Intake manifold removal / egr removal - TD27

[prawln]

Hey guys,

I'm new here and came across the side when I googled about removing the EGR from a TD27.

I've done a fair bit of searching and have found bits and bobs about removing the EGR but havent found any start to finish sort of instructions on what do to and what to remove. Reason for removing the EGR is after i removed the top part of the intake manifold and looked inside the manifold, she looks pretty manky. I'll include some pictures below also.

On another note does anyone have good tips on removing the intake manifold? I'm wanting to clean this right out at the same time.

[slide]

Welcome to the site
Where are you from?
Its pretty easy to do (both remove intake manifold, and remove EGR), providing you're any good with a set of spanners
You'll soon see how it all works if you get stuck in, else have a good search on this site as it's been covered in quite a few threads.
Feel free to do a big 'how to' write up when you do the job. I usually just do things, then afterwards think how I missed the opportunities for photos

[prawln]

Cheers mate,
I'm from Paraparaumu.

Will have another big search on what to remove etc, I got as far as needing 2 blank off plates and removing vac lines and tie open the butterfly valve or remove it completely.
Then in saying that I saw a video where a guy just got one blank off plate and put between one side of the EGR, is this ok to do or not really advisable?

If i go down the track of removing it all ill try remember to take pics etc, im the same, get to the end then remember to take pictures haha

Sorry also do the TD27s have quite bad blow by? mines either never been cleaned (only just got the mistral) or its trying to self lubricate itself through the turbo haha

[fish]

Thats all I did on my 4m40. Just make a blanking plate. Seems to work ok tho I messed up and over tightened one bolt so that it just keeps turning and the seal is not 100%. Anyone know how to fix that? Do you need to re tap?

[Big]

I messed up and over tightened one bolt so that it just keeps turning and the seal is not 100%. Anyone know how to fix that? Do you need to re tap?

helicoil it and it'll be sweet as.. essentially yes a re tap.. but get the kit as i't has more coils for other thing that may pop up..

[fish]

Cool just check them out. Tho I think it might be a metal sleve turning inside the alloy. Either way. Sory yo get off topic.
But yea a blanking plate is all you need. Im going to put a catch can on the breather to cut sll the crap going into the intake. That coupled with egr delete should mean all fresh air from then on.

[prawln]

Cheers fish,

Did you put it between the egr, leaving the egr still in there but blanked off or did you remove the egr completely and used 2 blank off plates?

[fish]

I left it in and just put one between the egr and manifold. Haddnt thought of doing two but might now that you have mentioned it. Could solve my seal isue. Cheers

[prawln]

So this weekend I have, removed the intake manifold, removed the EGR valve completely and butterfly from intake. So last on my list is the vac lines.

I have 3 that aren't connected to anything now (1 from EGR valve and 2 from the butterfly) What needs to be done with these?
I somewhat thought I would just cut the vac line down then just chuck a screw in the end and cable tie. Rangie I no.

Any help would be awesome!

Cheers guys

[hamboy]

Trace the vac lines back to the solenoids disconnect from there. As far as cleaning the manifold I've been told oven cleaner works quite well.

[prawln]

Cheers mate,

I've just take a look at the vac lines and have found where they go, should i disconnect the power to the solenoids or just undo the vac line and leave nothing on the end of the solenoid? it looks like there is a T junction on one of the lines.

[prawln]

Ok so I've removed all vac lines that went to the solenoids. The vac line that went from the solenoids to the alternator I removed and plugged up the line. I also unplugged the solenoids and removed.

Is anyone able to confirm this is correct?

[prawln]

No one?

[Crash bandicoot]

yep, you'd soon know if it wasn't as your brakes would become as hard as a rock(no vacuum assist)

[fish]

I just left it all there with just the egr blocked. Didnt see a need to remove anything.

[prawln]

So I've removed all vac lines from the solenoids and the solenoids and doesn't seem to be any issues!!

[kiwinoz]

Have you removed the butterfly thing too?
You don't want that flopping closed.

[shrub]

Im about to be doing the same. Couple of Questions
Did you have to buy a new intake manifold gasket or were you able to reuse it?
PCV blowby I assume you made a tank or can you get away with a chassis rail pipe.
Im cheap btw