EGR help please :)

Hi guys hope you can help. Ive looked in the searchs but just want some fresh opinions (really means I cant find the answers)
We have just done an EGR removal and just want to check a few things the landy is a 2002 EU3 TD5 Model before much better half drives off and kills himself...


Paddocks EGR removal Kit - I know, I know
And other bits by JGS 4x4


After reading the in depth instructions supplied by paddocks which are below

Remove bolts from EGR Valves and Exhaust Manifold at these points (what points, we are not entirely sure)
Replace valve with SS adapter on the left and SS blanking plate on the right

Job done???


EGR removal

Removed EGR Valve - No problems
Removed both Pipes from the actuator - No problems
Fitted replacement straight through part - No problems
Remove pipe on LHS of Heat exchanger - No problems
Removed RHS bolts on Heat Exchanger - No problems
Exhaust Manifold bolts - Cannot remove starting to round off

Fitted blanking plate inbetween RHS heat exchanger side and Pipe work from the exhaust manifold - so both sides are blanked off
See photo

Disconnected the electrical connectors to the both modulators
Removed both blue pipes and sealed with rubber bung (on modulators)

Is this all safe?

Is there anything else that needs doing?
I read somewhere that we should blank off the T-joint or replace the whole thing (Vacuum pipe)
Also do we need to remove the air feed to the solenoids and blank that off


How can you removed the bolts from the manifold (tried liberal amounts of WD40 already



http://i1232.photobucket.com/albums/ff364/Atech99/20130810_164202.jpg

That will work. You only need to get the manifold bolts out if you want to remove the small exhaust pipe all together.

Thank you

If you really want to get them out give them a good soaking in plus gas or similar every night then get a gas torch on them (a blowlamp wont do it as it dont get hot enough). They will loosen eventually but dont go mad or they will sheer off or crack the manifold.

I'd also replace the front plastic round crank case cover n all as it seems to be leaking. it only pops out and a few quid to replace.

Deffo a job worth doing as thats what I've done to mine

I also took the egr cooler off, wouldn't of done it this way but my water pipe from the header tank to the top of the EGR cooler snapped as it was the brittle