Fitting EGR kit
Td5 Alive supplied me with an EGR bypass kit. This is a direct replacement for the original EGR valve, and bolts neatly between the intercooler outlet and inlet manifold. The EGR valve body replacement is made from high quality, laser cut aluminium, with a rolled edge for secure fixing of the intercooler hose. The exhaust manifold blanking plate is made from 6mm thick mild steel, so will not distort under high exhaust temperatures. Both items are made from the same materials as original parts, so will give a perfect fit under all engine conditions.
Fitting of the kit ensures a smoother, unrestricted, clean, and cool airflow into the engine, which helps to improve torque.
Fitting was simple and is outlined below.
Remove the engine acoustic cover, held in place by 3 13mm bolts.
Remove cooling fan cowl held in place by 3 Phillips head screws.
Disconnect vacuum hose from the EGR valve, red arrow in the 1st photograph, then blank this off and tie up out of the way.
Remove 4x 8mm bolts marked by the green arrow holding the EGR valve to the inlet manifold. The one on the lower right is tricky and I used a Halfords ratchet spanner to good effect on this one.
Remove 2x 8mm bolts connecting EGR valve clip from cylinder head.
Remove 2x 5mm Allen bolts securing EGR valve pipe to exhaust manifold. These are marked by red arrow in photo 2. These are also tricky to get at, 1/4mm ratchet kit worked for me.
Loosen clip screw and release air intake from EGR valve, marked by yellow arrow.
The EGR assembly can now be removed complete.
Looking at the photographs below the restriction caused by the valve can be seen. Also the residue left by the dirty exhaust gases can be seen.
The 6mm plate is attached to the exhaust manifold with the 2 Allen bolts.
The new air intake is bolted to the intake manifold with the 4 bolts then the air hose is reconnected and the clip tightened.
Road testing next and driving round Edinburgh bypass the car definitely seems to pull better with more mid range torque. So a good improvement and I’ll keep you updated on progress.
Graeme
