2011 4.4 TDV8 EGR Failed

**Takb** · 12th September 2024, 09:23 PM

2011 L322 4.4 TDV8 AB with 305,000kms.

TLDR;
Can anyone recommend someone who can do an EGR delete on this engine in the Newcastle, Sydney or in this vicinity?
/TLDR;

I had significant smoke being generated out the tailpipe about 10,000 kms ago, particularly at start-up. Symptoms started when towing a trailer down the M1 to Sydney (car changed down going up the hills at Hawksbury and I smoke-screened the cars behind).
I had my induction system cleaned, injectors cleaned, inlet manifolds checked - no cracks. This fixed the problem.

About 5k kms ago, car started being sluggish/non responsive to throttle after cold start. At one point could put my foot to the floor at stand-still and revs stayed at idle. Eventually revs would start to build then be fine. Fine once warmed up.
Had my indie check this out and suggested that it's likely EGR valve and recommend delete.

Now 3/4 of the way through a 3500km road trip.
I started getting the sluggish behavior after first morning start again. Started getting the odd Restricted performance fault:
P006A-00 (27) Manifold absolute pressure - mass or volume air flow correlation
Cleared faults with the IID and kept going. Otherwise has been fine.

I cleaned the MAF and MAP sensors and only had one or two Restricted performance once after that.
Now morning starts have been rough. Revs barely enough to keep the engine running. Have to try to rev it in idle to get revs up (although it takes quite some time before it starts responding to any throttle input. Starts blowing smoke until revs pick up (could just be running rich). Car sluggish at slow speed (no or minimal response to throttle input) for 5 - 10 mins until it warms up and then fine. It starts responding when revs build and so more pressure in the inlet manifold. Symptom was that the Mass Air Flow value would not rise on throttle input (until revs finally built and I guess first turbo kicked in to push in some air).
I had been thinking that I might have a cracked inlet manifold that must close once it gets some heat.

But then today I got a new fault:
P0490-77 (27) Exhaust gas recirculation control - circuit high - Mechanical failure - commanded position is not reachable

If I clear faults, this comes back immediately. I had been monitoring live values on the whole trip and I did see EGR value position change. But with this new fault, I see that the computer isn't even commanding the EGR. See screenshots of live values attached.

And then another new fault today:
P0401-00 (24) Exhaust gas recirculation flow insufficient detected

So it now looks like my EGR valve is stuffed. I'm still 1000kms from home and starting the return tomorrow so hoping I can limp home. I'm about to find out. Anyone got suggestions on what I might be able to do to help limping home?

So bottom line: thinking I should get EGR delete. Do you agree?
I know that you can just get an software EGR delete which would be fine if the EGR closes completely. Given the readings I have, I suspect that mine isn't 100% closed so would need to physically blank.

I found some posts on FFRR suggesting that there are no EGR delete products available (unlike the 3.6) but people had been making their own blanking plates out of 2mm SS.

I have found a few "remappers" online that suggest they can do the ECU remapping for this engine.

I'm in Newcastle NSW so looking for either a local to do the remapping (I haven't found anyone yet) or else Sydney (there are a few websites offering this).

Can anyone recommend someone in this vicinity who can do an EGR delete for the 4.4?

Any other observations/suggestions?

First image is before the EGR fault.
Second image is after the EGR fault.
Third image are the faults I was originally getting (yes I always get P040D-00 (2F) fault but this I believe has no impact on performance).
BeforeEGRFault.jpg AfterEGRFault.jpg InitialFaults.jpg CurrentFaults.jpg

**Graeme** · 13th September 2024, 06:36 AM

Mine has a Viezu economy remap with EGR deletion (+21-26 Kw +50 Nm => 251-259 Kw & 750 Nm), done to eliminate sluggishness off the mark, reduce inlet tract blocking and to reduce the heat underneath the oil cooler. The remap was done by a local remapper late one afternoon as the existing map was read then sent to the UK for the changes then loaded within an hour. I'm very happy with the engine performance in all circumstances, including no loss of its ability to idle along rough tracks which was by biggest concern. However the EGR valve still goes through its check cycle which would likely cause a fault if the valve didn't move as required or if the electrical connector was disconnected.

I made a blanking plate some time ago but misplaced it when it became obvious that the EGR would need to be mapped-out, so I'll make another one day in case the valve doesn't seal after a check cycle.

Edit: Sporttech Auto Repairs in Guildford (western Sydney) is listed as a Viezu agent. I used the Wagga Wagga agent but most if not all LR specialist workshops could do a remap, time permitting.

Edit2: I had the PCM updated to the latest version prior to the remap because I was aware of a fix for jerkiness on cruise control at around 100 kph.

**Takb** · 14th September 2024, 07:57 PM

Thanks so much for this info Graeme. Reassuring to know that this is a successful path.

Last two days I’ve been driving back from Halls Gap and now in Canberra for the night before last leg home.
Things were rough when I left Halls Gap. EGR mechanical fault wouldn’t go away and car instantly into Restricted Performance mode. I can see that the EGR doesn’t operate in this mode. Commanded EGR is 0%. Figured out that manually changing gears with the paddle shifters using sport mode (so that it keeps the gear you select) let me manage ok in restricted mode (D8 gear is too high to maintain speed but D7 works fine).
A couple of engine off rest stops along the way, the EGR started moving again meaning I could drive without restricted mode (although hesitant and jerky from standstill). An overnight and a couple of rest stops the next day and the damned thing is now behaving perfectly. I just think the old girl had an aversion to Victoria since the symptoms started after the first night we were in Victoria and it was literally Albury on our return that all symptoms went away :-)

I spoke to my LR indie on the drive home and they confirmed that they can do the PCM update for EGR delete and will take a look to determine if blanking plates will be required or electronic disable is enough. I’m booked in for Monday. I’ll ask about the PCM update.

**Graeme** · 14th September 2024, 08:26 PM

Good to know that you're out of trouble. These engines have heaps of torque so working up some speed at minimum revs is possible.

I've used manual shifting with restricted performance on my previous D4 to get by, although pretty useless towing a trailer. I was also able to get up to speed in an idling TD5 D2 when the throttle potentiometer died in the middle of Canberra afternoon peak hour traffic then drive home about 3 hours away.

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