TheWoodsmane
Member
- Posts
- 72
- Location
- Guildford, England.
So, having been away for a week, I decided today was the day to tackle the EGR valve. What and Alan B'Stard!
Getting the fan cowl off, easy. Undoing the retaining bolts for the engine cover on the nearside, easy. The offside was fookin messy. The captive bolt has come lose at some point, so just spins. With some persuasion and patience, I finally got the bolt out to find the bracket the nut sits in was in pieces. I've had to leave that bolt and nut out for now until I can sort out a replacement. Any one know what this bracket is called so I can try a breaker for it? If not, I'll just take a picture and try and communicate through the medium of mime!
The allen bolts on the exhaust manifold were easy to remove, though I lost one under the AC compressor. Thank the gods of telescopic magnets!
I started to remove the actual bracket on the engine block that the EGR pipe is mounted to. But, the bolt looked fairly substantial, so I screwed that back in and removed the two bolts on the EGR pipe bracket instead. Does anyone know if this bolt that the EGR bracket mount is secured to the engine block needs a specific tension or is it just there to hold the bracket?
Then, I started on the EGR valve removal itself. The bolts weren't too tight. But, getting to them was difficult as there's not much room. I ended up doing the lower offside with an 8mm ring spanner, which took forever!
Getting the EGR out of the intercooler hose was stressful. It was well and truly secured in there. The outside edge of the hose has started to perish, so I think there's some new ones in the near future. But, with some serious tugging, it came free.
The blanking plate on the manifold needs a gasket. The old one looks like it was a copper ring or something and is stuck fast to the EGR pipe. So, I need to get some paste or instant gasket to make a better fit. Should be ok to drive down to Europarts to get some right?
Also, I found it tough to get the new fitting into the hose...it's in, but frankly, I'm concerned that it will blow off when the turbo spools up! I've tightened the hose clip as much as I dare. Anyone had a hose blow off after fitting one of these kits?
It wasn't as caked in the manifold as I was expecting. But, I did remove the MAP and soaked it in Brake Cleaner and wiped off most of the crud as best I could. It looks a LOT cleaner and it's now home.
I had intended to take lots of pictures. But, as things got progressively more fiddly (for a complete amateur like me at least) I just focused on the job in hand, so much of the really interesting stuff has not been captured. Sorry about that. Here's the ones I managed to get.
This is the bolt that just spun, and spun, and spun, with the captive bolt loose.
At last, it's off! Now the real work begins.
A lot of time passed here...and no photos as it was much more fiddly than I expected. But, I got it off.
There's no chance of rust in there!
View of the intake manifold once I got the thing off!
Inside the inlet manifold....mmm tasty!
So, wish me luck, I've started it. It runs. Now I'm going to try and drive it...this is the most adventurous I've been so far...so frankly I'm just a little terrified that it's going to go horribly wrong.
Getting the fan cowl off, easy. Undoing the retaining bolts for the engine cover on the nearside, easy. The offside was fookin messy. The captive bolt has come lose at some point, so just spins. With some persuasion and patience, I finally got the bolt out to find the bracket the nut sits in was in pieces. I've had to leave that bolt and nut out for now until I can sort out a replacement. Any one know what this bracket is called so I can try a breaker for it? If not, I'll just take a picture and try and communicate through the medium of mime!
The allen bolts on the exhaust manifold were easy to remove, though I lost one under the AC compressor. Thank the gods of telescopic magnets!
I started to remove the actual bracket on the engine block that the EGR pipe is mounted to. But, the bolt looked fairly substantial, so I screwed that back in and removed the two bolts on the EGR pipe bracket instead. Does anyone know if this bolt that the EGR bracket mount is secured to the engine block needs a specific tension or is it just there to hold the bracket?
Then, I started on the EGR valve removal itself. The bolts weren't too tight. But, getting to them was difficult as there's not much room. I ended up doing the lower offside with an 8mm ring spanner, which took forever!
Getting the EGR out of the intercooler hose was stressful. It was well and truly secured in there. The outside edge of the hose has started to perish, so I think there's some new ones in the near future. But, with some serious tugging, it came free.
The blanking plate on the manifold needs a gasket. The old one looks like it was a copper ring or something and is stuck fast to the EGR pipe. So, I need to get some paste or instant gasket to make a better fit. Should be ok to drive down to Europarts to get some right?
Also, I found it tough to get the new fitting into the hose...it's in, but frankly, I'm concerned that it will blow off when the turbo spools up! I've tightened the hose clip as much as I dare. Anyone had a hose blow off after fitting one of these kits?
It wasn't as caked in the manifold as I was expecting. But, I did remove the MAP and soaked it in Brake Cleaner and wiped off most of the crud as best I could. It looks a LOT cleaner and it's now home.
I had intended to take lots of pictures. But, as things got progressively more fiddly (for a complete amateur like me at least) I just focused on the job in hand, so much of the really interesting stuff has not been captured. Sorry about that. Here's the ones I managed to get.
This is the bolt that just spun, and spun, and spun, with the captive bolt loose.
At last, it's off! Now the real work begins.
A lot of time passed here...and no photos as it was much more fiddly than I expected. But, I got it off.
There's no chance of rust in there!
View of the intake manifold once I got the thing off!
Inside the inlet manifold....mmm tasty!
So, wish me luck, I've started it. It runs. Now I'm going to try and drive it...this is the most adventurous I've been so far...so frankly I'm just a little terrified that it's going to go horribly wrong.
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