Instructions for Anti Shudder Valve Type EGR. Introduction

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Janice Sparks
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1 BMW EGR Valve Delete Instructions for Anti Shudder Valve Type EGR Introduction

These instructions show how to install our BMW EGR Delete for EGRs fitted with an anti shudder valve, for all other elements of the EGR delete including exhaust manifold blanking and EGR cooler

2 These instructions show how to install our BMW EGR Delete for EGRs fitted with an anti shudder valve, for all other elements of the EGR delete including exhaust manifold blanking and EGR cooler blanking please check out our instructions here: Click here for link on non shudder valve EGR instructions These instructions just show the differences when installing the EGR delete tube on the intake manifold where there is an anti shudder valve fitted. X8R Ltd

3 Step 1: Release Intercooler Hose Lever up the clip on the inter-cooler hose and release hose. Step 2: Release EGR Cooler Pipe Loosen hose clamp and release EGR cooler pipe. Step 3: Blank Vacuum Hose

4 Remove vacuum hose from side of EGR valve. Insert our yellow plastic bung and secure with cable tie. Step 4: Remove Anti Shudder Valve Remove electrical connector and 3x bolts and remove anti shudder valve from front of EGR valve.

5 Step 5: Remove EGR Valve Remove x4 bolts and remove EGR valve from intake manifold. Step 6: Renew Intake Manifold to EGR Gasket

6 Clean the intake manifold as best as you can to remove any heavy carbon deposits. Remove old EGR to intake manifold gasket and insert our new gasket. Step 7: Fit Our EGR Tube Fit our EGR tube, note orientation as shown. Fit using our stainless steel bolts. Step 8: Fit Anti Shudder Valve

7 Fit anti shudder valve to our EGR tube and refit electrical connector. Step 9: Fit Intercooler Hose Push fit inter-cooler hose to anti shudder valve. If you need any further guidance on this install or would like to purchase the

8 parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018 Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner Delete Repair Kit Plate Blanks Introduction

9 Runner flaps fitted within the inlet manifold on Audi and VW 2.0 TFSI vehicles restrict airflow limiting performance. Our kit allows you to completely remove this system, vastly improving airflow; allowing better tuning and preventing failure of the runner flap components. The Problem The runner flaps within the inlet manifold limit airflow and performance. The factory fitted inlet manifolds on EA113 engines have runner flaps fitted within. Much like throttle body flaps these open and close to adjust airflow. These ultimately restrict airflow, even when fully open airflow is restricted. This becomes an issue the more the vehicle is tuned. Carbon can also build up on these moving parts providing more restriction and can in some cases causes failure of the moving parts within the manifold. Symptoms of the fault If the runner flaps are operating correctly there will likely be no symptoms of a fault. The benefits will only be realised when the runners are removed; improving

10 airflow. If the runners are faulty or carbon build ups have formed this can affect vehicle performance. Vehicles affected and compatibility 2.0T FSI EA113 engines: Audi TT MK (From 57 plate) 2.0T FSI Audi TTS MK T FSI Audi A3 MK T FSI Audi A4 B (From 55 plate) 2.0T FSI (FWD) Audi A4 B (From 55 plate) 2.0T FSI (Quattro) VW Passat B T FSI VW Jetta MK (From 55 plate) 2.0T FSI VW Golf/GTI MK T FSI VW R Models MK6 R T FSI Our solution Remove the runner flaps using our kit to improve airflow in the inlet manifold. Remove the runner flaps completely from the manifold using our kit. Our precision engineered CNC billet aluminium parts allow you to remove the runner flaps. Our parts replace the runner bearing blocks and the crank arm; sealing the manifold and vastly improving airflow. Ideal for stock vehicles to improve airflow and prevent carbon build up- even better for tuned engines. Customers with tuned engines have noted quicker throttle response, less turbo lag, improved torque and BHP gains when deleting the runner flaps. You will receive X4 Left hand bearing block blanks X4 Right hand bearing block blanks

11 1X Crank arm blank 1X Manifold gasket X8R Ltd Step 1: Remove Ball Joint Crank Arm Locate the ball joint crank arm on the end of the manifold. Using a small flat bladed screwdriver lever the retaining clip out of position and save for reinstall. Using a pair of grips pull the ball joint crank arm out of the manifold.

important to achieve a seal when blanking off.

12 Please note the seal on the crank arm in the images. If this comes out with the crank arm please remove and reinsert in to the manifold, this is important to achieve a seal when blanking off. Step 2: Insert Our Crank Arm Blank Insert our blank in to the hole left by the crank arm. Refit retaining clip (check image for orientation) this will secure the blank in position.

