EGR Valve Replacement on 2010 TDV8

I went to Lightning Ridge in June this year with my caravan and refuelled in Cann River. About 100kms later I had a loss of power which doesn't happen with the TDV8 so I was using Sporto gears, 4th when I should have been buzzing over the hills towards Canberra in 6th. [smilebigeye]
In Canberra I spoke to a mobile mechanic who diagnosed bad fuel and he was sure after a couple more refills it would improve. I bought some fuel additive stuff as well. When I returned from LR it seemed a bit better so I pressed on with it. I never had any unusual lights on the dash at any time during this whole affair. Some mornings I would start it up and get quite a bit of white smoke from the right exhaust pipe. Diagnosed with a crook injector this time. Then I spoke to you gurus and it leads me to EGR problem. One day the exhaust started to sound very throaty......kinda nice actually [smilebigeye]. Slight loss of power one day when we went to Orbost with the horse float and then a very throaty exhaust! In to the mechanic and the hole was found and the rest is history.

I can’t understand where the hole is located from the photos. Can you explain from this diagram.
https://www.aulro.com/afvb/images/im...017/11/236.jpg

Or this.

https://www.aulro.com/afvb/images/im...017/11/237.jpg

Attachment 132080

The part was sitting on a bench so there is other Jungle-a-mugela there which is not related to the EGR manifold.

This is the offending air duct.............

Attachment 132291

This is the offensive hole in said offending part......

Attachment 132292

Bear in mind that at no stage did I have any lights come on on the dash....EVER!
This is looking down the throttle body on the RHS.

Attachment 132293
I had sprayed Wurth's EGR cleaner down there a couple of times.
This is the LHS. I had never sprayed EGR cleaner down that side.

Attachment 132294

This is where my mechanic placed the emulators.

Attachment 132295

Attachment 132296

Pretty neat I reckon.....and not a red cable tie in sight. [smilebigeye]
While he was in the valley he replaced the oil cooler seals as well. They were fine but he was advised it was a good idea while he was in the area.
The air duct was $500 ex England delivered.
A gasket was $90.00
The emulators were $554.
He only charged me 4.5 hours labour @ $85/ hour.
Grand total of $1679. Pretty happy with that.
I drove it home, it felt fine, no lights on the dash and running cool. When I got home there was a slight smell of raw fuel so I'll take it back in about an hour to find the problem.
Fingers crossed all is well.

Update on my previous post. The car is driving sweetly and smoothly. I don't think it's quite as powerful as it was before but maybe I'm driving it more sedately. It is definitely using more fuel, about 1 - 1.5 L/100 in both towing mode and non towing mode. It still has plenty of power when towing my van so no complaints there.

Quote:

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Originally Posted by mustang2

G'day;
Just reading your thread and wondering if you've considered going non EGR (complete removal).
My 2008 RRS tdv8 is now losing coolant at an alarming rate when towing with no obvious power loss, overheating (with coolant still present) or any other symptoms of a blown head gasket.
Without dismantling my diagnosis is failed a egr valve or cooler on the right bank due to steam from that exhaust pipe.
Has anyone done a complete egr removal or know of a shop that does it including remap as I suspect I will be up for similar costs to replace failed parts?
I'm open to any advice.
Cheers.

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Mustang, curious if you ended up finding more info about a complete removal, i have my wifes tdv8 RRS apart at the moment, its already had the EGRs tuned out but one is stuck slightly opened i suspect so considering getting rid of them all together - i have to do the oil cooler gasket so i have to pull most of it out for that anyway.

Has anyone who has EGR tuned out unplugged them to see if it throws any errors? i assume it wont but would like to know before i get that far, im already pretty deep into it so to late to check it out now.

Not answering your question but perhaps indicative, my brother's stock 2008 3.6 RRS has the EGR connectors disconnected because one or both were sending incorrect position information. There is an instrument cluster warning so the connectors will have to be refitted for a rego check but he reports that the car goes well again and doesn't go into limp mode at the slightest whim.