Manifold and EGR Changed After Cleaning

[Arctic]

After sourcing a couple of diesel manifolds and cleaned them also couple of EGR's i decided to change them ready for the summer months ahead i know seems i have jumped the gun :roll: as its's now snowing :gmc: anyways some of the photo's below of how i am changing the manifold and EGR.
Fig 1 the components Arhh yes also the engine cover
1

EGR valve fig 2


Cleaned out manifold fig 3/4


4

Engine cover removel three bolts fig 5/6
5

marked with yellow dots
6

Next remove the air duct five bolts fig 7/8/9
7

marked with green dots
8

removed and ready to be set aside safely
9

manifold and EGR exposed fig 10


Unclip the fuel line fig 11/12
11

12

remove vacum pipe from EGR fig 13
13

release EGR pipe clip fig 14
14

Snow stops work in progress fig 15
15
To be continued

Resumed 5/2/12

Remove the hose from the EGR fig 16
16

release the cam sensor wiring gromit from manifold fig 17
17

Unplug the MAP sensor wire from the manifold opposite side fig 18
18

The manifold is now ready to be removed by undoing the eight bolts at the top and the five at the bottom fig 19
19

Once all the bolts and nuts loose/removed lift mainfold free along with the attached EGR fig 20/21 ready for the cleaned one to be fitted if you have one if not you will need to clean your own along with the EGR if cleaning your own do it on a nice warm day as this could take an hour or so.
20

21

As i already had a replacement manifold and EGR cleaned and ready to fit it was just a case of removeing the dirty EGR fig 22
22

Cleaned one and dirty one side by side this one is not that bad have seen some really crudy ones well blocked. fig 23
23

Next remove the MAP sensor 10mm bolt as the can get cruded up as well and will need cleaning with some carb cleaner fig 24/25
24

25

MAP sensor removed note the black sticky goo on the end this can sometime be really crudy and hard give it a spray to soften do not chip or scrape at the sensor once softened wipe clean with a rag also wet with carb cleaner then wipe dry.fig 26/27
26

27

Once cleaned fit the MAP sensor back along with the cleaned EGR to the manifold ready to be fitted back to the engine make sure all the rubber gaskets are in tact and in place properly fig 28/29
28

29

Fit the manifold back in place along with all the other items ie hose to EGR vacum little hose, MAP sensor wire,fuel pipe hose, cam sensor wire gromit etc double check everything is in place.fig 30
30

Replace air intake pipe fig 31
31

Then finaly fit the engine cover all this helps the engine to breath a bit better and can help with MPG fig 32
32

If you have a turbo sensor like i do this also can be cleaned at the same time with carb cleaner remove the small hose which connects between the EGR and the turbo sensor fig 33
33

Unplug the wiring to the sensor fig 34
34

Remover the other hose which connects to the intercooler and remove the sensor housing fig 35
35

Fig 36 the sensor inside the housing which can be sprayed with carb cleaner mine was quite clean really but still sprayed it once shaken dry reverse fit job done.
36

I also replaced the fuel filter at the same time which you may wish to do also you can find the how to for this on another thread hope this helps some members Arctic.

[Hodgy]

nice one Steve

[craig8661]

thats a good write up i have a spare inlet manifold for mine and a spare egr valve thats like new after helen went out and i put it throu the dishwasher to cleen the egr.

whats the best way to do the bypass using a old egr i noticed its alloy so cant weld it shut lol


oh also not forgoten to get helens tourer coulor code just cant be botherd to look at plate yet

[Arctic]

Originally Posted by craig8661

thats a good write up i have a spare inlet manifold for mine and a spare egr valve thats like new after helen went out and i put it throu the dishwasher to cleen the egr.

whats the best way to do the bypass using a old egr i noticed its alloy so cant weld it shut lol


oh also not forgoten to get helens tourer coulor code just cant be botherd to look at plate yet

Not done the EGR bypass myself but am led to believe you just pinch the little vacum pipe closed and refit the hose sure someone will correct me if i am wrong

[Dragrad]

Yet another excellent article

Been copied to here as usual

[Jakg]

When do you it, look at the disgusting mess that comes out - it's all thanks to your EGR.

Get it bypassed!

[deeks]

Originally Posted by craig8661

thats a good write up i have a spare inlet manifold for mine and a spare egr valve thats like new after helen went out and i put it throu the dishwasher to cleen the egr.

whats the best way to do the bypass using a old egr i noticed its alloy so cant weld it shut lol


oh also not forgoten to get helens tourer coulor code just cant be botherd to look at plate yet

to block my EGR off i used a 2p coin and removed vacuum pipe and put a self tapper in the end

[craig8661]

thats a idear then i took and blocked the vacume of it in theroy the egr with out the vacume should be gass tight but after all these years i recon it will leak some

[Arctic]

Originally Posted by Dragrad

Yet another excellent article

Been copied to here as usual

Seems some pics are missing from the thread Arctic

[HarryM1BYT]

Originally Posted by Arctic

Not done the EGR bypass myself but am led to believe you just pinch the little vacum pipe closed and refit the hose sure someone will correct me if i am wrong

There are various methods, in order of easiness...

1. If the small vacuum pipe is simply prevented from applying any vacuum, that will prevent the EGR valve from opening. Disconnect it and block the end of the pipe, or block and refit, or simply close up the stub pipe on the EGR and refit. It will not help if the exhaust valve is passing though.

AND/OR
2. Seal the stub where the exhaust fits onto the EGR.

3. Fit a modified EGR or a complete EGR bypass.

Any of the above will prevent any further build up of the horrible black gunge in the EGR and the inlet system.