Step 3: Remove the Runner Flaps and Clean

Pull each flap gently until the complete

this point it is a good idea to clean any

13 Step 3: Remove the Runner Flaps and Clean Manifold Using a pair of grips, grip the runner flaps and pull away from the manifold. Pull each flap gently until the complete assembly can be pulled loose from the manifold. At this point it is a good idea to clean any carbon deposits from the manifold. Particularly where the gasket sits and where the bearing block blanks locate. Step 4: Insert Our Bearing Block Blanks

Insert our blanks in place of the bearing blocks

flush with the manifold, if they do not fully

14 Insert our blanks in place of the bearing blocks from the runner flaps. These simply push in to position. The blanks are handed left and right, insert 4x left hand and 4x right hand blanks. Press the blanks firmly in to position to sit flush with the manifold, if they do not fully engage clean any carbon deposits and push back in to position. Step 5: Fit Our Replacement Manifold Gasket

15 Again ensuring the manifold is clean and free of deposits; insert our new gasket in to the groove on the manifold. This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018.

16 Land Rover Discovery Defender TD5 2.5 EGR Valve Delete Blank Kit (with or without cooler blanks) Introduction The Problem Carbon rich recirculated exhaust gasses leave deposits within the EGR valve which restrict or damage the EGR valve causing vehicle faults. The EGR valve on these vehicles is designed to redirect a portion of the vehicles

17 exhaust gases back to the engine through the intake manifold. Carbon rich recirculated exhaust gasses enter the EGR valve before the intake manifold, over time Carbon deposits gather in the EGR valve and can interfere with the operation of the EGR valve flap and can block air flow. Resulting in reduced fuel economy and vehicle performance. Often this build up damages the EGR valves which are expensive to replace. This malfunction of the valve or blocking of the exhaust port causes Detonation (also known as pinging or spark knock) causing misfiring or rough idle. Many examples can be found across the internet showing these EGRs completely blocked up with carbon; significantly reducing airflow to the intake. Symptoms of the fault Rough engine running Misfiring Decreased throttle response Loss of power or torque Smokey engine Low MPG / decreased MPG Vehicle stalling at low speeds Acceleration slow / sluggish Vehicles affected and compatibility Land Rover Discovery MK 2 MK II TD5, , all models. Land Rover Defender, TD5, , all models. Engine Codes 10P, 15P and 16P. Associated part numbers: , ERR6620, WAV100270, WAV Part numbers are for guidance only, please inspect your EGR to ensure you are

18 purchasing the correct kit. Our solution Our kit allows easy replacement of the EGR valve with our improved design part which stops any recirculated exhaust gases entering the intake manifold. Resolving vehicle faults and stopping carbon build ups in future. Install our completely Stainless Steel EGR blank and eliminate build up in the intake manifold. This allows the engine to breath better which can improve vehicle performance and fuel efficiency. Our EGR blanking kit stops these recirculated exhaust gases entering the intake manifold, eliminating the risk of future build ups. Our kit is the most comprehensive available including all components required to delete the EGR valve and will fit in the same way as the OEM part. You will receive: 1x Stainless steel EGR tube, precision machined and all constructed from stainless steel, featuring a substantial bead to ensure an air tight seal with the boost hose. 4x Stainless steel EGR to intake manifold bolts. 1x Intake manifold to EGR gasket. 1X solenoid vacuum pipe blanking plug with cable tie to secure. 1X Exhaust manifold blank with high temperature gasket and fasteners allowing you to remove the EGR to Exhaust manifold flexible tube that often blocks or splits. Our kit is top of the range and the most comprehensive kit available. Check out our instructions and video to see how our kit allows you to successfully eliminate the EGR valve on your vehicle. Possible advantages of EGR deleting: Turbo can spool up quicker and at lower revs resulting in less turbo lag. Prevents carbon build-up inside intake manifold and ports.

19 Smoother pick up from idle, engine running and better fuel economy. Increases in power and / or torque which slowly fades as carbon builds up. Improved fuel consumption / MPG. You will receive.1x Stainless steel EGR tube 4x Stainless steel EGR to intake manifold bolts. 1x Intake manifold to EGR gasket. 1X solenoid vacuum pipe blanking plug with cable tie to secure. 1X Exhaust manifold blank with high temperature gasket and fasteners. (2X EGR cooler blanking plates, gaskets and fastners) IF PURCHASED Step 1: Remove the Engine Cosmetic Cover

20 Remove the engine top cosmetic cover; 3 bolts in total one on drivers side and two on passengers. Remove the radiator / fan cover (4x Philips head screws) Step 2: Remove the Pipes From the EGR Valve

21 Pull the Blue vacuum pipe loose from the EGR valve. Loosen the Jubilee clip and remove the boost hose from the EGR valve. Step 3: EGR Cooler (skip This Step If Your Vehicle Doesn t Have an EGR Cooler)

