Airbag issue leads to.... EGR Bypass.

[Tourist]

Hello everyone - happy new year to all :-)

I thought I'd share my latest bit of Rovering with you all and also check to see if I need to do anything else while I undertake the latest bit of maintenance.

I'd had a recurring airbag light on the dash so borrowed a friend's laptop with the Delphi 150e diagnostic software to try and find out what was up. Turns out it couldn't help with that issue (which turned out to be a stubborn connector under the passenger seat, now solved), however, it did flag up a couple of issues with the EGR:

- P2141 EGR Throttle Control Circuit 'A' Low
- P0400 EGR System Regulation

This probably explains the black smoke that I've been getting when putting my foot down - I thought it was something to do with the remap.

I last had the EGR apart about 30,000 miles ago and it was dirty but nowhere near blocked. The inlet manifold was also pretty filthy and I didn't get the time then to clear it out so that is well over due.

I plan to do an EGR bypass using the DMGRS bypass kit (35 quid) and also clean the inlet manifold out (I've seen elsewhere here that oven cleaner and thick gloves are the order of the day). At the same time I'll replace the air filter as it's nearly due for replacement anyway. The PCV filter was replaced 2,000 miles ago so I'll leave it alone.

Is there anything else that I should consider while doing this work?

Cheers for the continued help - other than these few issues, the 75 continues to perform beautifully.

BTW, the car is a 2004 (54 plate) facelifted CDTi with 107,000 miles on the clock.

[snowman]

Just be careful when it's mot time as it has to be there if they see its been by passed it will fail the mot do a search and you will see
Regards paul

[Arctic]

Hi Simon.
It is best to remove the manifold EGR & MAP sensor as an whole unit, once removed you can then break it down.

Remove the EGR and clean it out, scrape most of the od gunk out with an old hacksaw blade using the back end not the teeth end, then with swarfega and an old tooth brush, wipe it out with an old rag, then spray it with carb clean and wipe again.

From this.
1

To this.
2

You can also gut the original EGR.
3

4

5

6

It is no good just cleaning the EGR or gutting it, if you do not clean out the manifold.

First remove the MAP sensor from the side of the manifold 10mm bolt.
7

8

Once remove wipe it clean with a rag sprayed with carb cleaner, do not poke anything into the hole.
9

10

Now remove all the red seals from the manifold.
11

12

The manifold is now ready to be cleaned, scape out any excess gunk.
13

14

Use rubber gloves and old clothes when doing the job as this gunk get everywhere, you will not get it off your clothes.

With all excess gunk removed spray it inside with oven cleaner, and on the outside, leave for at least 2 hours longer if you can, maybe repeat the spraying with oven cleaner after tow hours.
15


Then you can jet wash the manifold out.
16

You are aiming to get it like this below all clean inside and out.
17

Repeat the process above if you have to several times to achieve your goal.
18

Wipe off the seals clean as you can.
19

Then once the manifold is dry you can start to rebuild it.
20

21

22

23

24

The manifold is now ready to refit back onto the car.
25

Note i have used a original gutted out EGR.
26

27

Once fitted to the car, add and new air filter and if you have not before add new intercooler O-rings Viton only.

You car should run better without any black smoke now.

[myfirstrover]

Thanks for the pictures , proper job done there !

[Tourist]

Wow - thanks for that reply @Arctic - fabulous how to guide.

Looks like that's exactly what I'll be doing!!

Two quick questions - how easy is it getting the bolts pit of the head? - is it generally trouble free?

Also, what's involved with gutting the EGR? Is it pretty obvious what needs to be done once you have it apart?

Thanks again all for taking the time to comment and help me ��