EGR Valve removed

[clivvy]

hey chaps, finally got round to removing my EGR valve, got distracted with having to replace a drop link first, so that was a pain!

anyway, i got the egr off, although a bit awkward, wasnt too bad all in all.

Now, I need to get the blanking plates. I have 2mm sheet steel, can I cut this with suitable jigsaw blade, or should i persue someone that can sell me two?

the EGR itself, im not sure what to expect with it. The plunger jobber in mine, hardly moves in when i push it, what does that mean? The actual insides are black, but not coked to buggery, and I cant see how i am supposed to remove the top to clean it/check it?

 

[stinka]

Just take the steel gasket to your local engineering firm. Get them to make 2 copys from 5mm steel less the hole, cost me a tenner.

Throw the egr in the bin

Bolt in the plates instead but use copper rtv on face

 

[clivvy]

ah yes i remember you saying this.

well, i made my gaskets out of 2mm thick mild steel, is this suitable if i leave the EGR off? Ill look into this Copper RTV as well, ideally i want to fit my gasket tomorrow, but i need a suitable drill bit to cut the holes for the bolts, and this copper RTV stuff

 

[clivvy]

oh i see....needs to be 5mm thick?! do i apply the copper rtv as a gasket seal between surfaces?

 

[stinka]

Yes, 5mm thick plate and rtv between surfaces.

If you try and slip a 2mm plate in whilst leaving egr valve on,you must use rtv and ensure you don't rub it all off whilst reassembling. Too much of a pain IMO

 

[jims-terrano]

Is there a reason why you can't use 2mm plate on it's own? rather than using it sandwiched between the EGR Valve???

Jim

 

[briggie]

i guess too thin a plate and the exhaust gasses / pressure would distort it , rendering it useless

 

[clivvy]

in that case, seems to me 2mm thick plate is fine, so long as you are refitting the egr valve. As Stinka says, a pain but, in my case, i need it sorting tomorrow, so thats what im doing!

 

[briggie]

if you are refitting the egr clive , you may find that the existing bolts arent long enough ...... hope they are for you tho , but be prepared mate :thumb2

 

[clivvy]

aye, good point. I THINK they are, but I will take my bolts with me tomorrow when i am out and about (need a new drill bit to drill the bolt holes in my gaskets, and this Copper RTv stuff).

 

[clivvy]

when i did the EGR on my Stilo, the blanking plate was only about 1.5mm thick if that, strong but thin.

 

[stinka]

Bolts are fine, 2mm is nowt

 

[clivvy]

Why is it now? Its not I don't believe you, its just I have read its fine for our vehicles if refitting the egr?..

 

[stinka]

Huh ? 2mm is fine if refitting

4mm + if not

 

[clivvy]

Huh ? 2mm is fine if refitting

4mm + if not

:thumbs

 

[solarman216]

:thumbs

you only need a plate preferably copper around .5 mm thick if sandwiched between the valve and manifold, can be thinner no problem, I cut mine from an old copper cylinder, Rick

 

[clivvy]

Cheers rick. I don't have access to the materials, so I'll have to buy the gasket seal.

 

[clivvy]

well, sort of all done. what a massive huge pain in the arse refitting that egr was. My god, never known owt like it.

my blanking plates werent the best made, but i had them within the edges of the egr. I used plenty of copper rtv, and initially i couldnt do anythign but slide the plates around, making it impossible to re fit the bolts.

Eventually after a bit more work with the angle grinder, i managed to refit 3 of the four bolts. The last bolt is the smaller one that fits underneath, and i simply just could not get it to screw in, despite being able to push a screw driver through the hole, the bolt just wouldnt go, so i left it off.

Put everything back together, bit tired and pee'd off, took for a very short quick spin up the road, and unless its my imagination it does seem a lot better.

so, this bolt, can I get away with not refitting it, or should i try again? I have used two blanking plates, one for inlet and one for exhaust, plenty of copper rtv.....

also, whats this i need to so with the throttle actuator, can anyone advise on this please?

special thanks to Stinka and Rick for input, been invaluable so far.:thumbs

 

[stinka]

Yes you do need that bottom bolt as its exhaust side and it will blow. I know it's a total bastid to get to :lol

This is why I left it off and had the plates made, not gloating btw mate. I'm sure if you persevere you'll get it in.

I think I did an explanation of how I removed throttle flap and spindle in my inlet manifold gasket thread

 

[clivvy]

right, ill pencil in time next weekend to sort it out, hopefully it will be ok this week as it wont be driven very much, or for very far, and i used lashings of copper RTV so maybe that will help.

If id have had thicker steel, i think i would definatley have done it your method, but, its mostly done now.....although if i have more than 30 mins trouble with that bolt next week i might just do it all again with thicker steel!!