22 Only relevant for vehicles fitted with an EGR cooler: This repair stage is shown on the bench for clarity, it should be carried out on the vehicle and only the metal pipes should be removed, the EGR cooler should remain mounted and no other pipes removed. Remove metal pipes from both ends off the EGR cooler (EGR to cooler and cooler to exhaust manifold) Clean up the mating faces of the EGR cooler and ensure they are free from loose rust, carbon deposits and grease. Using our blanks, gaskets and fasteners blank off the EGR cooler. If the mating faces are particularly rusty you may need to use a sealing paste to achieve a good

23 seal. Step 4: Loosen EGR to Exhaust Manifold Pipe (non EGR Cooler Models Only) Locate the end of the EGR metal tube that connects to the exhaust manifold. Loosen bolts and release connection. Remove bolt that secures the tube to the engine block. Step 5: Remove EGR Valve Remove 4x bolts and remove the EGR valve and EGR to exhaust manifold tube.

Step 6: Clean Up the Mating Faces Clean up the mating faces

surfaces are clear of loose rust, carbon and grease.

manifold as you can through the hole exposed by the removal

Step 7: Blank Off the Vacuum Solenoid Trace the Blue vacuum

Remove the pipe from the solenoid and blank off using our

24 Step 6: Clean Up the Mating Faces Clean up the mating faces of the intake manifold and exhaust manifold, make sure surfaces are clear of loose rust, carbon and grease. Try to remove as much carbon build up from inside the intake manifold as you can through the hole exposed by the removal of the EGR valve. Step 7: Blank Off the Vacuum Solenoid Trace the Blue vacuum line back from the EGR valve to the solenoid. Remove the pipe from the solenoid and blank off using our blank and secure with the cable tie. It is important that you disconnect the correct pipe, disconnecting any other pipes can affect braking.

25 Step 8: Blank the Exhaust Manifold

26 Using our stainless steel blank, gasket and fasteners blank off the hole on the exhaust manifold. If the manifold is excessively corroded you may need to use a sealing paste here to get a seal. Step 9: Fit Our EGR Delete Tube

27 Fit our EGR delete tube to the intake manifold using our stainless steel bolts, remember to fit our gasket between the EGR tube and the intake manifold. Attach the boost hose to the EGR tube and secure with the Jubilee clip. Step 10: Check for Leaks

28 Before refitting the engine covers start the vehicle and check for any leaks. This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018 BMW EGR Valve Stainless Steel Removal Bypass Delete Blanking Kit Instructions Introduction

29 , Carbon rich recirculated exhaust gasses leave deposits within the EGR valve which restrict or damage the EGR valve causing vehicle faults. Symptoms of fault EGR valve failed, EGR valve clogged up, Rough engine running, Misfiring, Decreased throttle response, Loss of power or torque, Smokey engine, Low MPG / decreased MPG, Vehicle stalling at low speeds, Acceleration slow / sluggish The cause The EGR valve on these vehicles is designed to redirect a portion of the vehicles exhaust gases back to the engine through the intake manifold. Carbon rich recirculated exhaust gasses enter the EGR valve before the intake manifold, over time Carbon deposits gather in the EGR valve and can interfere with the operation of the EGR valve flap and can block air flow.

30 Resulting in reduced fuel economy and vehicle performance. Often this build up damages the EGR valves which are expensive to replace. This malfunction of the valve or blocking of the exhaust port causes Detonation (also known as pinging or spark knock) causing misfiring or rough idle. Many examples can be found across the internet showing these EGRs completely blocked up with carbon; significantly reducing airflow to the intake. Our kit allows you to completely remove the EGR system curing these faults for the life of the vehicle. The solution Install our completely Stainless Steel EGR blank and eliminate build up in the intake manifold. This allows the engine to breath better which can improve vehicle performance and fuel efficiency. Our EGR blanking kit stops these recirculated exhaust gases entering the intake manifold, eliminating the risk of future build ups. Our kit is the most comprehensive available including all components required to delete the EGR valve and will fit in the same way as the OEM part. You will receive: 1x Stainless steel EGR tube, precision machined and all constructed from stainless steel, featuring a substantial bead to ensure an air tight seal with the intercooler hose. Our kit is top of the range and the most comprehensive kit available. Check out our instructions and video to see how our kit allows you to successfully eliminate the EGR valve on your vehicle. Possible advantages of EGR deleting: Turbo can spool up quicker and at lower revs resulting in less turbo lag. Prevents carbon build-up inside intake manifold and ports. Smoother pick up from idle, engine running and better fuel economy. Increases in power and / or torque which slowly fades as carbon builds up.

