Freediscoranger · May 29, 2012

You can see the blanking plate in the bottom of this picture but my egr is still in place as i dont have the long hose to replace it all with. just unplugged it and put the plate there.

This is the top one of the two bolts to undo to take the whole unit out.

thebiglad · May 29, 2012

darren m said:
right heres what i,ve found out while messing with it this afternoon.

the turbo intercooler as a short pipe coming out the top of it this goes into a metal one , then another short rubber one that attaches to the manifold ( i think ) there is a T junction in this which goes to the EGR ( according to the manual ).

anyway while i had someone else trying to rev the engine i notice the short first pipe that comes out of the top of the intercooler crush up like it was being sucked the the engine cuts out.
any ideas what this would mean

thanks

It means that one of the pieces of rubber hose is almost certain delaminating internally and blocking the air flow. Take each one off in turn to check, starting with the rubber elbow on the turbo.

darren m · May 29, 2012

Freediscoranger said:
You can see the blanking plate in the bottom of this picture but my egr is still in place as i dont have the long hose to replace it all with. just unplugged it and put the plate there.
View attachment 32232
This is the top one of the two bolts to undo to take the whole unit out.
View attachment 32233

thank you for the pics
mines abit different , on that T peice that comes off the hose it does,nt have the joint you,ve blanked off ( just a straight pipe down to the EGR unit ) , but it does have the second one right up next to the EGR unit.

so guessing i could blank that off instead if i,m reading it right. i,m talking about the second joint on the left side of the EGR unit
also what do you do with the EGR when left on the whole at the top is still going to suck air is,nt it

thanks

biolandy · May 29, 2012

darren m said:
not quite sure where you mean , do you mean in the actual diameter of the pipe on the T peice , dont suppose you have a pic do you
did you leave the EGR in place ?
how did you block that off
thanks for your help

Don't have a picture but if you look at first piccy in post#21.
That is the union to undo,and inside you will find the bore of the gasket far larger than the bore of either pipe-2 pence piece drops in nicely.

darren m · May 29, 2012

mines slightly different , does,nt have that joint your talking about , just the one up against/attached to the EGR valve , guessing it would be same size and easy access to the bolts.
let me know
thanks

Diesel Do · May 29, 2012

You can blank it at any joint you fancy. As long as it stops the gas it doesn't matter!!!!
But as said if you've got a pipe sucking flat I'd have all the turbo hoses off and check for internal damage. ie. the rubber delaminating and causing a blockage!!!!

darren m · May 29, 2012

couple of hours this afternoon and everything is off.
all intercooler and tubo pipes , EGR , and intercooler its self

.

they are filthy , gonna be a massive task to clean them

.

new hoses and blanking plate have just arrived , so far so good

.

i had to take off the airflow sensor thingy and the power steering bottle and clamp to get access.
the elbow bend pipe as a great big hole init so thats one problem for starters.
going to shops now to buy 1/2 doz bottles of white spirits

thanks all

will let you know later how i get on

biolandy · May 29, 2012

petrol might be a better choice as it evaporates easier...cannot stress enuf intercooler must be bone dry before you refit

darren m · May 30, 2012

biolandy said:
petrol might be a better choice as it evaporates easier...cannot stress enuf intercooler must be bone dry before you refit

whoops only just seen this
so
how long should i leave it for to evaporate , i used 3 bottles of white spirits .
was hoping the sun would help me out . maybe ill get the airdryer on it.
should i have washed it out with water after( i did,nt ).

what will happen if its not dry please , worried now

thanks

Diesel Do · May 30, 2012

darren m said:
whoops only just seen this
so
how long should i leave it for to evaporate , i used 3 bottles of white spirits .
was hoping the sun would help me out . maybe ill get the airdryer on it.
should i have washed it out with water after( i did,nt ).

what will happen if its not dry please , worried now

thanks

Worst case it'll run on white spirit! Depends how much is left. If you did it off the car you should know if it was empty or not on car not so easy! A significant amount can blow it to bits but I'd hope you're not that daft

thebiglad · May 30, 2012

darren m said:
whoops only just seen this
so
how long should i leave it for to evaporate , i used 3 bottles of white spirits .
was hoping the sun would help me out . maybe ill get the airdryer on it.
should i have washed it out with water after( i did,nt ).

what will happen if its not dry please , worried now

thanks

DO NOT wash out with water. Drain out as much as poss, then leave outdoors to evaporate the balance.

darren m · May 30, 2012

it looks dry but will put some high pressure through it from my divers bottle and leave it a few hours.
than get the airdryer on it
there are a few flakes of dried stuff shaking out of it , will that be a problem

thanks

biolandy · May 30, 2012

you want to try and get it as clean as you can....any bits are going straight into engine.....only you can decide if this will hurt pistons valves etc

thebiglad · May 30, 2012

darren m said:
it looks dry but will put some high pressure through it from my divers bottle and leave it a few hours.
than get the airdryer on it
there are a few flakes of dried stuff shaking out of it , will that be a problem

thanks

Just put in a bit more WS to wash out the bits.

darren m · May 30, 2012

back on the road , and showing a good bit of improvement .
smoked like hell at first all black and sooty , but seems ok now.

just like to say thank you all for the help and advice you have given me , i could,nt of done it with out you

cheers

ps. used Rimmer bros for the parts , excellent service

, less than 24hr turn around

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