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Delica : EGR Fitting: PHOTO VERSION!!


 
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Mystery Machine
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Joined: 04 Jul 2003
Posts: 179
Location: Bristol

PostPosted: Mon Nov 10, 2003 14:47    Post subject: Delica : EGR Fitting: PHOTO VERSION!! Reply with quote

Following AndyC's informative instructions, http://www.pocuk.com/forums/viewtopic.php?t=5260 I had a go at fitting the blanking plate (prototype) this weekend (AND SUCCEEDED!!  )

If like me, you're more of a visual person, instruction cause more headscratching than progress - so I took piccies of the job (On an L300) so that between Andy's thread & this one, there's no reason not to have a go!! If some of my comments are the same as Andy's, I do apologise, it's just that he wrote it so well!  

Tools I used:

12mm socket (short extension handy!)
10mm socket
10mm open ended or ring spanner
Short (stubby) crosshead screwdriver
Wide flat bladed screwdriver
AndyC's instructions  
(Oh - & some WD40!)

Here we go:

Lift up engine cover & hold open.

Slide drivers seat forward and peel back carpet to expose air filter cover. Remove wingnut (in RED) & remove cover.


Using 10mm socket OR stubby screwdriver, loosen the hose clip (in RED) and pull of end of rubber hose from air filter housing.


From the engine bay, loosen the other 2 hose clips (in RED) A 10mm ring spanner might need to be used for the one on the right because space is tight!! From drivers side, remove the rubber hose by gently twisting & pulling.
Next, using a 12mm socket, undo the two bolts (in BLUE) that hold the metal pipe down. In order to get to the right hand bolt, pull off the breather pipe from the top of the engine (in GREEN) and leave it off until the end.
In order to remove the metal pipe, unclip the hose from its two clips (in YELLOW) to give you more space to move it!


I had GREAT difficulty removing the metal pipe - it was stuck solid to the rubber hose! (in RED) If this is the same for you, lever a flat screwdriver under the lip of the hose to break the join & use WD40 to free it up (try not to knacker your knuckles up as much as I did!!  )


If you haven't already, remove the breather pipe from the top of the engine (I had to anyway to get to the nut holing the metal pipe)


When removing the metal pipe, I accidentally pulled of this pipe (in RED) from the end of 'another' valve! If this happens to you, make sure you push it fully back on before putting everything back together!


From the drivers side, use a flat bladed screwdriver to CAREFULLY pop out the four plastic lugs that hold the rubber 'curtain' in place (in RED) I lost one (pinged off SOMEWHERE never to be found!) so be careful!


Now you can get to the EGR valve, where you will need a 12mm socket to remove these two bolts (in RED) When the bolts are removed, carefully pull the valve back (towards the left as seen in the photo) and remove the thin gasket. If the valve is oily (as mine was!!!  ) clean the surfaces where the gasket was sat, then insert the new blanking plate in it's place.


Make sure the blanking plate is in the right place, then insert the two bolts and tighten them up. You can JUST make out the shiny blanking plate between the oily valve and even more oily inlet manifold!!  (in RED)
Once tightened, clean up the valve & manifold if you desire (although I didn't bother - I just wanted to get in & have a cuppa 'cause I was FROZEN!!)  


In good ol' Haynes stylie, re-assembly is the reverse of the above steps!  

When finished, make sure ALL pipes are properly connected and nothing has been left loose.

Close up the covers, get in & DRIVE!!  

Hope this helps those who are thinking of doing the job?

Regards,

Bruce.
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PostPosted: Mon Nov 10, 2003 14:47    Post subject: Google Ads keep the POCUK free to join!


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astra
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Joined: 02 Oct 2003
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PostPosted: Mon Nov 10, 2003 14:49    Post subject: Reply with quote

nice one bruce! fancy having a go at an L400? Wink
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jo0lz
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Joined: 13 Jan 2003
Posts: 104
Location: Wirral

PostPosted: Sun Nov 16, 2003 22:33    Post subject: Reply with quote

Astra
Having seen where the EGR valve is on an L400 this afternoon at the Brizzle Meet....
me thinks its a piece of P*ss to put that banking plate in there with your bonnet up........ Laughing
compared to our L300's (like Brucie's pix) where we remove lots of knuckle-skin....OuCh!...just getting to the f**k*n' thing

I'm now thinking......where can I fit an Intercooler on an L300 ... Rolling Eyes

Jo0lz
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ali
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Age: 54
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Joined: 09 Oct 2002
Posts: 314
Location: sat at my pc...

PostPosted: Sun Nov 16, 2003 23:25    Post subject: Reply with quote

jo0lz....fit it on the roof matey...it will get loads of nice cold air up there... Shocked Very Happy .....if ya need any more help...just ask.... Wink ...
little ali... 8) ...
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astra
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Joined: 02 Oct 2003
Posts: 397
Location: Near Bristol

PostPosted: Sun Nov 16, 2003 23:29    Post subject: Reply with quote

jo0lz wrote:
Astra
Having seen where the EGR valve is on an L400 this afternoon at the Brizzle Meet....
me thinks its a piece of P*ss to put that banking plate in there with your bonnet up........ Laughing
compared to our L300's (like Brucie's pix) where we remove lots of knuckle-skin....OuCh!...just getting to the f**k*n' thing

I'm now thinking......where can I fit an Intercooler on an L300 ... Rolling Eyes

Jo0lz


LOL!!! hubs said the same! he's looking forward to having a bit of a tinkle under the bonnet hehe
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