve location when viewed from the passenger side, with the engine cover and airbox removed.
Posted Image

This 2nd pic is with the plastic engine cover removed and airbox hose, cover and filter removed. By taking the airbox out access was possible.
After taking the air filter cover and air filter out, 3 bolts are exposed (12mm Heads) undo these and remove the airbox.
Posted Image

To remove the EGR itself, there are two 12mm nuts and one 12mm bolt holding it on. There are also 2 coolant pipes which I removed (held on by hose clips) which just seem to be for cooling the EGR valve, as one is an input to the housing and the other is the output. Some water came out, so try and keep the hose as high as you can or bung the hose.
The 2 retaining nuts are either side of the EGR valve and the bolt is at the bottom and you'll have to feel for it, as it's not visible from above.
There is also an electrical connector, which operates the valve.
I've pictured the EGR valve removed and the hole it left, for clarity.
Posted Image
Posted Image

To be honest, although it was fairly dirty inside, it wasn't as bad as I thought it would be but (seeing as the car now has 136000 miles on it) I cleaned the EGR using brake cleaner and a toothbrush and manually exercised the valve.
Posted Image

I put it all back together and whilst I was at it decided to clean the MAF sensor with alchohol cleaner spray.
Posted Image

Anyway i've got a few more pictures if anyone needs any more detail.

I'll report back when i've drove the car next week, to see if it's any better.
If anything i've written doesn't make sense, please feel free to correct me.
Sorry to go on but hopefully this will help someone, as there doesn't seem to be much info about the earlier D4d EGR valves.



Thats a fab bit of info! So much better to see pic's of how its done. Have you got any on how to change the fuel filter by any chance?

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