Following advice from the many i removed the EGR today on the TD4

Very straight forward

Engine cover off, Intake piping off (4 jubilee clips & 2 x screws)
4 x 10mm bolts for EGR and the pipe clamp
Approx 10 bolts for the intake manifold

What i found surpised me at 72k miles the EGR was as bad as the photos on Roverron webpages, I was going to take pics but at this stage my hands were beyond cleaning

The valve cleaned up to almost new thanks to a dunk in petrol, a 1" paintbrush and then brake cleaner spray after removing most of the gunk with an old flat bladed screwdriver

The intake manifold was a different matter, It was going to take more than a few rags to clean this, I cleaned what i could & reassembled but will remove again when i find a part cleaner bath

Stuff needed
a full sheet of rags
1 x large tin of brake cleaner
10 + 11mm socket
flat screwdriver

1 blanked off the EGR pipe by cutting 1 inch short of valve and adding a metal 5mm dowel used for supporting MFI shelving to join back together

Performance wise, very very slight improvement but not much but i feel better in the knowledge its clean air going through the EGR now and its blanked off and the Roverron is working at its best

The intake manifold i will tackle again or buy new if i see one

Took about 1.5hrs

A must for anyone to remove this horrible gunk that sits in your system like a cancerous growth

Hi m8,
when you put the inlet man back did you use new gasket or made do with the old.I only ask as mine is full of gung so i need to do the same as u before i fit my roverron gissmo that came today. I ve got the one with the maff gis in it along with the tunning mod, any idea on the best settings to start with.

I used the same seals as they looked ok

If i was doing the job properly it worth locating a garage that will wash the manifold out as it looks like thie inside of a tar machine

I bought the Maf bypass with air temp £55 ish, very inpressed with the results

The dial started at about 8 o clock position and i tried it at 10 before leaving it at 12 o clock

Its a different car now

good thead shutty. . . . .this is a job worth doing if past 50,000 and worth blocking that silly dunt do nuffink valve. . . .

Hi all,
well have fitted the roverron gismo,what a differance (every hippo should have one).The only trouble is that now i am getting alot of touk steer on heavy excel.Would putting it back to 4 wheel drive help as i am in monde mode or is it a case of needing a lighter right foot.

Must be the 2 wd thing cos mine is ok

Could be tyres & pressures

How far did you set it

Set it on 6 first but have now put it on 3 as there was quite a bit of black smoke on the higher setting,(over fuilling i think).