Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
Total EGR valve removal.
Ok I have my body off and just about to put it back on tonight and was looking at removing the egr valves complete and link the pipe work together and leaving the metal pipe over the top of the engine what do you think cant see it being a problem here's a pic just roughly how it's going to go
Any advice welcome
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23rd Jan 2015 2:04 pm
DiscoDunc
Member Since: 08 May 2006
Location: Bristol
Posts: 16390
if you need any help taking everything to pieces - let me know Duncan
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23rd Jan 2015 2:09 pm
robbo770
Member Since: 29 Jan 2013
Location: Aberdeenshire
Posts: 2294
I completely done this during my body off last week,
You will need to get the manifold output flange pipes blanked by cutting off the tubes and welding up Note they are stainless steel flanges.
You will also need a new coolant black hose pipe to go from front engine output to FBH as fitted to the D4's
You also will need the D4 coolant temp sensor Tee which replaces the left top rad hose first Tee position and extend the sensor loom plug wiring to it.
Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
Cheers Rob so did you do away with the metal pipe over the top of the engineWanted D4s non runners pm for competitive price.
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23rd Jan 2015 2:17 pm
robbo770
Member Since: 29 Jan 2013
Location: Aberdeenshire
Posts: 2294
I trimmed it as it supports fuel and other pipes only by cutting the end back only FFRR SC 4.2
Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
Thanks rob so do away with all the EGR coolant pipe work and the pipe from the drivers side egr valve which goes all the way round to the Fbh and do away with the T in the middle with the sensor in,and the D4 pipe goes from where the T was to the FBH
With the exhaust I was going to use BAS blanking plates but not checked if there the same size yet as I cant get anyone to weld up the Stainless this weekend if they don't fit then i will have to leave it all this time Wanted D4s non runners pm for competitive price.
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24th Jan 2015 9:57 am
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20811
I cut my plates from 4mm steel, shaped them with a grinder using a gasket as a template My D3 Build Thread
Member Since: 29 Jan 2013
Location: Aberdeenshire
Posts: 2294
the blanks you need are totally different size from the BAS ones, the manifold has different sizes, as Mike has stated get some steel, use the flanges to draw round and trim, then clamp in vice together and drill the holes to make them, re-use the gasket that you had in the joint with some hylomar blue FFRR SC 4.2
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if they don't fit then i will have to leave it all this time 
