Guide: exhaust gas recirculation Valve removal EGR

[cully]

EXHAUST GAS RECIRCULATION

The role of the EGR system is to reduce the amount of nitrous oxide (NOx) expelled in the exhaust gases .
The nitrous oxides are produced by the combination of the nitrogen and the oxygen in the intake air under the effect of a very high temperature (greater than 1800 degrees C) .
During certain phases of operation the EGR reduces the amount of oxygen available in the cylinder .
The EGR valve, is subjected to a vacuum from the vacuum pump secured at the end of the camshaft and this
authorises recirculation of the exhaust gases to the air union .
The recirculation is of the progressive type managed by mapping .
The opening of the EGR valve is controlled by the EGR solenoid valve which is managed by the engine
management control unit which receives the following data :
coolant temperature,
engine speed,
engine load (the position of the accelerator pedal)

   

as a byproduct of this system it dumps crap back into the inlet which over time blocks the manifold also other issues arise like reducing turbo response from weak or poor seating ERG valve it has also been known to effect MPG.

so we want to get rid of its ill effects, it can be done in a number of ways
1,Disabling the vacuum line stopping the EGR from lifting
2,Blanking the Gas line into the inlet manifold
3,Blacking EGR valve at the exhaust manifold
4,Having the EGR valve mapped out in software
5,removing it totally

due to limited access down the back of the engine in the car most people only do 3/5 when the engine is removed but step 1/2 is possible while the engine is in the car


method 1,Disabling the vacuum line stopping the EGR from lifting

   

1= To exhaust Egr valve
2= Vacuum from behind servo disconnect and plug this
3= Exhaust Egr solenoid
4= Exhaust Egr solenoid plug blue
5= Air douser solenoid
6= Air douser solenoid plug black
7= To Air douser
8= Vacuum feed splitter tee


as standard 2 is connected to 8 but the picture shows it disconnected and blanked


Method 2,Blanking the Gas line into the inlet manafold

   

slacken off nut (green) do not remove no need to
remove 2x hex bolts (red)
part flange remove metal gasket (yellow)

   

take metal gasket as a templet and cut new blank plate from metal
also cut two new gaskets

you will find it easyer if you cut the gaskets and blank with longer tabs so you can handle them easyer

now the hard bit
part the flange to get the plate and the two gaskets to line up
do up the hex bolts and the lower nut you slackened

   

   

[Eeyore]

cully does disconnecting 4 also disable EGR?

[cully]

cully does disconnecting 4 also disable EGR?

yes but depending on which ECU you have it could log a silent fault code

you also have to consider disabling the air doser if you have one

[Jukie88]

Absolute hero for posting this as I want to get this done before the remap !!

[Toms306]

It's worth noting that unplugging or disconecting hoses won't always help. In my case it was stuck open, so unplugging made no difference, full blank to get rid as Cully has done is the best way definitely.

I haven't seen a 306 hdi with a doser though, is that just newer ones? As I also hadn't seen egr cooler on these until yours lol.

[Franko]

Mines a 2002 and has the doser (unplugged now!)

[cully]

if you have the doser
you are best not unplugging the electrical, you are better plugging the vacuum line that feed both solenoids as in the numbered photo

this is what i have done!

the reason i have inserted the plate recently is ,i want to eliminate tho possibility of the EGR valve letting by and causing my poor mpg
time will tell on that one once i have a few tanks of fuel through the car

[cully]

there are two version of the hdi engine in the 306
DW10TD AND EEC 95 DEPOLL =Euro2
DW10TD AND EEC 2000 DEPOLL =Euro3
the later engine has tighter emission controls than the earlier engine
the changeover date is 29/10/2000 or >08756 Dam number


euro2/3/4 is a standard for emissions set by The European union
the standard is set to be more stringent over time New models introduced must meet current standards
Non-compliant vehicles cannot be sold in the EU

   

[Toms306]

Ah, so I was right about the newer ones being more efficient for lower emmisions in the mpg thread then!

[no2lurch]

I plan to do method 2 to mine. but until i get the plate made up, do ui just need to plug the Vacuum line from behind servo? ive read i can unplug something behind the battery too? anyone have a picture of that please?

with the ege valve 'disabled' is the result instantly noticeable?

[DeeTurbo]

I plan to do method 2 to mine. but until i get the plate made up, do ui just need to plug the Vacuum line from behind servo? ive read i can unplug something behind the battery too? anyone have a picture of that please?

with the ege valve 'disabled' is the result instantly noticeable?

No noticeable results really, it just stops shit getting in your engine.

[no2lurch]

where the blue plug?

[Leedunn86]

Just a quick question, whats everyone plugging the vac line with was thinking of using a bolt and a jubilee clip to hold it, any better ideas ?

[cully]

anything that's a tight fit in the pipe is ideal cheap option is a 6mm bolt

[puglove]

ordered new gaskets so getting on this asap


cheers for the pointers at the weekend also


Rep

[no2lurch]

I had a peek at mine yesterday and found one of the vac pipes to be split open. I unplugged the green plug and cut the other vac line and blocked them both off with a bolt.

[Jukie88]

Do I get to this from above or below cos I can't see shit from the top :-(

[puglove]

from the top. you aint trying hard enough if you cant see it lol

[cully]

the reason i have inserted the plate recently is ,i want to eliminate tho possibility of the EGR valve letting by and causing my poor mpg
time will tell on that one once i have a few tanks of fuel through the car

well well well!
i do believe my Egr valve has been letting by!
i have gone from 39mpg too 45mpg and the only mod i have done is this plate

so wish i had plated the EGR a lot earlyer in the car ownership rather than just plugging the vacuum pipe


yes i plated the top manafold elbow from the top of the engine with the car on the ground, there is limited accsess but it is posible

[puglove]

worked it out sunday and im only getting 38-40 mpg out of the estate at the mo.........

[Midnightclub]

that thing under your right foot.. not a on/off switch

[cully]

that thing under your right foot.. not a on/off switch

theres an off side of that thing ?

[Jukie88]

I see it silver pipe runs along the top of the Manifold from the left hand side ??

[scottbmxer]

Anyone know an easy method to disable a phase2 dt egr? The solenoid is completely different

---

Anyone know an easy method to disable a phase2 dt egr? The solenoid is completely different

Atm ive just unplugged the cable

[Poodle]

The vac solenoid might look different, but the operating principle should be the same.

[Kezzieboy]

I should really do this on mine, I've always just chickened out because I could never find much info on the Air Doser, but I guess if that works on your's then I should get it done!

[Poodle]

The air doser works together with the egr to better control the amount of exhaust gas entering the inlet. It's all part of the same, unnecessary system.

[scottbmxer]

any1 got a photo of how to do this on an xud?

[Niall]

Tom this is a guide. Please stop spamming it full of crap about your broken Golf.

[Poodle]

Just realised that top picture is mine lol.

Just so people don't misunderstand/believe Tom's remarks above:
Lower emissions does not mean greater efficiency, in fact it usually means the exact opposite.