EGR n others

[Hazzo]

I've just spent the whole day, 8.30 - 3.30, trying to get the intake manifold off the truck, and failed, miserably.

Is the only way to do this is to get the egr pipe off the exhaust manifold and any tips on getting a decent 12mm tool in there to do the job, its a nightmare, as was getting the wrap-around, plastic clipped, injector pipes free, it was like one of those chinese puzzles.

If so I reckon the egr is going to be sealed off before I put this lot back together. I can see into the intake of cylinder 1 of the manifold and its gunged up bad through this useless valve, this can't be good for the motor, a bit like smoking 50 a day, which is what I got through doing the jobs. H

[Hazzo]

bump

anyone, decent tool for these 12 mm nuts on the egr to ex manifold, I've tried to use heat but the torch goes out when inverted, cant get a decent socket in and open end and ring spanners are rubbish as they aren't long enough to put pressure on or they start rounding the nut off.

If I could get the grinder in there I'd have chopped them out by now but there's no space for nothing, any tips/ideas much appreciated. TIA, H

[stormforce]

undo the handbrake casing on the bulkhead and push it down a bit as that will give a bit more room to get it there.Handbrake needs to be off tho.You may have to bend a 12mm spanner a bit aswell to get leverage.This is how i did it

[Hazzo]

Cheers mate I'll give it a try, sitting here peed off at the mo and just reading about removing the head and leaving all manifolds/egr in place, which makes more sense, trouble is I've no garage or crane lift and think I'd struggle to get the lot off without making more mess of the car, or my back. H

PS. I'd already loosened the HB thing and busted one ring spanner so think the tool shop might be the next stop for a decent one. Thanks

[stormforce]

the egr system is a pain.There is also i think a 10mm bolt at the back of the head aswell that needs to come out as its a clamp plate for the pipes.There is also a earth strap at the back of the head aswell again 10mm bolt
Slacken the handbrake from under the truck and not the rear hubs to give some slack on the hb cover on the bulkhead.I just thought there is a small split pin thing on the side of the hb cover take that out and the pin that goes through the alloy cover and that will give plenty of play and extra room for you

[Hazzo]

Cheers, yeah I saw the split pin through the cotter pin when I loosed that off. A mechanic mate came to the house after I phoned him, bringing tools to help out, between us and snapon we rounded the nuts completely so rather than dismantle it in situ I'm going to strip everything off and pull the head for inspection/replacement, which is where I was heading in the first place really as the car is too big for a doorstop and not starting it needs repair, no doubt I'll encounter further problems and return here for help, so thanks again for the input, much appreciated. Thanks, Hazzo

[Chillitt]

I have just done this. I moved the head forward with it still attached. Since then I have blanked off the tube where it goes into the EGR valve and cut a plate to blank off the exhaust end to match the flange on the pipe that I cut off the tube. Blow that for a game of soldiers. On the plus side, my replacement head turned up today, so I am off out to see how easy it is to put back together....

[Hazzo]

I have just done this. I moved the head forward with it still attached. Since then I have blanked off the tube where it goes into the EGR valve and cut a plate to blank off the exhaust end to match the flange on the pipe that I cut off the tube. Blow that for a game of soldiers. On the plus side, my replacement head turned up today, so I am off out to see how easy it is to put back together....

Chillit
moved the head forward with it still attached---- to what, the block. I don't understand. I've undone the nuts that attach egr valve(not pipe)/manifold to intake manifold and get some movement there but not enough to remove the manifold which is what I was trying to do to clean out the gunge, now I've rendered the nut f***ed at the exhaust end of the pipe but having all the periferals off the engine I'm gonna pull the head for inspecting and if alls well I'll either split the nuts to mod the egr or just grind them off the threads. H