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Vitesse

Member Since: 21 Mar 2014
Location: Sussex
Posts: 409

2015 Defender 90 Puma 2.2 XS CSW Santorini Black

2.2 Egr valve change

Just completed the Egr change for second time on my 2015 Puma. Took me about 8 hours the first time due to the immensely fiddly job and a lack of one or two tools and made a bit worse with aircon pipes in the way. The replacement yesterday took me 2 hours. A few extra tools such as flexible extension sockets helped immensely. Also, removing a little more hoses and pipes than recommended in the manual helped. Just thought I would share this experience as no doubt a few on here are likely requiring egr valves. Mine failed at 34000 miles and then 101000 mile's. I have some tips if anyone needs via PM. 🙂 2015 90 XS Santorini Black

28th Sep 2025 9:59am

macfrank

Member Since: 05 Nov 2015
Location: somewhere in the north
Posts: 1130

2015 Defender 110 Puma 2.2 SW Keswick Green

👍 I hope I wont need it but good to know!
How do you notice an EGR failure and do you now why it failed so early?

29th Sep 2025 3:21pm

Johan_B

Member Since: 20 Sep 2024
Location: Gothenburg
Posts: 153

2007 Defender 110 Puma 2.4 CSW Tonga Green

One way to notice is what I experience now. You can hear the EGR valve operating while you are driving.

Prior to that the chucka-chucka when you turn the engine off becomes lauder, or doesn't happen at all.
In the end it will get stuck and then produce a fault code and check engine light illumination. Possibly a limp home mode on the engine.

The problem is carbon/soot build up on the valve, the chucka-chucka is a cleaning cycle but it is insufficient. I will change mine soon and see if I can clean it and create my own part-swing system by always having a good one on the shelf.

29th Sep 2025 4:05pm

Vitesse

Member Since: 21 Mar 2014
Location: Sussex
Posts: 409

Yes, all of the above in terms of fault diagnosis. I also use an ultraguage so I can monitor Egr flow and %error
So in my case I can see the valve failing. And of course eventually the engine light
This is now the third Egr valve from new in 2015. Now just on 106000 odd miles. Car driven daily all that time with good distances etc

I did look to try and rejuvenate and old one but I found they are not easy to clean and should really be fully dismantled. That involves cutting some welded joints. I didn’t bother in the end. But if you can clean and re-use I would be keen to see the process 👍 2015 90 XS Santorini Black

29th Sep 2025 7:33pm

Trundlebus

Member Since: 15 Jul 2014
Location: Herts
Posts: 100

Or, blank it off and get the software changed to eliminate it from the system. Better mpg and better running engine. 😁

30th Sep 2025 12:40pm

Johan_B

Member Since: 20 Sep 2024
Location: Gothenburg
Posts: 153

Seems we have different valves between the 2.4 and 2.2. I haven't seen the component myself but seen reports on here that the 2.4 valve is serviceable.

30th Sep 2025 12:44pm

Vitesse

Member Since: 21 Mar 2014
Location: Sussex
Posts: 409

Yes the 2.4 egr valve is different. I am unsure if it is more serviceable or not. 2015 90 XS Santorini Black

30th Sep 2025 7:46pm

jbcollier

Member Since: 29 Apr 2024
Location: Edmonton AB
Posts: 273

2009 Defender 110 Puma 2.4 SW Alpine White

It is easy to take the 2.4 EGR valve to pieces. Getting it out in the first place is of equal fun.

I recommend removal and software delete as the EGR valve creates harmful deposits.

1st Oct 2025 2:41pm

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