31 Improved fuel consumption / MPG. What you will receive 1x Stainless steel EGR delete tube 4x Stainless steel EGR delete tube mounting bolts 1x Stainless steel exhaust manifold to egr pipe blank 1x High temp exhaust manifold blank gasket 2X Exhaust manifold blank bolts with locking washers 2X Stainless steel EGR cooler blanking plates 1X Intake manifold to EGR gasket 1X Vacuum tube plug with cable tie Vehicles affected Part numbers: , , BMW engines: M47 M47N M57 M47N2 M67 M47R 3 series E46 318d td d cd

32 320td d xd series E39 520d d d X5 E53 3.0d X3 E83 2.0d E38 7 Series 730d d E65 7 Series 740d Rover MG ZT Land Rover Freelander TD Land Rover Range Rover TD Vehicles which utilise a vacuum operated EGR will not normally show a fault code when replaced with our EGR blank. Vehicles with an electronically operated EGR will show a fault code which will need to be mapped out. This is the same for all suppliers of EGR deletes whether stated or not. This item is for diesel vehicles only not for petrol vehicles.

33 If unsure call or and we can look up your vehicle. Available from X8R Ltd Step 1: Remove Cosmetic Engine Covers Remove the 2 bolts (on some models 3) and lift off the covers.

34 Step 2: Remove Hoses Remove the vacuum hose, gently pull this off of the EGR valve. Loosen the jubilee clip on the intercooler hose and remove the hose. Step 3: EGR Cooler (skip This Step If Your Vehicle Doesn t Have an EGR Cooler)

Only relevant for vehicles fitted with an EGR cooler: This repair stage

vehicle and only the metal pipes should be removed, the EGR cooler should

Remove the metal pipes from both ends off the EGR cooler (EGR to cooler

cooler and ensure they are free from loose rust, carbon deposits and

Locate our blanking caps on to each end of the cooler and reinstall the

If you suspect the caps are not sealing repeat the process ensuring the

35 Only relevant for vehicles fitted with an EGR cooler: This repair stage is shown on the bench for clarity, it should be carried out on the vehicle and only the metal pipes should be removed, the EGR cooler should remain mounted and no other pipes removed. Remove the metal pipes from both ends off the EGR cooler (EGR to cooler and cooler to exhaust manifold) Clean up the mating faces of the EGR cooler and ensure they are free from loose rust, carbon deposits and grease. Locate our blanking caps on to each end of the cooler and reinstall the clamps ensuring the caps remain central as the clamps are tightened. If you suspect the caps are not sealing repeat the process ensuring the caps are central, the EGR cooler has a wide tolerance so a sealing compound may be needed to make an air tight seal. Step 4: Remove EGR Pipe From Exhaust Manifold (non EGR Cooler Models Only)

36 Remove 2x bolts and release the flexible metal pipe from the EGR to the exhaust manifold. Step 5: Remove the EGR Valve Remove 4x bolts retaining the EGR valve. Remove the EGR valve and the EGR to exhaust manifold pipe. Step 6: Clean the Mating Faces

Clean as much carbon from the intake manifold as you

To be thorough the intake manifold could be removed

For instructions on this please check out our swirl

Remove the old EGR to intake manifold gasket and

37 Clean as much carbon from the intake manifold as you can from the hole now exposed. To be thorough the intake manifold could be removed and thoroughly cleaned. For instructions on this please check out our swirl flap instructions. Remove the old EGR to intake manifold gasket and replace with ours. Clean the mating face of the exhaust manifold, remove any loose rust, carbon or grease. Step 7: Blank Off the Vacuum Pipe

If your EGR valve is vacuum operated blank the pipe using

Step 8: Blank the Exhaust Manifold Using our supplied

bolts; secure the EGR delete tube to the intake manifold, do

39 If your EGR valve is vacuum operated blank the pipe using our blank and secure with the cable tie. Step 8: Blank the Exhaust Manifold Using our supplied blanking plate, gasket, bolts and locking washers, blank the hole on the exhaust manifold. Ensure the locking washers are installed between the bolt heads and the blanking plate. If the exhaust manifold is very corroded some sealant paste may be needed to create a seal. Step 9: Fit Our EGR Tube Using our supplied stainless steel bolts; secure the EGR delete tube to the intake manifold, do not over tighten the bolts. These should be nipped up just to create a seal on the EGR to intake seal. Fit the intercooler hose to the EGR tube and secure using the jubilee clip.

40 Step 10: Test Seals Before refitting the engine cosmetic covers, start the vehicle and check for any leaks. Step 11: Refit Engine Covers

41 Refit engine covers. This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018

Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner Delete Repair Kit Plate Blanks Install Instruction Guide

instructables Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner Delete Repair Kit Plate Blanks Install Instruction Guide by x8rltd Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner