Blocking the EGR Valve

[the ferret]

hi mate i new here and this is my take on this subject
removing or blocking the EGR is not a performance mod !! it only works at cruise and it lowers the cumbustion chamber temp to reduce NOX "nitrides of oxygen" a very silent killer if it leaks into cab!!
the sooting is a by product we have to live with ,it is a polution control device and ""ILEAGAL" to remove or modify the same as removing a cat converter$10 grand fine if caught!!
so if you leave it there it already is a performance mod ! well kind off lol.
so in a nut shell , if i cut ur arm of ,you can live without it cant you ?? but if it wasnt ,it would be better !!

I look at it this way, by fitting a catch can, you remove most of the oil vapour which adheres to the butterfly and the inlet manifold and the MAF, contaminated MAF sends a message to the ECU to send more fuel, so on the ZD30 you end up with a hole in No 3 piston.
Blocking the EGR prevents the soot and carbon from sticking to the oil vapour within the intake system, be it the inlet manifold, the intercooler or butterfly.
This is all a part of the "NADS' system and is a proven modification to the ZD 30 direct injection motor prior to 2007.
Cheers, the ferret.

[the ferret]

My 2.8 has been blocked for 3 years now, no dramas. I also run 200 to 1 two stroke, no boost guage and no piro, all good 225.000 ks..

[Chaz]

hi mate i new here and this is my take on this subject
removing or blocking the EGR is not a performance mod !! it only works at cruise and it lowers the cumbustion chamber temp to reduce NOX "nitrides of oxygen" a very silent killer if it leaks into cab!!
the sooting is a by product we have to live with ,it is a polution control device and ""ILEAGAL" to remove or modify the same as removing a cat converter$10 grand fine if caught!!
so if you leave it there it already is a performance mod ! well kind off lol.
so in a nut shell , if i cut ur arm of ,you can live without it cant you ?? but if it wasnt ,it would be better !!

While I agree that everything you have said is true, unfortunately it doesn’t all apply to a ZD30 diesel engine with respect to EGR. Unlike EGR in most petrol engines, a ZD30 meters EGR and while there is a relatively low percentage at cruise, it does increase under considerable load. However it’s disabled at very high load and full throttle.

While its primary function is to reduce peak combustion temperatures, that has very little to do with exhaust gas temperatures. Peak combustion temperatures equate to very little time in the combustion process, but it does have the affect of reducing NOx emissions. Unfortunately with a diesel the negative effects of EGR far outweigh the positives. Even many of the larger diesel manufacturers have started to move away from EGR as a means of reducing emissions and many of the greener members of the community are beginning to question the true value of EGR as a means of control when so many vehicles emit more pollutants as a result of poorly maintained EGR systems.

You clearly have never tested your theory because you wouldn’t say it’s not a performance mod if you had. We’ve seen a 87nm gain at the wheels of a ZD30 Patrol below 2000rpm with EGR disabled, which was more than we got from fitting the 3”exhaust with high flow cat.

Yes, it is illegal to disable, but perhaps a 10K fine is better than an engine replacement every 100K km. My personal take on the subject is that it’s common for EGR systems to fail. They typically jam from all the soot and corrosion that the valves are exposed to and anyone that has had one jam open will tell you of the rough running engine, excessive smoke, lack of power and poor fuel consumption that their emission control system provides, by law!

[canuck]

I just did a quick search of the thread to see if any of this relates to the EGR on the TD4.2 in the Safari. No hits. So I am wondering if the template posted at the beginning will work or not on the Td4.2 with an EGR. My 91 5 spd has one. The wife's auto doesn't. Both are stock and NA.

[the ferret]

Mate, post up a pic of your EGR and I'll have a better idea, but I'm pretty sure it would be the same.
Cheers, the ferret.

EDIT. If you measure the two stud centres, they should be at 56mm.

[Mark S]

Hi guys, the butterfly valve that needs to be removed is on the inlet to the intercooler, closest to the firewall with the vacuum controller mounted on it??? Is that right??

Cheers.....Mark.

Sorry should have mentioned 2.8TD..

[the ferret]

Yeah Mark, If you remove the intercooler and it's bracket (4 bolts) it's a lot easier to get to the butterfly.
Remove the 4 m8's on the butterfly housing and then there are two tiny screws holding the butterfly onto the spindle.
Take the screws out and the butterfly will come away.
Take care with the "0" ring.
And yes, it's on the inlet toward the firewall.
Dont forget to unplug the fan!!
Cheers, the ferret.

EDIT, OH YEAH!!! don't kneel or sit on the top radiator tank, as you WILL snap the overflow spiggot!!

[Mark S]

Thanks Ferret, all done...simple job made hard if you dont remove the intercooler!!

Thanks again.

[canuck]

Mate, post up a pic of your EGR and I'll have a better idea, but I'm pretty sure it would be the same.
Cheers, the ferret.

EDIT. If you measure the two stud centres, they should be at 56mm.

Thanks. I'll measure them up.

Here are two pics of the Safari set-up. The first is my 91 5 spd and the second is my wife's 92 auto. Yes, there is no EGR crap on the 92. Got a friend to check the FAST with the VINs and it never had one. Both are JDMs.

1991 Safari


1992 Safari

[the ferret]

The template on page one is for the 2.8 mate. The 4.2 is a similar shape but the hole centres are 56mm for 4.2 and 45mm for the 2.8.
It may be best uf you use the original gasket as a template.
Make the plate using 1.6mm stainless.
I could send you the plate but the postage would be fairly high.
Cheers, the ferret.