Guide : How to remove EGR valve and how to fit the group buy EGR delete pipe

[Dann2707]

Okay so I installed my EGR delete pipe from the group buy section of the forum. A few people asked how to fit it so I thought I'd take a few pics for those who asked and hopefully it might help them!

 

I've never written a guide or anything before so apologies if I don't explain myself properly. I've circled some photos in Paint to show where the key parts are what i'm talking about.

 

The guide is simply showing how to remove the EGR valve, whether you want to remove it to clean it or to fit a delete pipe. The kit i'm fitting may be different to darkside or allard delete kit so it may vary when it comes to the gaskets etc.

 

 

I've put it into layman terms so most people can understand it.

 

 

 

Begin!

 

 

Remove the engine cover and you should get something like this (great start, if your engine isn't there i'm not really sure what to suggest haha)

 

Now the bit we're focusing on is the thing in the top left of the image with the goldy spaceship looking thing on.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Put a screw driver like shown behind the bayonet clip and pull upwards towards the sky, it will open up and you should be able to slide the black 90 degree silcone pipe out of the metal EGR itself.

 

 

 

 

 

 

 

 

 

 

Do the same for the other pipe at the other end of this small 90 degree silicone pipe. On mine I have an extra jubilee clip securing my pipe on because I wanted to make sure mine wasn't leaking any boost at all.

 

 

 

It should now look like this!

 

 

 

 

 

 

 

 

 

 

Now directly underneath the space ship. An EGR pipe attaches to the EGR itself via two 6mm allen key bolts. You need to remove these as show in the following pics, its pretty tight for room but I found the best way is to get a small allen key and get a ring key spanner on it for leverage and undo.

 

 

Circled is the bolt, it is pointing towards the sky and at the very top of the image just out of focus is the space ship looking thing for reference.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The circles display where the bolts are, obviously on the circle at the top it is underneath the EGR. i just put a circle there to show you its rough whereabouts underneath the egr valve.

 

 

 

 

 

 

 

 

 

Okay so now you should have removed two bolts now for the EGR pipe. 

 

 

The 3 bolts holding the EGR to the inlet manifold can now be removed.

 

 

 

 

These are in the following locations:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The 3rd bolt is underneath the valve and the circle shows its whereabouts roughly, its a bit fiddly again but you should find it easy enough with a long allen key this time. The bolt is horizontally facing like the other two bolts holding the egr to the inlet manifold. Arrow shows this

 

 

 

 

 

 

 

 

 

 

 

 

I used a ring key spanner on the allen key as shown to get some leverage to undo the bolts.

 

 

 

 

 

 

 

 

 

 

 

 

The egr is now loose and can be removed! It will be held on loosely by the vacuum pipes. One of mine is currently blocked up by a m6 bolt for the EGR as I can disable my EGR this way without an EML appearing. Yours should be attached to the nipple on the space ship.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I've highlighted these vac pipes with circles here. Simply pull them off the EGR valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

Your EGR should look considerably worse than mine, i've recently cleaned mine out. If you're simply cleaning out your EGR valve you can just clean it out now and re isntall by doing the reverse of what i've done up to here but carry on reading if you're fitting the EGR delete pipe!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The EGR delete pipe. Mines got a boost nipple for a boost gauge

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Now you have to remove this pipe that my fingers are on. This is the EGR pipe that transports exhaust gas to the egr valve. This is being removed and a blanking plate is going on the exhaust manifold instead.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove the two clips holding the air intake pipe on. Mole grips I find are great for this as it holds them in place whilst you slide them along the plastic pipe. Remove the pipe.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Okay so with this removed, have a look in the space you've just created and you should be able to see a goldy looking pipe connecting to the exhaust manifold. this is the egr pipe aforementioned that is going to be removed. 

 

 

Circled are the two bolts that need to be removed.

 

 

 

 

 

 

 

 

 

 

 

They will be on TIGHT! Exhaust gas is hot and warps them slightly so be careful removing them. Lots of WD40 required. 

 

 

Mine were 12mm but test yours before as some engines may differ.

