by acezwild » Sun Jan 27, 2013 6:10 pm
hi just wanted to add a couple things about the removal and replacement of a egr valve on a mk7 2.4 rwd transit, firstly it is a pain but it is do-able, my 07 transit was reving up and down while idling then it started to cut out , i replaced the maf map sensors no help there, so i wanted to tackle the egr and put in a blanking plate, i didnt have a pit or a lift so i put the van up at the front on some blocks for belly clearance, the egr is located at the back of the engine above the starter a small work light comes in handy here ,you need a 10 mil and 8 mil spanner preferably ratcheting spanners and also a 10 mil and 8 mil socket and a pair of needle nose pliers, lift the bonnet unplug the egr located at the back right hand side of the engine under the van the lower 10 mil bolt on the egr going to the manifold was easy enough to get at but kinda blocked by a rubber coolant pipe needle nose pliers on the pipe clamp and remove hose watch your face coolant comes flying out so will need topped up later , bit better clearance now to work , abit of wd 40 remove the 10 mil bolt quite easily but be carefull not to strip head of the bolt or you will start crying for sure, there is another 10 mil bolt above the one you just removed it is harder to see and get at i used a socket on this one and got it off the metal gasket just fell out keep it as you need it . this upper 10 mil bolt can also be accessesd from under the bonnet lift the bonnet and remove the plastic air scoop held on with 2 -8 mil bolts now you can see a bit better stand on a step and reach down the back of the engine long arms help ,there is the 10 mil bolt as i said you can get it from the top or bottom whatever is more comfortable for you. i traced the gasket and cut a plate out of thin stainless put in the plate and tightened up the bolts reconnected everything topped up coolant, tried the van and no luck i wasnt sure what inlet on the egr i was supposed to blank and this didnt help, back under i went did the whole process again this time undoing the 10 mil bolts then the 8 mil bolts on the egr the bottom 8mil bolt was fairly simple. the other 8 mil bolt i got from under the bonnet got the gasket on the 8 mil side of the egr where the metal flex pipe is and made another plate and blanked it off after much stuggling trying to bolt it all back together i reconnected everything topped up coolant , and started the van with both plates in in was a bit lumpy idling but an improvement, after the van warmed up it seem to idle perfectly i test drove it no problems power wise and no warning lights on the dash. next day it was cold started the van and it was lumpy idling again and cut out a couple times i drove it and when it was warm it was perfect again, idled great , so where im at is im thinking of taking off the blanking plate i have goin to the manifold the one held in with the 10 mil bolts and seeing if that makes a difference, as theres not alot about the struggles of the 2.4 rwd erg valve replacement i hope this helps you guys i will let you know how i get on with the removal of the other blanking plate.