discodave Posted October 16, 2006 Share Posted October 16, 2006 Hello All, I,ve got a blanking plate and a new air intake hose for my 300tdi and started to remove the egr valve, anyone got any tips on how to remove the alan screws that hold the thing on the exhaust manifold. i've tried a normal alan key but i think it's gonna break before anything moves, i've also got a set of socket alan screws but cant get them in for the egr valve in the way. any ideas? B) Quote Link to comment Share on other sites More sharing options...
freeagent Posted October 16, 2006 Share Posted October 16, 2006 all i can thionk of is keep soaking it in WD40 or similar, over a period of 2-3 days.... you could try undoing it when its hot, as long as you wear gloves... Quote Link to comment Share on other sites More sharing options...
Jason Posted October 16, 2006 Share Posted October 16, 2006 Hello All, I,ve got a blanking plate and a new air intake hose for my 300tdi and started to remove the egr valve, anyone got any tips on how to remove the alan screws that hold the thing on the exhaust manifold. i've tried a normal alan key but i think it's gonna break before anything moves, i've also got a set of socket alan screws but cant get them in for the egr valve in the way. any ideas? B) I had a similar problem with my TD5, plenty of WD40 and a big hammer, it took a while but it worked Quote Link to comment Share on other sites More sharing options...
Les Henson Posted October 16, 2006 Share Posted October 16, 2006 I'd say try it with a hot engine first, then WD40 or penetrating oil. Les. Quote Link to comment Share on other sites More sharing options...
tuko Posted October 17, 2006 Share Posted October 17, 2006 Hello All, I,ve got a blanking plate and a new air intake hose for my 300tdi and started to remove the egr valve, anyone got any tips on how to remove the alan screws that hold the thing on the exhaust manifold. i've tried a normal alan key but i think it's gonna break before anything moves, i've also got a set of socket alan screws but cant get them in for the egr valve in the way. any ideas? B) I did the very same thing to my wifes Disco last week and I had no prob's with the alen key bolts. Her Disco is a 1997. Here's a write up. EGR Removal. I can say, that the removal of the EGR carp has made a significant difference in the vehicles response, when the pedal is pushed closer to the floor. It did smoke a little extra for a few days, but now it appears to have settled down. As for fuel economy, well I haven't had the time to figure it out, but I would expect it to atleast stay in the same range. (If the old girl doesn't change her driving habits, thanks to the new response of the motor) Todd. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted October 17, 2006 Share Posted October 17, 2006 I found benefit in getting some tension on the screw (but not excessive), then clouting the side of the manifold near the screw to 'shock' it. You could also try using a punch to shock the screw head itself. Quote Link to comment Share on other sites More sharing options...
Cal Posted October 17, 2006 Share Posted October 17, 2006 I had to give it loads of WD40 over a number of days and a fair bit of heat from a small blow torch and then a lot of effort with the allan keys - it gave eventually and gave a really loud crack like I'd buggered the whole engine... Have fun! ;-) Quote Link to comment Share on other sites More sharing options...
white90 Posted October 17, 2006 Share Posted October 17, 2006 be sure to have a decent fitting allen key/allen socket and try to tighten it before you try to loosen them. may help o break the seal/corrosion Quote Link to comment Share on other sites More sharing options...
BogMonster Posted October 19, 2006 Share Posted October 19, 2006 Lots of WD40 and shock the head of the bolt with a small hammer, worked on mine. And then lots of copper grease on the new ones! Quote Link to comment Share on other sites More sharing options...
MudAllOverIt Posted October 19, 2006 Share Posted October 19, 2006 The flange on the EGR value is quite thick so if the bolts are really stuck and/or the heads are knackered you can get away with cutting the bolt heads off and fitting a blanking plate and gasket to the remains of the bolts with a couple of nuts and spring washers. Getting to the bolts is bit fiddly but not too difficult with a Junior hacksaw and lots of swearing I did this as a temporary measure about a year and a half ago meaing to drill the bolt remains out and re-tap the holes but I never got round to it. No problem at all so far -- probably just leave it is as it is now Quote Link to comment Share on other sites More sharing options...
discodave Posted October 20, 2006 Author Share Posted October 20, 2006 thanks for the advice. junior hacksaw and lots of swearing sounds right up my street but i started the job the other day and when i offered up the new top hose first i found that it was around two inches too short. supplied by mistake but it's currently in the post to be changed for the correct one so i'm still awaiting bits. i've disconected the electrics and vacuum pipe for the time being and it seems ok til i can remove it once and for all. B) Quote Link to comment Share on other sites More sharing options...
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