25-06-2013, 01:53 PM
(This post was last modified: 25-06-2013, 01:54 PM by tigerstyle.)
(25-06-2013, 01:16 PM)Poodle Wrote: Yours will be the earlier type without the coolant heat exchanger. It's exactly the same process to bend it so you can fit the blanks in, just easier and roomier than the newer sort, lucky you! Get a crowbar in there and give it a bit of persuasion. If you're really struggling for access, support the sump with a jack, remove then top engine mount and let the jack down slowly to roll the engine forwards, will give you a few more inches. If you do that just be careful nothing gets pushed into the back of the rad.
I'm not one to turn down bad advice, but having just finished the job, I would say it is far far far easier to just loosen the inlet elbow and make room that way on the inlet side of the EGR pipe. Two 13MM bolts as well as the bolts you'll already have undone for the EGR is all it takes to get 10-15MM of backwards (towards passenger side shock tower) play in the inlet elbow, enough room to slip in the EGR blank and gaskets with ease. No prying on the EGR pipe needed or danger to rad.
You'll need to take of the small 'L' bracket holding up the inlet to do this, the guide mentions just loosening the bolt is enough, but it's only 2 10MM bolts and the hole bracket comes off anyway. As well as a further 10MM bolt holding the two inlet pipes together preand post turbo, but it's all on display up there so obvious to see.
I found it quite easy to paperclip the EGR blank and two gaskets together to help line them up, get both bolts in finger tight and then slide out the paperclip before tightening everything up.
Hope this comes up in a future search and helps someone out! I would have taken pictures but my hands (and yours) will be very oily and black by this stage, and I haven't trained my dog to use the camera yet...