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Old 27-05-16, 06:38 PM   #1
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Default 2003 807 2.0 hdi egr removal

Can anyone write me a quick guide on how to get the egr valve off these cars. Mine is sticking open now and again so I want to take it off for a clean or replace. I can only get access to 1 bolt from the top. I could do with a "this is the best way to do it".

Thanks
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Old 28-05-16, 07:13 AM   #2
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I did get it off on our 2.2 but it was a struggle, think lower bolt was undone a flat at a time. You could support the sump on a block and undo the top engine mount which would then allow you to pull the engine forward to give a bit more space at the back.
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Old 28-05-16, 10:47 AM   #3
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I thought of moving engine slightly, but it's the engine that's in the way and covering up the bolt. I'm thinking I might have to put it on the ramps and remove the exhaust manifold and take it off there. It's in a right pain of a position.
I'm thinking of trying those egr cleaners too which you put into the intake and the fuel additive. Then run a regeneration through pp n see if that unsticks it.
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Old 28-05-16, 01:38 PM   #4
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If yours is a 16 valve I did get ours off without touching manifold, at least the old pneumatic EGR need less maintenance than the current electrical ones mounted at the inlet end of the pipe. I only took it off out of curiosity but it was fine and that's after 200K
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Old 28-05-16, 06:18 PM   #5
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I bought a mini torx ratchet set from tinternet, it was about 20 but it's bloody brilliant for awkward places as the tool is about an inch tall as the bit fits right into the ratchet - made getting my EGR off a piece of cake...
It was a Stanley set...

No need to do any recalibrating or anything, the light will go off on its own if it's fixed, or you can do a scan with diagbox, read the faults then clear the fault.....
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Old 29-05-16, 07:26 AM   #6
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Don't forget to clean the cold end of the EGR pipe at the inlet manifold junction, ours was almost down to a pin hole!
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