Big.Mike Posted September 27, 2012 Share Posted September 27, 2012 Hi All, I'm hoping that one of you will be able to look at this and go "it's a...." and where it's plugged in! It comes up from the back of the 300tdi, it's a CSW 110 (if it makes a difference). The wires are green and pink (although it looks a little faded). Cheers, Mike Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 27, 2012 Share Posted September 27, 2012 Have you had the EGR removed? It looks like the cable for that Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 27, 2012 Author Share Posted September 27, 2012 Have you had the EGR removed? It looks like the cable for that No, not yet... Quote Link to comment Share on other sites More sharing options...
PS_Bond Posted September 27, 2012 Share Posted September 27, 2012 Going purely on the location - there's a 2 pin plug under the rubber cover around the rocker cover, damned if I can remember what the sensor is though. Not oil pressure, not water temp. Possibly linked to the EGR controller, but IIRC the EGR valve plug comes from the front backwards? Didn't check the wiring colours while I was there though Quote Link to comment Share on other sites More sharing options...
PS_Bond Posted September 27, 2012 Share Posted September 27, 2012 Think I've got it on the wiring diags - temperature sensor to the EGR ECU. Pink with a black trace, green with a blue trace? C027 (on the head, between rocker cover & inlet manifold) Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 27, 2012 Author Share Posted September 27, 2012 Okay, that looks right, you can see a black trace one the pink wire... The next question: do i plug it back in? Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 27, 2012 Author Share Posted September 27, 2012 As for the egr valve removal, I can't get the top bolt out of the manifold casting. Damn it. Been trying for three days! Grrrr... Quote Link to comment Share on other sites More sharing options...
PS_Bond Posted September 28, 2012 Share Posted September 28, 2012 I plugged mine back in despite it not being connected at the other end - beat loose connecters in the engine bay. I presume you've Plusgassed the bolt to death? Heated it yet? Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Try undoing it after a good run with a few steep hills, that'll stick plenty of heat in it. Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 Try undoing it after a good run with a few steep hills, that'll stick plenty of heat in it. I think I might have to get some hex head sockets, I can't seem me getting enough torque with an allen key. I've put nearly a can of WD40 on the thing, it's just not getting to the thread. I really don't want to break it off, getting it out will be a pain! Cheers, Mike Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Also try tightening and loosening alternately as that often helps. Also worth trying an impact driver, the shock may help loosen it, relatively cheap and also gets you your hex sockets. http://www.halfords.com/webapp/wcs/stores/servlet/product_storeId_10001_catalogId_10151_productId_530655_langId_-1_categoryId_165469 Appologies if I'm teaching you to suck eggs Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 Appologies if I'm teaching you to suck eggs You are but in the red heat of frustration it's sometimes worth a reminder. Particually as normally my next move is to drill the blooming thing out! I've always avoided impact drivers on old bolts because of the "breaking in the bottom of a hole" issue. Are they that bad? Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Appologies, hard to know what level people are at I don't thing they are blind holes, I'll go and check on the spare manifold I have. I've found impact drivers to be ok ... depends how much you belt them and how good your grip is! Maybe I've just been lucky in the past but don't think I've snapped any bolts with them. Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Apologies Mike, just checked they are blind holes. Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 Appologies, hard to know what level people are at I'll give the driver a go, they're fun! Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 Apologies Mike, just checked they are blind holes. I'll give the driver a *Gentle* go! Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Lol Let us know how it goes. Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 Lol Let us know how it goes. Bolt 1, Big Mike 0. The bl**dy bolt has sheared in clean in half, right where it goes in the casting. Luckily, I bought some screw extractors whilst at Halfords. The bolt is still in there pretty tight. Thanks, Mike Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 If you get stuck I'll dig out the tapping size drill and taps for it and post them down to you if you need them.... or if you are up this way you could pick them up. Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 28, 2012 Author Share Posted September 28, 2012 If you get stuck I'll dig out the tapping size drill and taps for it and post them down to you if you need them.... or if you are up this way you could pick them up. That's really kind of you, I've got a set of taps. I'm hoping that it'll just pop out with the screw extractor (ha!)... On thing I need to work out is if I can drive her without the gasket done up fully (or in fact with only one bolt). Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted September 28, 2012 Share Posted September 28, 2012 Fingers crossed the extractor works.... I guess if you drive with only one bolt in it will be similar to if the main manifold gasket was leaking (but not quite as bad). So you won't get a great deal of boost from the turbo and it'll be quite lethargic. Oh and it'll leave soot over anything near to the gasket Quote Link to comment Share on other sites More sharing options...
PS_Bond Posted September 28, 2012 Share Posted September 28, 2012 If it comes to it, I have a manifold on my dead engine (although perhaps I should take the EGR valve off first). What are the chances of getting a weld onto the bolt remains? Recent experience would suggest that would stand a better chance of success than those infernal screw extractors. Quote Link to comment Share on other sites More sharing options...
discomikey Posted September 30, 2012 Share Posted September 30, 2012 IIRC its a knock sensor in the top of the head between the inlet manifold and the rocker cover. Quote Link to comment Share on other sites More sharing options...
RedLineMike Posted September 30, 2012 Share Posted September 30, 2012 IIRC its a knock sensor in the top of the head between the inlet manifold and the rocker cover. its a temp sensor for the EGR as posted in the first page what use would a knock sensor be on a engine with a mechanical pump Quote Link to comment Share on other sites More sharing options...
Big.Mike Posted September 30, 2012 Author Share Posted September 30, 2012 Fingers crossed the extractor works... Oh and it'll leave soot over anything near to the gasket What a weekend. All for one bl**dy bolt. This is all , but if it helps someone else it it's all good. In my experience screw extractors are great when you have a screw with a stripped head. This was a fused bolt, I've never seen the like before. So the screw extractors didn't work. This is what I did: Used a centre drill to put a small hole in the centre of the broken end of the bolt. Drilled a 4.5mm hole in the bolt with a HSS drill bit. Tried the screw extractors. Put some WD40 in the hole and left it to soak. Had a cup of tea. Tried the screw extractors. Ran the Engine for 20 mins until the manifold was hot. Tried the screw extractors. Burnt my fingers on the hot screw extractor. Swore. Swore some more. Had a cup of tea. Drilled a 6.5mm hole with a HSS drill. Tried the screw extractors. Caught my finger on the sharp edge of the manifold. Bled all over the engine cover. Swore some more. Found a plaster (Hello Kitty, we'd run out of Ben10 ones). Washed the soot, rust, WD40 and oil out of the wound. Swore. Put some gloves on. Washed the blood off the engine. Drilled out the to 7mm with a HSS drill. Waggled the drill around gently. The bits of the broken bit came out. Ran an M8 tap into the hole with a good dollop of copper grease to pull any remaining bits of bolt out of the hole. What I learnt: Wear gloves. Put copper grease on bolts. Bolts can fuse in place, using what I can only imagine is magic. I am comfortable enough with my masculinity to wear Hello Kitty plasters. Screwfix don't sell good drill bits. It is not a half hour job to remove the egr valve. 5 days it's taken. A 300Tdi motor really needs the T bit. The manifold gets really, really hot. It all seems to be good now, thanks for all the help and offers of help. Which is great, cos' I can now drive to work tomorrow! As for the original question, I can't see anywhere to plug in the loose end of the wire! Cheers, Mike Quote Link to comment Share on other sites More sharing options...
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