Egr removal

[s40 man]

Can any one help with my 1.9d egr I want to replace the gasket witch I have i losend the bolts of but it won't budge help please

[kieran40]

There's a guide on here somewhere there's two parts to the egr the outer and the inner the outer should come off easy the bit with the leccy plug, the inner is a bit tricky it gets stuck in the block, I used a block of wood and a hammer just tapped it back and forth and wriggled it out, it's not as difficult as you think when you do it once

[skyship007]

Originally Posted by s40 man

Can any one help with my 1.9d egr I want to replace the gasket witch I have i losend the bolts of but it won't budge help please

Firstly, there is a good guide in this forum:
http://www.volvoforums.org.uk/showthread.php?t=108558

Secondly you will need a spare intake O ring AND metal EGR gasket. Also the 3 bolts that mount the EGR are supposed to be replaced IF you have the OEM hex heads fitted. So you might need those 3 bolts, in addition to the O ring and gasket.

If you don't want to risk damaging the EGR, I would also buy the Volvo EGR removal tool, or an equivalent (About 50 quid) hook spanner.
The Volvo dealers don't clean EGR's, they only replace them with new ones, although most seem to be OK if removed and cleaned correctly.

Rufe the Swansea Volvo dealer is probably the best place to get the parts.

Do you have any actual symptoms of a blocked EGR at present, as they can last a long time if you get some motorway WOT time in every month ??

[kieran40]

You don't need a special tool skyship op put youre money in youre pocket lol, the tool is nice to have but a block of wood and a rubber hammer do the same job just aswell

[candor]

Has anyone a pic and dimensions of the tool? It sounds like it might be easy to knock one up.

[happy diver]

2" x 4" x 8"

[skyship007]

Originally Posted by candor

Has anyone a pic and dimensions of the tool? It sounds like it might be easy to knock one up.

I agree, it should not be difficult. Just use the new EGR gasket as a template for the shape of the arc and the size of the 2 pins, then fit a handle etc.
They seem to be about a tenner on Fleabay, IF you can figure out which is the correct one:
http://www.ebay.co.uk/sch/i.html?_od...er&_sacat=9800

That way you can hit the tool handle if it refuses to budge. Previous forum members have reported that some of them can be very difficult to remove and have finished up using either a pipe wrench or hammer and wood, both of which might damage the EGR.

[bobthecabbage]

My top tip would be to pour a kettle full of just boiled water over the bit of the intake manifold the EGR fits into. Pour it slowly over a minute or two to really give it a chance to warm up.

A pair of decent water pump pliers, something like this

http://www.screwfix.com/p/rothenberg...FWT3wgoddBIAPQ

Are useful to rock it back and forth. You don't want flat jaws on the pliers as you need to engage the lugs where the bolts go to get enough grip. Gripping the round part won't be sufficient. I'm not sure whether a heavy duty filter wrench/strap might do it.

Volvo recommend spraying rust solvent on where it seizes but something like wd40 will help if that is all you have.

It'll take all your strength to move it at first but then just move it back and forth whilst trying to work it outwards at the same time. Start with small movements, maybe a mm back and forth.

Mine was an easy one but it wouldn't shift at all without the heat. If one kettle doesn't help, try a second!

[happy diver]

http://www.google.com.au/url?sa=t&rc...96041959,d.dGc