Thread: EGR and turbo issues with the TDV6 2.7 diesel engine

Took both egr pipes off to inspect the EGR valve positions. Left side is fine. Surprisingly the right side egr is stuck open (with no error codes). This would explains the black smoke and hopefully the loss of power. The hole in the throttle body is directly opposite the right hand egr exit point so it makes sense that the opposite side should melt.

How could that EGR have blown open given that it was not connected to the power? Am I wrong in thinking that the force must have come from the manifold side and there had to be enough force to open it against exhaust pressure. Having the Egr disconnected meant the ECU could no longer close it even if it wasn't mechanically stuck. This is a chinese valve by the way and only about 18months old.

I am still trying to understand how the turbo hose blow off is related.

Maybe the additional pressure from the EGR being open caused the hose to blow.

There being no codes could mean that the right EGR was stuck open when I first disconnected it (bypassed it) but the trouble with this theory is that the car was driven to QLD and back with no issues.

Originally Posted by loanrangie

2.7 manifolds are not known to split, thats the 3.0. Sounds like the EGR worked its way open causing the hot exhaiust gases to melt the intake Y pipe.
I blanked my EGRS with slip in metal plates that i made from 1.15mm zinc annealed steel, these have slots and just drop in between the valve and the pipe work to the intake.
If you fit plates like this and keep the new working valves plugged in like you have you should be good, my valves were replaced by the previous owner so they were fairly new when i blanked them. I left all the pipework in place and haven't done any software mods, just removed the butterfly in the intake so the vehicle thinks they working and doing their job - done 40k since and apart from the occasional EGR DTC code it runs great.

What is the reasoning for taking off the butterfly intake valve?

Originally Posted by egr victim

What is the reasoning for taking off the butterfly intake valve?

The valve closes to allow gases to flow from the egrs then opens when they are closed, without removing it you are restricting airflow from the filter box.