whitebullet
24-02-2008, 12:10 AM
HOW TO BLANK OFF EGR VALVE ON THE V6.
First of all, if you don’t allready, then you need to know what the EGR looks like. It is on the driver’s side of the engine bay at the back, circled in red here.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0156.jpg
Now all you will be doing is removing this, placing a blanking plate in the place of its gasket, and refitting it. As haynes would say, this would be a 2 spanner job probably, one spanner for the removal and refitting of the EGR valve, and one spanner for making the blanking plate.
Tools Required:
T45 Torx bit (male), with ratchet and extension bar preferably.
Emery Cloth/Rough Sand Paper.
1 piece of thin gauge metal, approx 6”x 6” minimum, I used some 0.8 welding sheet we had in work, but basically, just needs to be very thin metal.
Marker pen.
Tin Snips (for cutting metal).
Bench Grinder – not essential, but helped me shape the plate. Some sanding paper, or emery cloth will be more than sufficient if you have not got access to a bench grinder.
Drill and drill bit capable of drilling through metal.
Remember, as allways, Safety First! This may be an ‘easy’ job, but exhaust parts can get very hot, and can cause injury. Please ensure that you take care to make sure the parts you handle are not hot enough to burn you. It is sensible to leave engine cool down for a while before attempting this job. Neither myself or VV-OC would be liable for any damage or injuries caused as a result of following this How 2, as you would be doing it at your own risk.
STEP 1:
First job here is to unclip the connector that go’s to the top of the EGR valve. Also unlcip the connector next to it in the same loom, just to the right. Moving both these out of the way will give you better access to the EGR valve.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0157.jpg
STEP 2:
Using the T45 Torx socket on the extension bar and ratchet, remove the two retaining bolts, that hold the EGR valve to the pipe. Take a little care here to not drop them down the back of the engine.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0158.jpg
STEP 3:
Now the retaining bolts and the connector are all removed from the EGR valve, you are now able to completely remove it from the car. In fact, you probably allready have, as once the bolts are out, it takes no effort to remove it from where it sits, and will probably just fall out as your taking the bolts off. Take care to retrieve the gasket that sits between the EGR valve and the pipe, as this will be the template for making the blanking plate.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0161.jpg
STEP 4:
Take the gasket and place it on your metal plate that you have ready. Use a marker pen to draw around the outline of it carefully. Now also mark up the two holes that the bolts would go through. Do not worry about the 2 holes in the centre, these are no longer required, and are what we are blanking off here. Now you need to cut around the outside of the template. It up to you how you do this really, I used a pair of tin snips, and taking small cuts, I made the gasket shape slowly, and then used a bench grinder to help me get the shape I needed. This does not have to be perfect, but needs to quite close match to the outer shape of the gasket.
STEP 5:
Now we have the basic blanking plate, you will need to drill out the 2 holes required to place the Torx bolts through. Take the drill and after clamping the blank plate down, drill out the two holes required. Take your emery cloth/rough sand paper and use it to smooth over the two holes you have just drilled.
It should now resemble this (see the difference between the blank plate on the left, and the original gasket on the right)
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0166.jpg
STEP 6:
Now it’s a matter of refitting the EGR valve and the new blanking plate to the engine. I got to say it… refitting is a reversal of removing :D Just place the gasket in place and put the EGR on to it in the correct position, and bolt it back down. Reconnect the electrical connection on top, and your away.
There is no benefit in removing the EGR pipe that it sits on, as once the EGR is blanked off, exhaust gas can simply not enter back into the intake manifold. The ECU light should NOT come on, as the EGR valve is still connected up to the ECU, and as far as it knows, it is working fine.
First of all, if you don’t allready, then you need to know what the EGR looks like. It is on the driver’s side of the engine bay at the back, circled in red here.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0156.jpg
Now all you will be doing is removing this, placing a blanking plate in the place of its gasket, and refitting it. As haynes would say, this would be a 2 spanner job probably, one spanner for the removal and refitting of the EGR valve, and one spanner for making the blanking plate.
Tools Required:
T45 Torx bit (male), with ratchet and extension bar preferably.
Emery Cloth/Rough Sand Paper.
1 piece of thin gauge metal, approx 6”x 6” minimum, I used some 0.8 welding sheet we had in work, but basically, just needs to be very thin metal.
Marker pen.
Tin Snips (for cutting metal).
Bench Grinder – not essential, but helped me shape the plate. Some sanding paper, or emery cloth will be more than sufficient if you have not got access to a bench grinder.
Drill and drill bit capable of drilling through metal.
Remember, as allways, Safety First! This may be an ‘easy’ job, but exhaust parts can get very hot, and can cause injury. Please ensure that you take care to make sure the parts you handle are not hot enough to burn you. It is sensible to leave engine cool down for a while before attempting this job. Neither myself or VV-OC would be liable for any damage or injuries caused as a result of following this How 2, as you would be doing it at your own risk.
STEP 1:
First job here is to unclip the connector that go’s to the top of the EGR valve. Also unlcip the connector next to it in the same loom, just to the right. Moving both these out of the way will give you better access to the EGR valve.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0157.jpg
STEP 2:
Using the T45 Torx socket on the extension bar and ratchet, remove the two retaining bolts, that hold the EGR valve to the pipe. Take a little care here to not drop them down the back of the engine.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0158.jpg
STEP 3:
Now the retaining bolts and the connector are all removed from the EGR valve, you are now able to completely remove it from the car. In fact, you probably allready have, as once the bolts are out, it takes no effort to remove it from where it sits, and will probably just fall out as your taking the bolts off. Take care to retrieve the gasket that sits between the EGR valve and the pipe, as this will be the template for making the blanking plate.
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0161.jpg
STEP 4:
Take the gasket and place it on your metal plate that you have ready. Use a marker pen to draw around the outline of it carefully. Now also mark up the two holes that the bolts would go through. Do not worry about the 2 holes in the centre, these are no longer required, and are what we are blanking off here. Now you need to cut around the outside of the template. It up to you how you do this really, I used a pair of tin snips, and taking small cuts, I made the gasket shape slowly, and then used a bench grinder to help me get the shape I needed. This does not have to be perfect, but needs to quite close match to the outer shape of the gasket.
STEP 5:
Now we have the basic blanking plate, you will need to drill out the 2 holes required to place the Torx bolts through. Take the drill and after clamping the blank plate down, drill out the two holes required. Take your emery cloth/rough sand paper and use it to smooth over the two holes you have just drilled.
It should now resemble this (see the difference between the blank plate on the left, and the original gasket on the right)
http://img.photobucket.com/albums/v17/rufe_v6/DSCF0166.jpg
STEP 6:
Now it’s a matter of refitting the EGR valve and the new blanking plate to the engine. I got to say it… refitting is a reversal of removing :D Just place the gasket in place and put the EGR on to it in the correct position, and bolt it back down. Reconnect the electrical connection on top, and your away.
There is no benefit in removing the EGR pipe that it sits on, as once the EGR is blanked off, exhaust gas can simply not enter back into the intake manifold. The ECU light should NOT come on, as the EGR valve is still connected up to the ECU, and as far as it knows, it is working fine.