Before

My egr, 'seeping' black dairylea like goo.

My egr caked in the stuff. Valve was actually stuck and didn't freely move due to carbon and goo!
New shiny shiny! (Exhaust stump is about 5mm too long making matching the holes for bolts a pig!

Egr blank in place.


Spot the gap that made it sound like a tractor/defender!

So,fitting my egr blank was a bit of a pig! Didn't really go to plan. Dropped the 5mm Allen key for a start. (30 minutes retrieving it) old egr comes away easy enough. But the jubilee clamp that holds the exhaust port to the egr port needs prising off with a screwdriver. Old egr was caked with oil and carbon (see pic after a quick wipe and a clean) tried moving the valve with needle nose pliers and it was stuck fast. (My car has done 55k and has full service history) the new stainless shiny egr bypass was well made but the stump to the exhaust port was a shade too long so it didn't meet and the bolt holes were a bit out. Got a bit of a dab on wrestling it into place! (Then dropped one of the stainless bolts on to under tray! Grrr) put it all back together and started it up. Sounded like a frickin tratter! Dismantled it all and the exhaust stump and exhaust port don't quite meet! Wrestled with it some more and used a socket on the clamp bolt. Got it a bit tighter (is there supposed to be a gasket in here?) put it all back together again and now sounds ok again. Fingers crossed. Silicone pipes coming tomorrow although I'm not convinced 51mm are going to fit. (Any tips people?)

Well, I ended up dismantling it all again and used 'gun gum' (remember that stuff?) on the egr bypass stump! Clamped it all together, reassembled and now runs great. I haven't done the silicone hoses yet. I think I'm going for full inter cooler mod (search on here) So waiting till end of month (payday)