Thinking about blanking the EGR Valve..

[gotgcoalman]

Manifold removal.........



3x 10mm bolts indicated by red arrows and 2 hidden 13mm nuts indicated by the yellow arrows.

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1 of the sneaky nuts (deep socket required

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If youv'e got this far a bit of pulling and wiggling (and bending if the bottom mount bolts didn't come out)
should have half the nannas in your hands.
Give then a thorough clean (see earlier post)

Refit in reverse to removal when your'e happy that as much of the Egr muck is out of the manifold.
Or your'e wife/partner is fed up of finding everything youv'e been within 10 feet of is covered in un removable black stuff.
Bet your'e glad you wore gloves now.

Once back together you have 200 feet of spare rubber pipe associated with the Egr surpluss to requirements.
Oh and the fittings are open.

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Take some of the surpluss pipe and do this.
Recycling at it's best.

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Forgot to mention removing the throttle linking rod.
Use a screwdriver to pop it off the ball joints at either end.
If youv'e got this far either pop it back on or use it as a back scatcher as it's no longer needed.

Hope this helps.

[VanPlan]

I managed to buy one off ebay for £3.50 bargain!

I fitted it and sealed it with some gasket sealer.

I damaged the link arm when connecting it back up to the butterfly. Trip to the salvage yard needed now!
I was supprised how clean the manifold was. Just a quick wipe.
Topping up with all new fulids and a service tomorrow. Then off for an M.O.T!

Hopefully I can report back the changes of blanking th EGR, Performance, Mpg, Emissions.

[VanPlan]

Nice 'how to' by the way

[gdlc]

Thanks a lot Gotcoalman for this perfect guide !

[rich666]

once you have the intake manifold off what did you use to clean it?

[gotgcoalman]

once you have the intake manifold off what did you use to clean it?

Used a length of flexible but strong plastic strip to get the thick stuff out then plugged 1 end with rags
and blasted the open end with foam cleaner (might have been Mr Muscle)to remove as much of what was left.

If you know anyone with a steam pressure washer or better still a parts bath/cleaner slip them a pint or two
to clean it for you.

Egr goo is nasty stuff to get off (use many pairs of rubber gloves)
It also gets onto anything white you pass within 10 feet of

[rich666]

ha duly noted

[gdlc]

Finally managed to get the inlet manifold out of the engine (quite difficult with the non-banana type !)

I have removed all the EGR thing, blanked it, and cleaned the inlet manifold.

But it appears there is lot of soot in the engine, in the part where the inlet manifold fits (i don't know how to call that in english).

Is there a way to clean it too ? Is it a good thing or could it be dangerous for the engine ?

[gdlc]

Well I cleaned the head (where the inlet manifold goes) with a blowpipe ! I hope I did'nt any mistake, they were so much soot in it !

I'v now another issue. I'm trying to blank the exhaust manifold too, but the bolt are sheared and won't moove. I tried the blowpipe on it but no way to make them "red". Putting penetrating oil on the bolt has no effect since the thread can't be seen. I'm trying to use a hammer & chisel to turn them but it seems they are well seized... Not an issue part of the engine to work and not much place, so drilling is complicated...

Any idea ?

[VMH]

You don't need to blank it at the exhaust manifold side GDLC. I wouldn't risk snapping the bolts off and causing your self loads of trouble.
I just bought a 1995 model with 150,000 mls which smoked quite badly when i bought it. I have given it a full service, cleaned out the inlet manifold, blanked off the EGR valve and chucked a liter of petrol in the tank in the hope of cleaning the fuel system a bit (it didn't look like it had been looked at for many years)
It still smokes a bit under load though. Is this normal?
I might try locking the butterfly valve open next. See what happens.

[gotgcoalman]

You don't need to blank it at the exhaust manifold side GDLC. I wouldn't risk snapping the bolts off and causing your self loads of trouble.
I just bought a 1995 model with 150,000 mls which smoked quite badly when i bought it. I have given it a full service, cleaned out the inlet manifold, blanked off the EGR valve and chucked a liter of petrol in the tank in the hope of cleaning the fuel system a bit (it didn't look like it had been looked at for many years)
It still smokes a bit under load though. Is this normal?
I might try locking the butterfly valve open next. See what happens.

Take the butterfly out (it's not needed now)

Change the oil before it's due (as soon as it gets a bit black/gloopy)regardless of milage.
Might have to change it after a few hundred miles,then another change a thousand miles or so after.
The engine will be happier. (my oil is just starting to darken @ 5000 miles and i usualy do a change @ 6000)

Fuel system cleaner.
Yep i drop the odd pint of petrol in during cold weather,although i've been putting acetone in the tank for the last few months.
Roughly 1ml/litre of fuel.
No rotting of seals or poor starting issues.
Average before 24 mpg based on 2 tank fulls.
Average after 28+ mpg (not a lot i know but for 50p worth of acetone it saves a couple gallon of fuel over the tank full)

What colour is the smoke?

[VMH]

It is black smoke.
Like i said i don't think the last guy had ever serviced it. The oil that came out was like treacle and the new oil black as soon as i checked the level after starting it. I will change it again soon.
I have locked the butterfly open for now as we are busy doing a stage for a festival over the next couple of weeks but after that, if it is still smokey i will remove it, re check the pump timing and maybe get the injectors tested.
I need to replace the fuel cut off solenoid anyway as it is stuck open.

[gotgcoalman]

Black smoke under load = over fueling.
Normal if the pumps been turned up and you plant your foot

either

Turn the pump back a little if the smoke is really bad,

or

Get more air into the inlet to compensate for the extra fuel.
more fuel needs more air to burn efficiently.

[VanPlan]

Just an update since blanking and taking out the butterfly out...

The engine us more gruntier and louder at high revs

The van pulls like a tank up hills

I get better mpg now

The van starts as normal but a little bit of smoke on start up, nothing to worry about.

Power is amazing, could barely hit 60 now easily goes over 70 haha

Very happy with the results its a no brainer.

There should be a thread on things like this to improve driving performance! Would really help newbies

[dick]

hello vanplan, has it made that much difference, i was thinking of doing mine, cheers