300 tdi EGR ??

[K2]

Hi Guys need your expertise re blue smoke again. We stripped down intercooler and pipes. Intercooler free of black sludge, from EGR connection and into inlet manifold very thick blacl sludge :!:  Thermostat has been stuck open not yet investigated anything else. Smoke from exhaust very thick but only when cold. Any ideas :?: Also suspicious looking oil seepage from two injector seals :!:

[bezzabsa]

could be from lots of small local journeys - Fords always used to suffer from that - as engine isnt getting up to temp, so a lot of 'dampness' running through ya engine - take it for a good 2 hour drive every so often

[DD]

Hi Guys need your expertise re blue smoke again. We stripped down intercooler and pipes. Intercooler free of black sludge, from EGR connection and into inlet manifold very thick blacl sludge :!:  Thermostat has been stuck open not yet investigated anything else. Smoke from exhaust very thick but only when cold. Any ideas :?: Also suspicious looking oil seepage from two injector seals :!:

hi there, remove the egr valve, blank it off, throw valve in bin, clean out manifold. have a look here - http://forums.lr4x4.com/index.php?showtopic=7757

[Guardian.]

egr to manifold does glue up, thats what happens it uses the used exhaust gasses, full uf crap.
remove the egr and blank it off, this will slowly clear over a long period of time, it will not get any worse anyway.
as for the performance boost, dont read to much into it, you will be lucky if you notice any by just blanking this.
the only thing i noticed on one i did was it took that hesitation away before it started accelerating from still, not ever noticed any difference on any other.

[K2]

Thanks guys all this info made a lot of sense. Never had this problem on the 200 tdi, obviously. So could have pulled half the disco apart. Project for the weekend remove offending EGR and with any luck gradual decrease in blue smoke as you can see me coming for miles. LoL

Cheers Guys  :D