Guide/How to remove EGR valve/Turbo
 

DIY
*Caution*
I am NOT a mechanic, I am NOT an electrician, I am NOT a certified plumber,
but I CAN fix things.
Due to this I am not responsible for your mistakes or any damage that might occur while doing this.

This Is how I removed Turbo, EGR valve and manifold.
Lets get to the point!

1. Remove that big pipe...
http://www.bildites.lv/images/lwmg3wmch9ed0xk0xa07.jpg
using flat head screwdriver. Easy enough. It's green because it's easy to remove or easy to access it, red is hard to access.

2.Remove the sensor using flat head screwdriver, do not brake the plastics holding it in place. Fairly simple.
http://www.bildites.lv/images/5tg2zrd46n3lb6tnvzdr.jpg
after that use the same screwdriver to get that clip off from just bellow the sensor. Use it from one side and carefully lift it off, once the one side is off, you can use you fingers to get it off completely.

3.Unscrew these bolts.
http://www.bildites.lv/images/gghbwsvhsqhwz5kbyz0.jpg
http://www.bildites.lv/images/l3qtid7gq82z6ahnqkij.jpg

4. Remove the rubber hoses simply by pulling them off.
http://www.bildites.lv/images/g0qvdkgbrgo7f5e4ao2b.jpg
and unscrew the bolts and remove the black thing.
http://www.bildites.lv/images/gonazcxiqa6oca9k4fb5.jpg
remove this as well but you can keep hoses attached to it.
http://www.bildites.lv/images/uki41qz40duvm58e0zgo.jpg
In the end it looks like this.

5.That valve removed.
http://www.bildites.lv/images/854dvevywkict2do2wh.jpg

6. It looked like this.
http://www.bildites.lv/images/fl218ihxubrkkfo25wgq.jpg
I removed air filter cover for easy access to bolts and hoses.
Remove filter itself or it will stain easily.

7.Remove 3 bolts that holds first part of EGR valve(I had only two bolts there so I found why and where my engine oil went missing two weeks after oil change) NB: I used older picture, so it contains some parts that were removed in previous pictures.
http://www.bildites.lv/images/8yt1k858yqpwuy7my0o.jpg
http://www.bildites.lv/images/1q1jsn9leulyb9pcml1a.jpg

http://www.bildites.lv/images/wl89b25lowepx2u6tbbj.jpg

8. Remove inner part of EGR valve by using some anti rust spray, Carb cleaner (or something like that)
To remove it, I used a peace of wooden stick and rubber hammer. Try to hit it with a little force, bit by bit, turn it clockwise and then a few degrees anticlockwise (thx gatos for information about this).
Do that until you are able to use both your hands and then just one hand. Then turn it so you can use one edge and slowly using wooden stick and hammer force it out, bit by bit.
http://www.bildites.lv/images/lsgcdq672lyc543jythk.jpg

then it looks like this:
http://www.bildites.lv/images/tmi90mihewpnk8pcf1s.jpg

This is why you should clean things once in a while. There was a noticeable gap between that seal and main body, that's why things started to fail. Easiest thing is just replacing the part, but cleaning works fine as well. Recommend it.
http://www.bildites.lv/images/ah9a02dtxn7zcjtyxb0e.jpg
http://www.bildites.lv/images/yozogwh87482va8ede4.jpg
cleaned

That`s it for EGR now, its turbo removal next.


1. Remove the bolts
http://www.bildites.lv/images/xhwdiiace4u29kdx1iz.jpg
OPTIONAL: Remove heat shield for more space
2.Bolt marked with red arrow is under those two bolts, hard to access that's why its red.
http://www.bildites.lv/images/0judo95u527ywzmrz46q.jpg
P.S. Use rust removal or some kind of anti rust remover, those bolts are quite tight.

3.
http://www.bildites.lv/images/m830zt9gbpzy9kclzecg.jpg
red arrow indicates that bolt and turbo removal directions.
--Edit---
Under turbo itself, there is oil return pipe, 2 bolts there. Bolt closer to engine was the hardest one to reach, small working area and deep inside engine compartment

More pictures of failed turbo.
http://www.bildites.lv/images/ssvt01q7n4g52nltnsyv.jpg
looks like its been working hard..
http://www.bildites.lv/images/tijse6quzs7x64jlhaeh.jpg
http://www.bildites.lv/images/0qgbfpdkk2z4f7k0wv4c.jpg
http://www.bildites.lv/images/6l0eq7nr5ddgrjtyau2i.jpg
http://www.bildites.lv/images/30gmkswv9mns886g6h.jpg
Nice and clean
http://www.bildites.lv/images/5tbjy86thfv52os8qieq.jpg
http://www.bildites.lv/images/8fd7tkail9fletteivtj.jpg


That`s it, my first dismantled turbo.
Currently looking for a new one....
Maybe someone can suggest some a bit bigger turbo that doest need any engine modification to handle more power? I've heard that performance ones cost roughly the same as replacement turbo.
(S40 1.9 sport Turbo diesel, 2002, manual. 115 hp)

Feel free to correct me, I will edit this text if necessary.

Hope this helped to someone.



Tags:
Removal, fix it yourself, EGR valve, Turbo removal, Turbo, Oil, cleaning, hoses, engine