Hey folks, just trying to remove my EGR as I type. Removing the water pipes from the EGR, I take it there's supposed to be a significant amount of coolant coming out?

due to gravity yeah, plug the pipes so you dont lose to much or just replace when your finished

Smashing, cheers. Just need to get the buggers off ow.

Tex if your bypassing the cooler with a new length of rubber heater hose its best to use new jubilee clips, remember to keep the bit of heat wrap on the pipe where it goes into the back of the head as its right next to the exhaust manifold.

i used a length of copper pipe on mine, cant remember the diameter but it was your usual household stuff

and remember to put some silicone sealer on the blanking plates

Yeah, something tells me the copper pipe option would've been easier! I've got hose and jubilee clips though, so I'll have to make do. Got the pipes and the cooler pipe off, swearing at the old exhaust manifold bolts atm...

It will be 15mm copper pipe which is the simplest method and is fine if you aint bothered what it looks like but IMO it looks gash and has more joins.
I used 15.8mm rubber heater hose, £2.50 for a metre from the parts counter at halfords, very little extra effort and it looks much better.
I've heard folk say that the jubilee clip at the back of the head is a nightmare, personally I found it a doddle and tightened it with a 7mm spanner, simples!

Well all the top-end, easy-to-reach stuff is done (multplug, vacuum hose and top blanking plate)... I'm still struggling to crack those bottom exhaust manifold bolts though. I've doused them with WD40 a few times, but I just can't get the leverage to shift them... Any tips?

There's a "How To" in the How To Section.

Posted by: GaryF

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There's a "How To" in the How To Section.

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I know, that's what I'm following

Posted by: Tex_L200

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Posted by: GaryF

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There's a "How To" in the How To Section.

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I know, that's what I'm following

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Good luck, the only awkward part I found was fitting the new hose buy-passing the cooler.

The manifold bolts on mine were very rusty and I was shitting it incase they snapped, but they did give after a good soak, if they will only go a couple of turns keep soakining them with WD and just work them back and forward I was just using a 3/8 snap on ratchet and deep socket, but I do drink lots of Irn Bru

As there is a long list of things we can't do with the new shape (veg oil, K&N apollo, etc), how about this? Is it advised to remove the EGR on the new shape, too?

Posted by: skotl

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As there is a long list of things we can't do with the new shape (veg oil, K&N apollo, etc), how about this? Is it advised to remove the EGR on the new shape, too?

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Bootsie or Manraj will be the best to give you advice on EGR Valve, but I seem to remember it would screw the electronics up. Give them a PM

Right. It's off to Halfrauds for some 'Shock and unlock' spray.

Some owners have removed the EGR on the new shape, think its still a do it yourself Job regarding blanking kits as no one seems to sell them. There doesn't seem to be a need to remove them from new shapes as the EGR is an improved design, bigger cooler with 7 plates as opposed to the classics 2 plates.I was advised that there was no need to replace them on this model. Unfortunately the new ones cant be fitted to the classics, they are on the other side of the engine and pipework is different.I dont see any gain in removing something that works and was designed in with the knowledge that the earlier models had problems. As for the de cat its over to Manraj for that he will give you the upgrade advantages of that.

raj did his - it was a pain in the tail he said , doesn`t seem to have made any difference, theres another guy here who was selling the decat as he had been advised not to do it - on balance, personally I wouldn`t do it, until more feedback is in.

Basil

They do it in Aus but they have vastly different climates to deal with. I looked into it myself re the EGR and enquired of one of the classic sellers, he advised not to do it he said there was no need and he was not planning to make plates for it. I have done 67k in mine and no problem, check all the temp and pressure readings and its as the book and I am well satisfied with the mpg. I check the water and oil every week and I have never had to add water or oil ever, says it all for me.

All done, all working. Just got to fit the P-clip tomorrow as it needs a 5mm (yes, that poxy small, as opposed to the 6 or 8mm ones I had available). Pipe's a bit long, but I'm gonna put the P-clip on the heat-shield rather than the engine, so all should be well.

Cheers for all the help folks, The Halfords 'Shock and Unlock' spray worked a treat. Much better than WD40. ...and that rear jubilee clip was a pain in the backside, so I put one of the pinch-fit connectors on that came off the original pipes. Seems to be a tight enough seal.

Also, having done the decat and the K&N air filter upgrades, taking the EGR off seems to have brought it all together and it feels like a much better truck now.

nice one

Good job! And thanks to Bootsie and Basil for talking me out of it

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Probably going to fit my blanking plate this week as I have some days off, just ordered some pipe to bypass the cooler while I'm there, quick question though.

The EGR blanking kit I bought off Werbung: the 'bay didn't come with gaskets. Do I need some...?

I just put mine straight on , no gaskets at all, it sealed fine