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[2LV8ETR]

I have posted this topic previously using another site's info, but I have a better way of doing things and this will be from experience with my own photos to assist you in eliminating this stupid piece of crap.

First things first, what's an EGR valve?
The EGR valve helps your car more efficiently and completely burn fuel by recirculating a portion of your exhaust and running it through the combustion process again. This results in a cooler, more complete burn of the fuel which decreases you car's noxious emissions by prohibiting the formation of some harmful gases.
The benefit of the EGR is just to meet emission targets, nothing more. The problem is that with most emissions devices, you end up with losing power and economy as a result.
The benefits of blocking the EGR are less black smoke, increased power, less crud (carbon particles) being passed back through the system, and a slight increase in fuel economy. Some would also argue it adds to head problems as it gives uneven temperature across the head. It makes sense to do it.

When I used this process, I was rebuilding my engine at the time so everything is easily accessible. You can do it if you aren't rebuilding your engine, but the inlet and exhaust manifolds need to be removed to perform this procedure the way I did it. I would only recommend it if you have at least basic engine knowledge, otherwise use this process here - Blocking Off Toyota Surf EGR Valve.
If you end up using this procedure, when you remove the inlet manifold you'll see all of the shit that has accumulated in the manifold and you'll understand why your diesel chugs out more smoke than Puffing Billy.

Here's what I did.

1: Remove the inlet manifold EGR studs.

 EGR Removal 01 Inlet Studs.jpg   1.1MB   35 downloads

2: Use a core (welsh) plug to block off the manifold bypass tube opening.

 EGR Removal 02 Inlet Core Plug.jpg   938.04KB   29 downloads

3: Silicon the opening for the insertion of the core plug.

 EGR Removal 03 Inlet Core Plug Silicon Manifold.jpg   1.01MB   22 downloads

4: Silicon the core plug.

 EGR Removal 04 Inlet Core Plug Silicon Plug.jpg   633.27KB   16 downloads

5: Position the core plug in the EGR bypass opening.

 EGR Removal 05 Inlet Core Plug In Position.jpg   1.06MB   16 downloads

6: Bed the core plug. I used a hammer and a gympie, to ensure equal diametric pressure. The last thing you want to do is to insert it on a skew as it will compromise the seal.

 EGR Removal 06 Inlet Core Plug Bedding.jpg   743.96KB   17 downloads

7: Clean of any excess silicon and viola! The core plug in-situ.

 EGR Removal 07 Inlet Core Plug Installed.jpg   999.97KB   11 downloads

8: Remove the exhaust manifold EGR studs.

 EGR Removal 08 Exhaust Studs.jpg   966.48KB   14 downloads

9: My studs wouldn't budge so I had to use a hacksaw to remove them.

 EGR Removal 09 Exhaust Stud Removal.jpg   784.2KB   8 downloads

10: The studs after they've been cut.

 EGR Removal 10 Exhaust Studs Removed.jpg   667.38KB   13 downloads

11: As with the inlet manifold, use a silicon on both the core plug and the EGR bypass opening.

 EGR Removal 11 Exhaust Core Plug Silicon Plug.jpg   767.63KB   11 downloads

12: Clean of any excess silicon and viola! The core plug in-situ. The process is now complete. All you have to do now is finish rebuilding your engine or put everything back together.

 EGR Removal 12 Exhaust Core Plug In Position.jpg   722.98KB   14 downloads

Here are the silicons I used. The copper mix is for the exhaust side and the black is for the inlet side.

 EGR Removal Silicons Used.jpg   879.88KB   14 downloads

The core plugs I used were purchased from Veale and the part numbers are CPA71205 and CPA67205.

Now you can throw this shit out!

 EGR Removal EGR Valve And Recirc Tubes.jpg   1.34MB   18 downloads

I have been using the car now for six months and I can attest to an improvement in fuel economy and power, and also less black smoke from the exhaust.
It also makes working around the engine easier because it's no longer in the way.

DO IT!