2001 3.2 Di-D EGR Removal

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4ePikanini
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Vehicle: 2001 Pajero LWB 3.2 Di-D GLS
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2001 3.2 Di-D EGR Removal

Wed Jun 15, 2011 4:41 pm

I tried to just block the vacuum system that activates the EGR valve but it was still smoking at idle and having a rough idle at times.

I suspected it was the EGR still being funny and after the delete set out below my idle smoke and rough running is gone.

Tools required

- Phillips screwdriver
- 10mm socket
- 12mm socket
- 2" Extension
- 12mm ring flat spanner

Open the bonnet and remove the engine cover using the 10mm socket to loosen the 4 screws and further undoing them with the screwdriver

Image

Then remove all these 12mm bolts/nuts with the 12mm spanner and/or ratchet using extension as necessary. Be careful on the exhaust bolts as they round easily and are very tightly rusted in usually.

Block off the vacuum pipe that you remove from the EGR valve

Note : I didn't point out the brace on top of the tappet cover but it's very straightforward.

Image

Bolt on your blanking plates at the opened holes by the intake and the exhaust using the existing gaskets that came out.

Replace engine cover

Close bonnet ;)

Job done.
Marius Fourie
MY DIY WEBSITE
2005 Touareg R5 Air & Bi-Xenon
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GertM
Vehicle: 2002 Pajero 3.2 DiD SWB
Country: South Africa
Location: Pretoria RSA
Posts: 197
Joined: Mon May 16, 2011 6:51 am

Re: 2001 3.2 Di-D EGR Removal

Thu Jun 16, 2011 3:39 pm

So you removed the whole thing and then just "chuck it away"?

Funny, but I was thinking the same yesterday when I blanked off the two holes. Why not take off the whole thing? It serves no purpose, and 'strues bob - here you did it!

I blocked the exhaust side off at the point in the top of your picture, because it looks like everybody is doing it like such. It is interesting that you blocked it at the other hole.

Thanks for sharing!
2002 3.2 DiD Pajero SWB Gen 3
It sounds like a truck but its tough as nails

Gert
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paw_by_paw
Vehicle: 3.5 L Pajero LWB Blister Fender
Location: Secunda-Mphumalanga
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Re: 2001 3.2 Di-D EGR Removal

Fri Jun 17, 2011 4:06 pm

Hi 4E,
A stupid question if I may? What is the function of the EGR and what poosible influence would the removal have on fuel consumption?
Is the removal of the EGR in principle the same for a 3.5 ?
Your comments please.
Regards
''Life Can Be Good - It Can Be Exceptional Too ' !!!
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4ePikanini
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Re: 2001 3.2 Di-D EGR Removal

Fri Jun 17, 2011 4:24 pm

paw_by_paw wrote:Hi 4E,
A stupid question if I may? What is the function of the EGR and what poosible influence would the removal have on fuel consumption?
Is the removal of the EGR in principle the same for a 3.5 ?
Your comments please.
Regards
Principle is the same.

Much to read here.

http://en.wikipedia.org/wiki/Exhaust_gas_recirculation

The gain of removing isn't beneficial in performance instantly but rather to prohibit gunk buildup in the intake manifold.

Over time (100'000km+ ) the crank vent oil vapours combine with the EGR gasses and causes a gunk buildup in the intake components. On petrol engines, the throttle body is vulnerable and can cause low rev issues.

scroll down in this link to see a badly gunked up intake on a jetta diesel.

http://forums.triplezoom.com/showthread ... AKE-SLUDGE
Marius Fourie
MY DIY WEBSITE
2005 Touareg R5 Air & Bi-Xenon
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al
altusvdberg

Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 2:58 pm

im rebulding my motor and want to chuck the EGR completly just whant to know what was its job origialy and what is the pro and cons of removing it
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4ePikanini
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Vehicle: 2001 Pajero LWB 3.2 Di-D GLS
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Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 3:02 pm

altusvdberg wrote:im rebulding my motor and want to chuck the EGR completly just whant to know what was its job origialy and what is the pro and cons of removing it
see this link


http://en.wikipedia.org/wiki/Exhaust_gas_recirculation
Marius Fourie
MY DIY WEBSITE
2005 Touareg R5 Air & Bi-Xenon
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macjohnw
Vehicle: 2005 3.2DID Gen 3 LWB Auto
Country: RSA
Location: White River, Lowveld
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Joined: Thu Jan 07, 2010 3:55 pm

Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 3:41 pm

What did you use for the blank-off plate and will it take any serious pressure?
2005 Pajero 3.2DID LWB Auto GLX
1999 Pajero 3.5V6 LWB Manual - R.I.P.

Extras: Free flow exhaust and a few dents due to skimpy short summer dresses, rogue steen bokkies and self-stupidity
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4ePikanini
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Vehicle: 2001 Pajero LWB 3.2 Di-D GLS
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Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 3:46 pm

macjohnw wrote:What did you use for the blank-off plate and will it take any serious pressure?
I used 6mm thick steel plate.
Marius Fourie
MY DIY WEBSITE
2005 Touareg R5 Air & Bi-Xenon
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GertM
Vehicle: 2002 Pajero 3.2 DiD SWB
Country: South Africa
Location: Pretoria RSA
Posts: 197
Joined: Mon May 16, 2011 6:51 am

Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 9:20 pm

4ePikanini wrote:
macjohnw wrote:What did you use for the blank-off plate and will it take any serious pressure?
I used 6mm thick steel plate.
Do you think that 3 mm aluminium plate will be sufficient to block off the exhaust side?
2002 3.2 DiD Pajero SWB Gen 3
It sounds like a truck but its tough as nails

Gert
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4ePikanini
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Vehicle: 2001 Pajero LWB 3.2 Di-D GLS
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Location: East London, South Africa
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Joined: Sun Jun 14, 2009 9:38 pm

Re: 2001 3.2 Di-D EGR Removal

Mon Jun 20, 2011 9:37 pm

I wouldn't chance it. The egt's are too high for aluminium. The aluminium head survives as it has constant coolant carrying heat away. The aluminium plate will only have radiant heat dissapation and I feel it won't be sufficient. It may not melt completely but may become maliable enough to deform and fail.
Marius Fourie
MY DIY WEBSITE
2005 Touareg R5 Air & Bi-Xenon
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