EGR which end?

Hi folks went to fit my EGR blanking plate earlier today managed to undo one of the bolts but the bolt on the bottom has rounded off!
I've been attacking the end which ends roughly just underneth the top hose and thermostate. Is it possable to fit the blanking plate on the other end which seems even more diffacult to get at. Any advice would be welcomed.

what engine?

Sorry forgot 1999 td5

Are you fitting it exhaust end, or EGR valve end?

how rounded off is it??
can you get an allen key bit into a mini ratchet on an extension and attack it that way...that's how i did mine

probably best to give it a good laquer of WD40 while you scratch your head!

Tried the WD40 han allen key bit on a extension bar and ratchit can only apply so much pressure then it slips round to the next position

Just to answer congo's question i'm fitting it to the exhaust end but how easy is it to fit the blanking plate to the EGR valve end? If i can't get the bolt undone the i would have to try this line of approach.

Loads of WD40 - or a penetrating spray could be better.

If its totally buggered, usual step is to try and cut a slot in the head and use a screwdriver on it. Loads of heat often helps.

I couldnt get the top bolt out of mine (exhaust end) and eventually it sheared off - I then had to drill it out and fit a nut and bolt.

I coulnt see how it could be fitted to the other end, but I was led to believe that it could have been.

That makes two of us! i can't see how it fits to the other end either i'll carry on as i am then last resort GAS! also did you disconnect the EGR sensor once you fitted the plate?

Nope - just fitted the plate.

Soak it with PlusGas or WD-40, or best of all some kerosene with a little engine oil added.

Get a long handled 4-ounce pin hammer, and tap the stuck Allen screw 200 times smartly on it's head. Eventually it will loosen if you are patient. Don't use brute force or a big hammer - a 4 ounce pin hammer, and hundreds of decent raps is all that's needed. This will also pein down the head of the socket screw and your Allen hex key may fit tighter.

It WILL come out if you are patient.

I had to to do this to my TD5 at under 20k miles

CharlesY

ah good old 300tdi with 10mm bolt granted the kit i got came with new longer bolts which are 6mm hex's, so i'm making a note of all of this in my head incase it ever needs removing (doubt it but you never know)

metallicachick86 said:

ah good old 300tdi with 10mm bolt granted the kit i got came with new longer bolts which are 6mm hex's, so i'm making a note of all of this in my head incase it ever needs removing (doubt it but you never know)

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you should always re-assemble with just a tiny smear of grease... however being the exhaust manifold, use a touch of copper grease! you know it'll never come off again but then, you never know...!

I just fitted my EGR blanking kit today and I went for a little run afterwards to see if I could tell any immediate difference.

To be honest not a lot !! I think she running a bit smoother and I had a sense of her maintaining speed easier up a hill near me.

The big issue was the amount of black tar-like substance in the inlet manifold.

I didn't have chance to strip down and clean it today, but I must.

Pictures included to show the job. I didn't blank off at the exhaust manifold as I could budge the bolts, but as the pictures show I have blanked off after the valve as those bolts came undone easily. Can't see that there will be any difference in resutls doing this way as it's still blocked off - any comments?

thebiglad said:

I just fitted my EGR blanking kit today and I went for a little run afterwards to see if I could tell any immediate difference.

To be honest not a lot !! I think she running a bit smoother and I had a sense of her maintaining speed easier up a hill near me.

Click to expand...

Wait till you start to notice how much further a tank of fuel takes you.
Then come back and tell us.
CharlesY

You may only notice an improvement if the EGR is faulty in the first place. The blanking plate can be fitted either end of the exhust connection.