Bell Auto Services EGR Blanking Kit Fitment |
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Removing the EGR Butterfly Valve Actuator1537 viewsRemove the 4 TORX screws to remove the actuator. The small black link (circled) connects the actuator drive arm with the butterfly valve spindle (arrowed). The spindle can now be very carefully levered out using a screwdriver inserted beneath the arrowed bit in the photo. A bit scary to do as it takes a fair bit of pressure before the spindle will free itself from the butterfly. Once it starts moving though, it gets easier to pull out.
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Air Box Lower Securing Bolt1072 viewsThis bolt must be undone in order to remove the air box. It is long and tricky to get out and could be dropped easily.
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Air Box Removed1058 viewsView showing air box removed from front of EGR butterfly valve housing
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Air Conditioning Pipes (File 1)983 viewsIt\'s the smaller of the 2 pipes that is leaking. Both pipes are encased full length in the foam sleeve. You can see where the support bracket has \'crushed\' the sleeve. The bracket is what holed the small pipe. There is a bracket at each end and one in the middle. You need to remove the suspension reservoir to get to the centre bracket. Be aware that the bolts securing the brackets may be corroded and are likely to shear off on removal!
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Air Conditioning Pipes (file 2)807 viewsShows location of front-to-rear air con pipes behind NS front wheel. You can just see the Vredestein tyre. The pipe connectors are tucked in behind the wheel arch inner cover. This has to be partially removed for access to bolts holding pipes together.
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Blanking Kit Fitting Procedure2448 viewsHow I fitted the kit to my D3.
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EGR Pipe Bracket 891 viewsRemoving EGR pipe bracket securing bolt
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Remove Clip951 viewsRemoving the air box/EGR butterfly housing securing clip
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Engine Cover Removed900 viewsView of the engine before blanking off the EGRs. The inset sort of shows one of the EGR valve/pipe flange securing bolts. The EGR valves are not easy to get at!
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EGR Valve/Pipe Flange895 viewsThe bolts in the inset are the ones to be removed. Note the rag stuffed down beside the EGR to prevent dropped bolts or gaskets disappearing for ever. Don\'t forget to take the rag out if you don\'t want your D3 to go up in flames next time you use it!
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EGR Blanking Kit Fitted.943 viewsLook, no EGR pipes. The circled bits are the new blanks.
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Air Box Jubilee Clip734 viewsLoosen to allow air inlet pipe to be removed from the air box
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Tie-Wraps773 viewsWhen the EGR pipes are removed, you lose the brackets these cables are normally secured to because the brackets are part of the pipes. This is my solution to the problem - refit the bolts with an almost closed tie-wrap around them, then slip a new tie-wrap through the loop on that one and around the cable.
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Contents of the BAS EGR Blanking Kit852 viewsThe O-ring seals are fitted to the 2 larger blanks at the top of the picture. You need to fit 2 O-rings to each blank.
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EGR Pipe Clips830 viewsRemove the 2 circled clips to disconnect upper ends of EGR pipes from the stub pipes fitted to the EGR butterfly valve housing.
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EGR Butterfly Valve Actuator and Air Box Connectors930 viewsRemove the 2 circled plugs.
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Lifting the EGR Butterfly Housing1018 viewsRemove the bolt circled in yellow. The housing can then be lifted carefully from the front. The \'Y\' shaped duct at the back will swivel at the points circled in red. Be careful of the connector at the back (arrowed) - I snapped the lugs that held it to something back there by pulling the housing up too far!
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Redundant Parts977 viewsThese are what you are left with once the EGR blanking kit is installed. Best to hang onto them in case you need them again!
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Stub Pipe Blank Fitted954 viewsRemember to fit 2 O-rings from the kit to each one!
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Stub Pipe837 viewsRemove these and fit the blanking plates. Make sure the seal comes out too!
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EGR Stub Pipe865 viewsThis is one of the stub pipes that are fitted to the butterfly valve housing. When both are fitted, they meet in the middle of the housing and must present quite an obstruction to the flow of air to the engine inlet valves! Look how cruddy it is. All that muck is being fed to your engine. Ugh!
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EGR Actuator Cable876 viewsThe cable is tie-wrapped to the EGR pipe bracket so I had to cut the tie-wraps. The bracket is part of the pipe.
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EGR Valve Blank1083 viewsHere is one of the blanks fitted to the EGR valve.
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