EGR valve removal-peice of cake!

Well it all started off well, got all the pipes out the way and then after soaking the bolts for several days, got the bottom one off the valve to manifold, but the top one snapped after gentle persuation for an hour!
Well out came the drill, eventually drilled out the remains of bolt!
Down to halfords £35 lighter for a set of tap and dies!
Started to re thread hole and snap, the quality tap snapped!
Yes it started all over again! Back down to Halford to get a replacement set. And finally got it sorted. As you can see from the pics it was then dark! Lets hope it was worth it?

looks like you had fun doing that job

I bet you will notice some differance though so it is worth while. Have you done away with the cat as well? as thats what made the real differance to mine.

The de-cat is the next on the list, lets hope the bolts undo ok and i don't have to lay on my back drilling underneath!
Looking at getting a pipe off flea bay as look cheap enough.

When doing the de-cat pipe just make sure you jack up the body from the suspension to give you room to fit the pipe, took me 2 hours to figure that one out :doh:

Thanks for the tip.
Should save me a couple of hours!

Well worth doing the de-cat pipe, improves pick up but i found a slight increase in noise. I suppose you cannot have everything but the feeling of being pushed back in you seat out weighs the noise.

Well purchased de cat pipe last night off flea bay, so hopefully it will turn up before the end of the week so i can get it fitted before i go back to work. Sounds like its worth doing the mods as noticing a difference already with the EGR valve gone!

hi, let me know how the de-cat pipe goes...
planning the same 2 mods to mine in the next couple of weeks, cheers

Will do Rizlaman, lets hope it goes more smoothly than the de cat!

Hi just done my EGR fitted the kit with the by-pass as well cannot believe the difference in performance. The engine feels much more free revving and delivers more power. When i took off the old EGR it was completely gunked up, had to clean out the manifold as well.

Nice easy DIY job though, well worth the £30 ish for the kit, would recommend to anyone to get it done.

Got a EGR kit for xmas now got to fit it, done the De-Cat a couple of months ago, deff make a differance, lot more responsive, not quite like a racing car but hey, we can all dream at the lights......

I would like to remove my EGR but I'm worried that i will bust the 2 bolts and then have problems with the new replacement bolts,, Ive been planning on doing it for the last 3 years ,,but them bolts look very rusty and i just know with my luck they will bust.I take it that you have to use a ratchet socket extension bar and a Allen key bit to fit in the socket.

busagsx1300 said:

Well it all started off well, got all the pipes out the way and then after soaking the bolts for several days, got the bottom one off the valve to manifold, but the top one snapped after gentle persuation for an hour!
Well out came the drill, eventually drilled out the remains of bolt!
Down to halfords £35 lighter for a set of tap and dies!
Started to re thread hole and snap, the quality tap snapped!
Yes it started all over again! Back down to Halford to get a replacement set. And finally got it sorted. As you can see from the pics it was then dark! Lets hope it was worth it?

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To get the most benefit from this mod you would be well-advised to wash out the intercooler with white spirits or petrol.


Doing the de-cat pipe mod should only take about 1 hr but the key to success (imo) is:

1. Jack up the chassis (not the axle) to create more working room between the engine and the axle;

2. Undo the three nuts that hold the downpipe onto the turbo from underneath, using all your socket extension bars. These nuts usually come undone quite easily, unlike the the ones on the manifold when blanking off the EGR valve.

Best single mod you'll ever do is the de-cat pipe one.

Allen 666 said:

I would like to remove my EGR but I'm worried that i will bust the 2 bolts and then have problems with the new replacement bolts,, Ive been planning on doing it for the last 3 years ,,but them bolts look very rusty and i just know with my luck they will bust.I take it that you have to use a ratchet socket extension bar and a Allen key bit to fit in the socket.

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Put a blank off in the joint between the flexi pipe where it meets up with the inlet manifold pipe-you just need to stop the egr pipe talking to the inlet-I used a 2p piece for this fits fine

Allen 666, my bolts were also very rusty....a good hours soak with penetrating fluid and a bit of care when removing did the trick for me. Give it a go you will be pleased with the result..

I will give the 2 pence coin ago first.As you say it probably don't matter what end of the pipe you blank of so long as it stops the gases i will have a look under the bonnet in next day or to to see if i have to remove anything else first to gain access to the other end of the egr pipe.

well worth doin egr blank off, got my kit off the bay for £14 to the door an its made a big differance, lot more responsve, i cleaned out the inlet too. left it submerged in the kero bath for 30min haha...

im glad the de-cat is worth while, i have one on order so should be here asap, was only £24 to the door plus i got £26 for the last disco cat i weighed in so ill actually make £2 from decatting it hahaha...

OK i looked at the other end of the egr pipe that runs across the front of the engine to the big pipe ( 1999 TD5 Disco)and that looks quite difficult to see where the hard gold colored pipe goes in to the big fat rubber pipe.Oh well i will keep on putting wd40 round the allen bolts on the manifold i can get a allen key on the front bolt but the rear bolt not too sure about that unless every one uses a ratchet and bar and socket with a screwdriver allen key thing stuck in the end of the socket then turn and wish for luck.

Allen 666 said:

OK i looked at the other end of the egr pipe that runs across the front of the engine to the big pipe ( 1999 TD5 Disco)and that looks quite difficult to see where the hard gold colored pipe goes in to the big fat rubber pipe.Oh well i will keep on putting wd40 round the allen bolts on the manifold i can get a allen key on the front bolt but the rear bolt not too sure about that unless every one uses a ratchet and bar and socket with a screwdriver allen key thing stuck in the end of the socket then turn and wish for luck.

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First remove the plastic fan cover, then you will see a steel flexy-pipe that goes from the exhaust manifold round the front of the engine and into the EGR valve itself, on the lhs of the engine as you look at at.

The EGR valve is held in place by 4 x 10mm (I think) small bolts plus the large diameter rubber hose.

Challice said:

im glad the de-cat is worth while, i have one on order so should be here asap, was only £24 to the door plus i got £26 for the last disco cat i weighed in so ill actually make £2 from decatting it hahaha...

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Where was that from?


I didn't have to take anything to bits to remove my EGR valve, and although the bolts were a bit rusty they came un-done. Also a 99 TD5 so you should hopefully be ok!