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JIMMY JEEP · **Posted:** Sun Jan 13, 2008 10:44 am

Has anyone got any piccies of egr valve location, i've seen piccies on here of one being taken apart but it doesnt show were it came from and i cant see anything like it in my engine bay ,maybe Uk spec ones are different .

Uffe · **Posted:** Sun Jan 13, 2008 12:44 pm

I have the same problem. I've been trying to find the EGR valve on my EU KJ for nearly an hour. I just can't find it on the battery side. My turbo is on the opposite side of my battery, and on the turbo I have found a disc-shaped object like this one on top of my turbo:

It is sitting just below the middle point on the boost hose between where the hose comes up from the turbo and goes to the CAC.

Hard to take pictures on my own. This is our EGR valve in europe. It is controlled by a vacuum electric motor.

I think this is the one we use in the jeeps:

crd liberty · **Posted:** Sun Jan 13, 2008 1:27 pm

It is on the battery side. AFC is first off the Boost hose and under the AFC is the EGR.
Very hard to see. I don't know how to send pictures in here or I would.
Steve

crd liberty · **Posted:** Sun Jan 13, 2008 1:33 pm

http://www.lostjeeps.com/forum/phpBB3/vie ... r+location

kccrd · **Joined:** Thu Mar 08, 2007 10:35 pm **Posts:** 267

Are you sure you guys in europe have the egr on your engine I thought they were only on the US engines.

Uffe · **Posted:** Sun Jan 13, 2008 4:02 pm

I don't have a flow control valve on my CRD as per your photo. I just have the CAC output going directly to the intake manifold with a small hose on the opposite side. I just went and checked, and it seems that I have a loose clamp on the EGR input port in the inlet. The EGR output port goes directly into the intake manifold via a hose on the backside of the engine. I don't have the EGR as shown by those photos you linked to either.

The EGR hose goes directly from the EGR at the turbo side of the engine back around the back part of the engine and directly into the intake in the engine.

I did not find anything that even looked like what your image shows when I went to look 2 minutes ago. I have a 2003 EU model, where we don't have such strict emission regulations. 2003 was also before the CRD was introduced in the US and also before they introduced the VGT/VNT on the CRD.

I think jimmyjeep and I share this engine version.

PS: Would have taken pictures but the camera decided it had too little battery to function properly

crd liberty · **Posted:** Sun Jan 13, 2008 4:35 pm

You have a gasser? Pootie?
If so the EGR valve is not what I sent you.
Wish some of the other guys were responding. They know much more than I.
The EGR on the VM Motori is as shown above.
It bolts to the intake manifold and is controled by the Flow control valve(FCV) which is
controlled by the Mass air filter(MAF).
Yours may be different? Dunno know bout that.
Steve

JIMMY JEEP · **Posted:** Sun Jan 13, 2008 4:59 pm

Uffe is the photo of the part you posted located near the coolant header tank?. Do we have an egr valve then or not or do we have one but different to the Us models? I,m really confused now.

crd liberty · **Posted:** Sun Jan 13, 2008 5:12 pm

Battery side>>> Does the large hose go from the intercooler into a metal thingy?
If so that is the Air Flow control valve. FCV.
That in turn goes into the EGR.

MrMopar64 · **Posted:** Sun Jan 13, 2008 5:45 pm

The EGR system on the Export vehicles differs greatly from the NAFTA vehicles, especially on years prior to '05 (MY02-MY04). For vehicles, circa 2002-2003, a system such as this should be present. THese pictures are specifically from the 2.5L RG engine (RG-minivan) but was the same for the 2.8KJ as well.

There were also some vehicles thru 04-05 that had the improved cooler seen on NAFTA vehicles but with a pneumatic actuator like previous versions instead of the (crappier) electronic actuator. Interestingly enough, the pneumatic valve actually has a higher actuator force than the electronic valve and is enumerably less prone to sticking. Early versions of the application (02-04) didn't use the throttle valve since EGR rates were low enough to preclude its inclusion in the package.

JIMMY JEEP · **Posted:** Sun Jan 13, 2008 5:55 pm

MrMopar64 wow you know your stuff ,so educate me ,i'm still a little lost my kj is a 2004 2.8 so are you saying i dont have an egr valve as the emissions are low enough without for the european market.

MrMopar64 · **Posted:** Sun Jan 13, 2008 7:35 pm

When you work on them for a living you tend to figure out all the little nuances that make them tick.

The 2004 2.8 in your KJ has an EGR valve for sure, if i remember correctly no Throttle Valve, or EGR Flow Control Valve as called by DCX. I forget when the transition of EGR valve placement was, but if you don't have the EGR valve and cooler on top of the exhaust manifold then the placement will be as shown. It's on the driver's side of the engine underneath the intake manifold towards the back of the engine.

