Removing EGR

[Garbe]

I want to remove the EGR stuff while the engines in pieces,

I'd really like some help with which bits to remove, and what to blank.
here's some pics of the intake chamber.

1
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/127.jpg

2
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/128.jpg

3
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/129.jpg

4
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/130.jpg

5
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/131.jpg

6
http://www.twobrutal.co.uk/forum/images/recovered/2006/08/132.jpg


Also to blank of the hole in the manifold what material should the blanking nut be made of??

[Peebs]

Its a bit difficult to explain in writing, but I'll give it a go.

In pic 1, you can see the two UFO type thingys, they need removing and a blanking plate made for where they bolted to on the plenum. The associated vacuum piping will need to be blanked near the throttle body.

Pic 4 is showing the throttle position sensor and idle speed control valve and therefore you REALLY don't wanna remove these :)

On the underside of the plenum (pics 5 & 6) you need to remove the darker grey (almost brown) rectangular ally part and blank that off too. Note : the two rubber pipes going into this recangular part, carry water! You will need to think about this bit (as it's the bit I can't really explain), but basically you can do one of two things, get a longer bit of pipe and reconnect to where it came from, or just connect a small pipe from the start of the water circuit to where it finishes (about 40-50 mm away from each other)

As for the exhaust manifold bit, you simply need to blank the pipe as close to the manifold surface as you can. I welded a small plate onto the double screwed part that goes directly into the manifold, but you could either find or have made a bolt that will replace it and use a large copper washer to seal it.

Hope this helps :)

[Garbe]

Thanks for that peebs

[lodgeman]

can take pics of mine if it helps?

[Garbe]

That would be great lodge,
thanks

[JB]

Good post Garbe
Having fitted my engine completely standard I have also been wondering about removing the EGR.
What are the advantages/disadvs of removing it chaps?

[lodgeman]

apparently 450 bhp!!!!!!:whistle: :whistle: lol lol

[Marksman]

What are the advantages/disadvs of removing it chaps?

More BHP but less baby seals.

Hmm, not one of my more useful posts that one. :slap: :woods:

O.S.

[Garbe]

JB
I read it releases BHP
Also it stops your intake from gunging up.
And it makes the engine look more beautiful, thats the reason i'm doing it :gay:

[lodgeman]

pics as requested

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/155.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/156.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/157.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/158.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/159.jpg

hope that helps :whistle:

[JB]

Cheers Al very helpful!































Will it blow my engine up though?

[Garbe]

Thanks Al.
jb it's not the removal of the EGR, it's the right foot that does that.

[Garbe]

Al
in the first pic, has the hole in the exhaust manifold been welded up.

[lodgeman]

yes paul welded both of them up!i just ground them down flat and sprayed with vht.

[Garbe]

Nice quick solution, got to find something to blank them of with as i can't weld, evening classes methinks.

[Garbe]

Been thinking about a solution for the egr pipe coming from the exhaust manifold,
What if i cut the pipe, flatten it and fold it over 3 or 4 times in a vice, will this seal sufficiently, as the metal is quite hard.

[lodgeman]

how about a cap from a copper pipe-they come in different sizes and seal with an olive(metal one:snooty: )

[Garbe]

Will copper be ok on the exhaust, will it not expand at a different rate than the iron of the manifold ?