S40: Guide/How to remove EGR valve/Turbo

[Biotoxic]

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...

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.

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.



4. Remove the rubber hoses simply by pulling them off.

and unscrew the bolts and remove the black thing.

remove this as well but you can keep hoses attached to it.

In the end it looks like this.

5.That valve removed.


6. It looked like this.

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.





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.


then it looks like this:


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.


cleaned

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


1. Remove the bolts

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.

P.S. Use rust removal or some kind of anti rust remover, those bolts are quite tight.

To make turbo removal even easier you can unscrew these(marked with red square) two bolts holding exhaust pipe in place.

note that they are located under the car an those two bolts are screwed into engine block just above sump.
If you remove them, exhaust pipe will remove freely away from turbo and you won't need to force it away from it. Just not to forget to screw them back in again after you have finished installing turbo in exhaust manifold.

3.

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.

looks like its been working hard..




Nice and clean




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

[gatos]

Absolutely brilliant. This should go to the Sticky area. Hope a moderator will do so soon. I wish you made this guide a few months ago.... lol

Great, informative and many pictures. No doubt that a lot of people will benefit from this.

It's nice to see new members coming here and not disappearing after they get the help they need. Instead, you came here, asked questions, got help and then made this. Thanks

[Biotoxic]

Thx, my car broke down on my way to Belfast (broken turbocharger shaft) . I had to do it and I was willing to do it
Thing is, when I will put all things back together, I hope works.

By the way it took me 2 days or about 16 hours(including cleaning) to do this first time, had to figure out how to remove different things, how this works, where it goes that kind of things, using this guide it should take no more than 4 hours.

[littlehomer]

Brilliant!

Thanks so much. I'll be working through this at the next opportunity.

I'd undone the three bolts on the EGR, but the outer part wouldn't come off.

The can is loose and it's leaking gas.

This will do the trick perfectly!

Many Thanks,

Daniel.

[gatos]

Hey Biotoxic. I just wanted to suggest that you post your guide in the x40 S1 Articles section where only detailed guides of doing things to the car go. This way, it is easier to find and it won't get lost amongst the 100's of other threads

[The Improver]

Well Biotoxic, you quote yourself as -

I am NOT a mechanic, I am NOT an electrician, I am NOT a certified plumber,
but I CAN fix things.

Your photography isn't bad, all 27 inclusive shots, in fact... it's wonderful!!!

I hope you get the good outcome that's deserved.

[Biotoxic]

Originally Posted by gatos

Hey Biotoxic. I just wanted to suggest that you post your guide in the x40 S1 Articles section where only detailed guides of doing things to the car go. This way, it is easier to find and it won't get lost amongst the 100's of other threads

How can I do that? There is no Edit button any more...

[DWM]

Originally Posted by Biotoxic

How can I do that? There is no Edit button any more...

I agree with gatos. I think the most effcient way would be to put a post in the Forum Support section asking for it to be copied over as more than one forum member has sugested that this would be helpful.

[cumbrianmale]

copied to articles

[graemedench]

I've got a spare compresor wheel if your interested? just remember that its a REVERSE thread on the nut holding it on.
I'll have another spare soon. Also hopefully just after christmas I 'll have a spare turbo for sale too, (low milage)

Currently moding my second turbo.