JIMMY JEEP · **Posted:** Sun Jan 13, 2008 7:55 pm

I'll have a look tommorow when its light and see if i can take any pics .If mine is the more simple type of egr valve will i be able to disconnect it without throwing up any fault codes ,as can be done on mitsubishi pajeros? Sorry for all the questions, i've read stuff on L.O.S.T but it hasnt really helped as it would seem things are different to US spec's .

MrMopar64 · **Posted:** Sun Jan 13, 2008 11:25 pm

Although the 2004 vehicle (and older) use the EDC15 instead of the EDC16 and thus different SW, you will still get a check engine light and/or fault code for disconnecting the EGR. You have to be careful to in no circumstance disconnect the vacuum line from the EGR valve or from the modulator. If the supply to the modulator is open and allowed to suck air into the vacuum system as opposed to being closed and drawing a vacuum then the crankcase will pressurize from the air flow and the oil will be forced (quickly) from the crankcase. The best bet is to perform a mod such as disconnecting the MAF sensor so that power won't be reduced. While things are slightly different in terms of hardware the overall concept from a strategy sense is the same so the same principles such as the SEGR still work.

Uffe · **Posted:** Mon Jan 14, 2008 3:57 am

MrMopar64 wrote:

The EGR system on the Export vehicles differs greatly from the NAFTA vehicles, especially on years prior to '05 (MY02-MY04). For vehicles, circa 2002-2003, a system such as this should be present. THese pictures are specifically from the 2.5L RG engine (RG-minivan) but was the same for the 2.8KJ as well.

There were also some vehicles thru 04-05 that had the improved cooler seen on NAFTA vehicles but with a pneumatic actuator like previous versions instead of the (crappier) electronic actuator. Interestingly enough, the pneumatic valve actually has a higher actuator force than the electronic valve and is enumerably less prone to sticking. Early versions of the application (02-04) didn't use the throttle valve since EGR rates were low enough to preclude its inclusion in the package.

Nice. This is exactly what I have in my 2003 model. Vacuum operated EGR, single hose going behind the engine into the intake manifold just behind the CAC hose.

Also it is good to know not to disconnect the vacuum line from the modulator. Wouldn't it be possible to just plug it instead?

On the modulator the middle plug comes of real easy. I'm a little concerned now that it might pop off by itself.

Photo of what I _THINK_ is the modulator here: http://www.ausjeepoffroad.com/forum/att ... 1191231500

JIMMY JEEP · **Posted:** Mon Jan 14, 2008 6:17 am

So if i disconected the Maf would that disable the egr without any fault codes.Or is there no viable way to shut the egr valve down without throwing codes . Once again thankyou to any one who has given advice and their time answering my questions. I'm just glad i didnt buy the orm kit as it would,nt have worked on our models

Uffe · **Posted:** Mon Jan 14, 2008 8:06 am

One thing they do on the Nissan Patrols is to make a piece of aluminum and place that in the EGR internal intake. Effectively blocking the path of the exhaust gas into the EGR valve. I am not sure if that will throw codes or not. I believe since we have no measure of the amount of EG in the intake we can do this without the KJ throwing a CEL.

You make a piece of metal and sandwich it on the EGR valve body, closing the EGR valve to exhaust gasses. Easy peasy. (if you know how to cut metal

)

JIMMY JEEP · **Posted:** Mon Jan 14, 2008 9:07 am

I have taken some photos in engine bay i've looked above the starter for the egr valve but i cant spot it maybe these photos of components will help identify it.
Starter motor area

near turbo hose and coolant resevoir

some component or other with a filter underneath?

Uffe · **Posted:** Mon Jan 14, 2008 9:56 am

1st pic: Intake plenum with CAC output on one side and the small hose on the opposite side is the EGR hose from EGR valve.

2nd pic: disc-shaped vacuum operated EGR valve, boost hose, small bit of exhaust manifold heat shield, coolant container, engine noise shield, AC alu pressure line.

3rd pic: Vacuum modulator (sounds like a little scooter at times, electric motor doing PWM vacuum signals on the EGR valve), airbox, power steering fluid container, brake master cylinder etc.

When I get home from work I will copy your pictures and do some editing and re-post them with names. Maybe Mr.Mopar could do that so I am not alone in my claims

MrMopar64 · **Posted:** Mon Jan 14, 2008 4:45 pm

Uffe's comments are correct. You have the older system with the EGR cooler and valve mounted on the exhaust manifold with the pipe running around the back side of the engine and into the intake pipe with no Throtte Valve Present. These engines shouldn't have any issues with EGR failing (that I know of), but disconnecting the Mass Air Flow sensor should give you results similar to the newer vehicles in that the EGR is disabled with no limp home, but you will have the CEL.

I'm also presuming that your vehicle is RHD based on all the items on the inner fender panel on that side of the vehicle.

egr

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