Anything I should be aware of ..... Hose change&EGR mod

mikey7985 · Nov 3, 2013

Hi all just wondering if there is anything I need to be aware of before doing the EGR mod and silicone hose change?

All looks pretty simple but just in case I thought I would ask.

disco300tdidom · Nov 3, 2013

No all pretty straight forward. Have you bought a egr blanking kit yet because you really don't need to if you can get hold of a welder?

Ian jones · Nov 3, 2013

Do the job right and clean the intake manifold and ports out

mikey7985 · Nov 3, 2013

Yeah I have bought the mod already. Is it a case a blasting the manifold with some Mr muscle or I have some stuff called G101 which is pretty hardcore stuff.

mikey7985 · Nov 3, 2013

Oh do I need any new gaskets at all?

Optimus Prime · Nov 3, 2013

shouldn't need any gaskets if you are careful.

When you change the long intercooler hose across the front of the top of the engine, cut a section off the old hose, split it, and wrap round the new one where the fixing screw will rub on the hose, to prevent it chafing the new one.

mikey7985 · Nov 3, 2013

Optimus Prime said:
shouldn't need any gaskets if you are careful.

When you change the long intercooler hose across the front of the top of the engine, cut a section off the old hose, split it, and wrap round the new one where the fixing screw will rub on the hose, to prevent it chafing the new one.

I did wonder about that screw!!!! Bit of a daft design really isn't it!!!! Will defo do that.

Thanks

Ian jones · Nov 3, 2013

Optimus Prime said:
shouldn't need any gaskets if you are careful.

When you change the long intercooler hose across the front of the top of the engine, cut a section off the old hose, split it, and wrap round the new one where the fixing screw will rub on the hose, to prevent it chafing the new one.

I found the hose in question was a bit thinner and clears the screw head !

Epicuser · Nov 3, 2013

Ian jones said:
I found the hose in question was a bit thinner and clears the screw head !

Nice colour-oh, it's the same as mine :lol:

hd3 · Nov 3, 2013

I found the hose in question was a bit thinner and clears the screw head !

same here .. 'xcept few days ago checked it .. and there was a small indentation from that screw .. .. must be from vibration .. ( and/or hose expansion from turbo boost )
tie-wrapped a spare bit of s.hose around it just in case ..

mikey7985 · Nov 3, 2013

Yeah I think I will tie wrap an extra piece of hose on just to be sure

nickcc · Nov 4, 2013

If the long inter cooler hose is original the lower clip is usually inaccessible, using a small open end spanner on the clip will make it easier to unfasten.

Epicuser · Nov 4, 2013

^^^ what he said. I used a 6mm open ended spanner on mine until I could swivel it round enough to then use a long screwdriver.

mikey7985 · Nov 4, 2013

Great stuff!! Gonna do the hoses and EGR mod at the same time next week. :0). Will let u know how I get on.

mikey7985 · Nov 4, 2013

Ian jones said:
Do the job right and clean the intake manifold and ports out

I am happy cleaning the manifold but am a bit worried about the ports!! What's the best way to clean them?

Ian jones · Nov 5, 2013

mikey7985 said:
I am happy cleaning the manifold but am a bit worried about the ports!! What's the best way to clean them?

Nothing to worry about , wrap a thin rag around your finger , insert in the port and twist as you remove your finger , it should remove the gunk from around the port , repeat with a clean bit of rag until clear , be careful not to drop any thing down them !

Epicuser · Nov 5, 2013

Do you need to replace any gaskets when you do this?

Ian jones · Nov 5, 2013

Epicuser said:
Do you need to replace any gaskets when you do this?

No , the gaskets are pretty robust , but what a horrid messy job , the gunk is the blackest black I have ever come across

oven cleaner got half of it out the rest was white spirit and lenths of bed sheet passed through the port holes in the intake manifold with a lenth of wire coat hanger , worth while doing though , its like giving your engine a new set of lungs

hope these tips help !

Ian jones · Nov 5, 2013

hd3 said:
same here .. 'xcept few days ago checked it .. and there was a small indentation from that screw .. .. must be from vibration .. ( and/or hose expansion from turbo boost )
tie-wrapped a spare bit of s.hose around it just in case ..

I will check mine

mikey7985 · Nov 6, 2013

Going to get it done on Friday afternoon I think..... What sort of time scale do you guys think I should be looking at to get it done start to finish?

Anything I should be aware of ..... Hose change&EGR mod

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