Introduction: BMW EGR Valve Stainless Steel Removal Bypass Delete Blanking Kit Install Instruction Guide

The Problem

Carbon rich recirculated exhaust gasses leave deposits within the EGR valve which restrict or damage the EGR valve causing vehicle faults.

The EGR valve on these vehicles is designed to redirect a portion of the vehicles exhaust gases back to the engine through the intake manifold. Carbon rich recirculated exhaust gasses enter the EGR valve before the intake manifold, over time Carbon deposits gather in the EGR valve and can interfere with the operation of the EGR valve flap and can block air flow. Resulting in reduced fuel economy and vehicle performance. Often this build up damages the EGR valves which are expensive to replace. This malfunction of the valve or blocking of the exhaust port causes Detonation (also known as pinging or spark knock) causing misfiring or rough idle. Many examples can be found across the internet showing these EGRs completely blocked up with carbon; significantly reducing airflow to the intake.

Symptoms of the fault

Rough engine running

Misfiring

Decreased throttle response

Loss of power or torque

Smokey engine

Low MPG / decreased MPG

Vehicle stalling at low speeds

Acceleration slow / sluggish

Vehicles affected and compatibility

BMW engines M47 M47N M57 M47N2 M67 M47R

3 series E46

318d 2001-2005

318td 2002-2004

320d 1997- 2005

320cd 2003- 2006

320td 2000-2004

330d 1998-2003

330xd 2000-2003

5 series E39

520d 1999-2003

525d 1999-2003

530d 1997-2003

X5 E53

3.0d 2000-2003

X3 E83

2.0d 2003-2006

E38 7 Series

730d 1997-2001

740d 1998-2001

E65 7 Series

740d 2001-2005

Rover 75 MG ZT 2001-2005

Land Rover Freelander TD4 2001-2006

Land Rover Range Rover TD6 2002-2006

This item is not compatible with quick release style hoses.

Vehicles which utilise a vacuum operated EGR will not show a fault code when replaced with our EGR blank. Vehicles with an electronically operated EGR will show a fault code which will need to be mapped out. This is the same for all suppliers of EGR blanks whether stated or not.

This item is for diesel vehicles only not for petrol vehicles.

Associated part numbers:

11717785452, 11717804378, 7785452, 7804378, 11717793484, LR005791, WAV000040, 7.28138.00.0, 7.28138.02.0, 7.28264.00.0, 7.28264.06.0, 555229, 14406, 14433, EGR251, EGR258, ERV190, ERV208, Pierburg.

Part numbers are for guidance only, please inspect your EGR to ensure you are purchasing the correct blank.

Our solution

Our kit allows easy replacement of the EGR valve with our improved design part which stops any recirculated exhaust gases entering the intake manifold. Resolving vehicle faults and stopping carbon build ups in future.

Install our completely Stainless Steel EGR blank and eliminate build up in the intake manifold. This allows the engine to breath better which can improve vehicle performance and fuel efficiency. Our EGR blanking kit stops these recirculated exhaust gases entering the intake manifold, eliminating the risk of future build ups.

Our kit is the most comprehensive available including all components required to delete the EGR valve and will fit in the same way as the OEM part. You will receive:

1x Stainless steel EGR tube, precision machined and all constructed from stainless steel, featuring a substantial bead to ensure an air tight seal with the intercooler hose.

4x Stainless steel EGR to intake manifold bolts.

1x Intake manifold to EGR rubber gasket.

1X vacuum pipe blanking plug with cable tie to secure.

2x Stainless steel EGR cooler blanks to allow you to blank off the EGR cooler if installed on your vehicle.

1X Exhaust manifold blank with Cemjo high temperature gasket and fasteners allowing you to remove the EGR to Exhaust manifold flexible tube that often blocks or splits.

Our kit is top of the range and the most comprehensive kit available. Check out our instructions and video to see how our kit allows you to successfully eliminate the EGR valve on your vehicle.

Possible advantages of EGR deleting:

Turbo can spool up quicker and at lower revs resulting in less turbo lag.

Prevents carbon build-up inside intake manifold and ports.

Smoother pick up from idle, engine running and better fuel economy.

Increases in power and / or torque which slowly fades as carbon builds up.

Improved fuel consumption / MPG.

You will receive

1x Stainless steel EGR delete tube

4x Stainless steel EGR delete tube mounting bolts

1x Stainless steel exhaust manifold to egr pipe blank

1x High temp CEMJO exhaust manifold blank gasket

2X Exhaust manifold blank bolts with locking washers

2X Stainless steel EGR cooler blanking plates

1X Intake manifold to EGR gasket

1X Vacuum tube plug with cable tie

Step 1: Remove Cosmetic Engine Covers

Remove the 2 bolts (on some models 3) and lift off the covers.

Step 2: Remove Hoses

Remove the vacuum hose, gently pull this off of the EGR valve.

Loosen the jubilee clip on the intercooler hose and remove the hose.

Step 3: EGR Cooler (skip This Step If Your Vehicle Doesn't Have an EGR Cooler)

Only relevant for vehicles fitted with an EGR cooler:

This repair stage is shown on the bench for clarity, it should be carried out on the vehicle and only the metal pipes should be removed, the EGR cooler should remain mounted and no other pipes removed.

Remove the metal pipes from both ends off the EGR cooler (EGR to cooler and cooler to exhaust manifold)

Clean up the mating faces of the EGR cooler and ensure they are free from loose rust, carbon deposits and grease.

Locate our blanking caps on to each end of the cooler and reinstall the clamps ensuring the caps remain central as the clamps are tightened. If you suspect the caps are not sealing repeat the process ensuring the caps are central, the EGR cooler has a wide tolerance so a sealing compound may be needed to make an air tight seal.

Step 4: Remove EGR Pipe From Exhaust Manifold (non EGR Cooler Models Only)

Remove 2x bolts and release the flexible metal pipe from the EGR to the exhaust manifold.

Step 5: Remove the EGR Valve

Remove 4x bolts retaining the EGR valve. Remove the EGR valve and the EGR to exhaust manifold pipe.

Step 6: Clean the Mating Faces

Clean as much carbon from the intake manifold as you can from the hole now exposed. To be thorough the intake manifold could be removed and thoroughly cleaned. For instructions on this please check out our swirl flap instructions.

Remove the old EGR to intake manifold gasket and replace with ours.

Clean the mating face of the exhaust manifold, remove any loose rust, carbon or grease.

Step 7: Blank Off the Vacuum Pipe

If your EGR valve is vacuum operated blank the pipe using our blank and secure with the cable tie.

Step 8: Blank the Exhaust Manifold

Using our supplied blanking plate, gasket, bolts and locking washers, blank the hole on the exhaust manifold. Ensure the locking washers are installed between the bolt heads and the blanking plate. If the exhaust manifold is very corroded some sealant paste may be needed to create a seal.

Step 9: Fit Our EGR Tube

Using our supplied stainless steel bolts; secure the EGR delete tube to the intake manifold, do not over tighten the bolts. These should be nipped up just to create a seal on the EGR to intake seal.

Fit the intercooler hose to the EGR tube and secure using the jubilee clip.

Step 10: Test Seals

Before refitting the engine cosmetic covers, start the vehicle and check for any leaks.

Step 11: Refit Engine Covers

Refit engine covers.

This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on +44 01843 446643 or email us at sales@x8r.co.uk . Please also check out our instruction guide on YouTube.

www.x8r.co.uk

Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2016

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