EGR removal

[Jukie88]

Can some one please do a guide labelling which pipes do what and how I go about it please :-( or link to one but I can't seem to find any cheers

[DeeTurbo]

Here's how I got mine off.


You can see above the turbo one of the nuts that hold the valve on the manifold. Boy was it a pain to get to this and the other one. This one I got to from below and the other from above the engine.

The first spanner I used I could feel the nut starting the round so I had to try get a socket on to it but the inlet pipe was in the way. To get the inlet pipe out the way I had to remove the 90 degree elbow off the inlet manifold, the vacuum pump off the side of the engine and I had to move the engine forward a bit by undoing the top engine mount. With that all done the clutch cable kept getting in the way also.



EGR port on the 90 degree elbow. Not looking to bad in there.



Pipe coming from the EGR.



Inside the 90 degree elbow. Nice and clean.





Pic of the bay.



Close up of the piping and what had to be removed.



Engine on the crane, this crane has been modified for stuff we do at work.



The EGR removed.



The valve covered in crap.





Inside the valve where it goes on to the the exhaust manifold. The valve hasn't been activated in a long time I think it's been around ten years.





The new plate fitted.



Inside the inlet manifold.



The plate fitted to the 90 degree with a push fit adaptor so I can measure the boost pressure.

You can just unplug the solenoid that activates it.

1. vacuum line to EGR valve
2. vacuum supply line from Vac pump
3. EGR solenoid
4. EGR solenoid blue plug
5. Air douser solenoid
6. Air douser solenoid black plug
7. vacuum line to Air douser valve
8. vacuum supply joint Tee from Vac pump via the master cylinder


on my HDI i have unplugged the pipe (2) from the Tee (8) and plugged (2) with a suitably sized plastic plug to prevent loosing vacuum from the brakeing system as shown in the picture

[Jukie88]

Fml that looks like alot of work !!!!

[DeeTurbo]

Yep, that's why most people just disconnect the vacuum pipe to the solenoid.

[kentiiboii]

Top pipe just behind the engine just place a small blanking plate purchased from eBay. Very niggly but does the same. .

[Jukie88]

So if I remove and block that vacuum pipe would it have the same effect if any ??? Also if I buy a blanking plate would I still has to remove the whole unit ?? Sorry to ask annoying questions but it all look diddly and abit tight I don't wanna go pulling the wrong pipes around lol

[Poodle]

Yes, same effect. The blanking plate is exactly what it says on the tin, you don't have to remove anything, just insert the blanking plate between the EGR port and the inlet elbow with a gasket each side and do it back up.

[Jukie88]

Awesome what are the actual pros of removing the EGR ??

[gareth7]

Your engine will only get clean air, not recirculated exhaust gas mixed in with it.......

Take your inlet elbow off and you'll see loads of black tar like crap that will have built up purely because of the EGR

[Jukie88]

May aswell degunk it then if intake it off ?

[gareth7]

Might as well mate........wear gloves though, it's nasty stuff lol

[Jukie88]

Is it easy enough to take the elbow off ??

[gareth7]

Yes mate, two 13 mm nuts on the studs holding it to the inlet manifold, two bolts for the EGR pipe work connection and another single one on a small bracket. Then it's just a jubilee clip holding the silicon hose on the bottom......that one can be a little fiddly.....easier if you take the battery off as it gives a little more room.

[Jukie88]

Had a quick look and it's looks like an ok job but it's pissing down :-(