The engineer in me (and perhaps the Scot) upon taking off the EGRs on my FF decided to pull apart the assembly. The engineer hat to see how it was built and what the problem might be. The Scot to pilfer parts as the motor looked quite a nice size!

Anyway the saga started when I intermittently (twice in about 4 months) saw the P045-6C so decided to replace the valve assemblies.

This is what I found:

And exactly the same thing had happened to the other one. Except this one looks like its been blowing exhaust into the motor housing.

Quite interesting.

Did the valves fail in the open or closed position?

Any signs of cooling water leakage. I read a theory that the egr may leak coolant, possibly leading to turbo failure.

I'm thinking of fitting emulators so interested also to find out if there's a possibility of the valve leaking exhaust gas when it's in the closed position eg sealing face wear

They hadn't actually failed - the ECU was detecting that sometimes it wasn't getting the full range of movement.

With regards to emulators I think that the ECU also has sensors (maybe just temperature? - it's in the workshop manual I think) to monitor the behaviour. So if those don't fall within parameters it detects it. Interestingly there are only two connections to the motor. So haven't looked into too much depth if it gets its feedback from that connection or somewhere else.

Will have another look when I go to put them back on the car. Ed

Thanks for that

Can't quite tell from the photos if it's a butterfly valve or poppet valve

Is there a chance the valve could leak when closed?

Cheers

It's a valve like in the cylinder heads. Basically the motor turns a couple of cogs, that then rotates a the valve stem which has a couple of lugs which run in guides in the casing. As it rotates the stem moves down the case and opens the valve. Ed

Ok cool. Thanks again

The Tdci engines in Defenders apparently detect AGR faults - like removal or blocking up - by measuring an expected decrease in the MAF reading when the EGR is open. If the MAF does not drop with the EGR open (as exhaust goes in instead of fresh air) then the EGR must have failed and it shows the MIL lamp. Maybe RRs use the same idea?

Chris

That rings a bell Chris. Ed

Can't you get them deleted with a remap..?? Pete
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Probably - but then they are there for a reason

I haven't heard of any of the reputable people mapping them out yet but I haven't been looking to be honest.

If I ever get some time / a garage of my own then I might be tempted to try it myself (perhaps with a spare engine - anyone willing to donate one?). I think part of the problem with the facelifted stuff is everything talks to everything else even more than it used to. In the various forays I've had into the workshop manual it details what sensors are on there and how they work so not too difficult to reverse engineer and build an Engine Control Unit, i.e. something with a loud pedal and an engine - none of this gubbins in the middle  Ed

I would take a look at the slightly smaller version of that engine (V6) the EGR delete re-map is a must do, just because you've got 2 extra cylinders doesn't mean that the V8 will not suffer similar problems to the V6, infact I think that you'll find there are a lot of common faults...... turbo hoses, turbo's and EGR's for a kick off  Yesterday I couldn't spell Engineer... Today I are one!
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Very true but they do have completely different layouts which does contribute. The V angle is different to my understanding and because of this the turbos on the TDV8 are lower down because they can't fit them on top. Ed

miggit wrote:

I would take a look at the slightly smaller version of that engine (V6) the EGR delete re-map is a must do, just because you've got 2 extra cylinders doesn't mean that the V8 will not suffer similar problems to the V6, infact I think that you'll find there are a lot of common faults...... turbo hoses, turbo's and EGR's for a kick off

The TDV6 and the TDV8 are not related, in any way, shape or form

Was always under the impression that they were both developed as part of the Jv between ford and PsA. On he face of it they are completely different as they have different v angles 60deg for the v6 and 90 for the v8.

The bore and stroke are however exactly the same as is the compression ratio.  There is nothing that can't be fixed with a hammer😜😜
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