Forum 4x4

Hi Tony,
I have a 2005 model.
I have done the easy, mechanical, low cost option called the "block off the EGR supply". I have been running it for about a year now, no problems.
If you follow these simple instructions you can effectively stop any exhaust gases flowing into the intake manifold.
Find some 0.25mm steel shim and cut a piece about 25mm diameter with a little tab for you to hold it with some pliers. Loosen the two bolts on the flange of the rear EGR pipe that bolts onto the cooler block. I found that removing the fuel filter assembly helped in doing this part.
Spring the pipe a bit so that you can slip in the blanking plate then nip up the bolts again.
Now you need to remove the butterfly plate from the flow control valve (FCV).
To do this unclip the power lead to the FCV, remove the CAC hose, then the four allen bolts that hold the FCV onto the intake elbow. Just be careful not to damage the gaskets as these can be reused.
When you have the FCV on a bench carefully close the butterfly against the spring action. You could probably get some help from someone at this stage to hold the plate shut while you remove the two T15 torx screws that hold the plate to the shaft.
Do not push down with too much pressure here so as to not bend the shaft. The screws are loctited in so they require just a little force to crack them loose.
Once the screws are out just slowly return the butterfly to the open position, then you can pull out the butterfly plate.
Reinstall the FCV and CAC hose etc and you are good to go.
The only negative from this is that you will have a slightly rougher shut down because the FCV does not snuff out the engine.
I have also discussed this on LOST in a number of threads (MACKJ is my sig).