 

 

This is a better pic showing the two bolts to be removed

 

 

 

 

 

 

 

 

 

 

 

 

Remove them and give the pipe a wiggle and it will come out like this

 

 

 

 

 

 

 

 

 

 

 

 

Now to fit the blanking plate, put the gasket under the metal plate and fit where the pipe just went.

 

 

 

 

 

 

 

 

 

 

 

This picture shows the blanking plate being fitted to the exhaust manifold

 

 

 

 

 

 

 

 

 

 

 

Now put the rubber gasket on the EGR delete pipe as shown in this pic

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Offer the pipe and gasket up to your inlet and stick the 3 bolts in. Do them all up finger tight, do not torque one up fully then the other then the other! 

 

 

 

 

 

 

 

 

 

 

 

You now need to remove the original coupler from the pipework, as you have a new egr delete pipe that doesn't use the shoddy bayonet clips. I used an angle grinder and cut straight through it. 

 

In hind sight I went too far and should have taken it steady as I cut straight through the rubber pipe which didn't give me much room to play with when fitting it back on the egr delete pipe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

But it went on perfectly as shown.

 

 

 

 

 

 

 

 

 

 

I then blocked up the vacuum pipes. One is larger than the other so I used an m6 and an m5 bolt. The smaller one for the anti shudder valve.

 

 

 

 

 

 

 

 

 

 

 

 

And that's it. Put the air intake pipe back on with the mole grips or whatever you used and you're good to go!

 

 

 

 

Hope this helps someone, let me know what you think if it needs anything adding. Like I said this is my first written guide so it's probably not the greatest.

 

 

 

Daniel!

Edited 18 November, 2013 by Dann2707

[joelk2010]

Thanks Dan

 

Potatoes are cool

[KBPhoto]

It is great for numpties like me though.

The pictures REALLY help.

I'm not planning an EGR delete but do want to check and clean SWMBO's and your guide is spot on for me.

Looks like I've got (another) job at the weekend...

Thank you for taking the time.

[Titanium_Man]

The most informative guide I have read on installing this, great job

[BJB540]

Great guide. Thank you Dan.

[George]

Brilliant write up, this helps a lot. I will be cleaning my egr valve soon, so this is a big help.

Thanks for the time & effort.

[Thisday]

Cheers, Dan, will be using this when I change my egr!

[coskev]

Spot on guide Dan

 

Will be doing mine later in the week so the pics have helped alot cheers

[_Jim]

When I did mine I took the 3 bolts out on the EGR (the bottom one is a PITA).

Then took the pipe between the airbox and inlet off and undid the two nuts on the manifold connecting the gold pipe to it.

You can wiggle the whole lot out then without struggling to remove it at the egr end.

[sepulchrave]

Great guide, for the love of god someone apply glue and stick it to the forehead of the next retard to ask how you do this.

[devonutopia]

Pinned to the top!  

[adilVRS]

Many thanks Dan - a true gent to his word!

 

[Dann2707]

I didn't think this would get such a good response!

 

Glad it's helped some of you and hopefully others in the future

[rtz62]

Excellent DN, as mentioned in a previous thread it is great to have a blow-by-blow account with images for people like me.

Btw KBPhoto, are you married to my wife! I've been referring to her as SWMBO forever and can't remember her mentioning you!

[Padrino]

Good write up Dan, thanks

[coskev]

Fitted mine yesterday

 

One thing you missed out in your guide, the most important tool, you need girl hands!!! 

[Dann2707]

Haha so true

[JoshH]

Good guide, did you leave your egr bolts only finger tight?

Had to whack mine up tight due to boost leak from the gasket!

[Dann2707]

Damn I should have added to that! I meant do them up finger tight initially to make sure it's on the inlet evenly then do them up tight!

[JoshH]

Haha that'll keep you on your toes, forgot to

Mention though I ended up doing mine up too tight which split and pushed out the rubber gasket!

Instant gasket to the rescue!

[Titanium_Man]

Roughly how long should I allow for this Dann? Doing my mates on Friday as a test run before doing my own

[Dann2707]

As a first attempt probably around an hour or something like that mate?

[Titanium_Man]

Cool cool

[DanGum]

Great guide mate! Will be following this when I come to do mine

[Matt Dixon]

Which engine do you have fella? I have the Asz and allard delete but the EML came on, I didn't block the pipes. Could that be the reason?