How to clean the D4D intake and EGR sytem

Re: How to clean the D4D intake and EGR sytem

Postby adman001 on Wed, 21 Jun 2017 8:39 +0000

Massive thanks to everyone in this thread, particularly Steveb! Did a friends' EGR clean last weekend, and will be doing mine this weekend too.

Few things we found last time:
- somehow we removed 6 bolts and 2 nuts when removing the intake manifold. I think we pulled two bolts off surrounding parts, but we kept tabs on everything and it all went back in fine
- removing said bolts is a bit nerve wracking if you're a novice as you can't fully see what's going on under the manifold. just take your time and be very clear to feel which bolts below to the manifold vs common rail!
- actually cleaning the bastard is a nightmare. that soot/oil mix is nasty, and even with countless rags and gloves, everything turns to poo. whatever brush you use will be clogged in 2 strokes... gonna hit up some more hardcore cleaner for doing mine
- in reassembly of the heat exchanger, bolt up the two nuts on the block but leave the bolt loose for when putting the EGR/throttle body back in place as it needs a bit of slack to get a good seal to the manifold & heat exchange. once those bolts are night a snug, do up that bolt on the head exchanger

It took us a long time, maybe 10 hours. The only mechanical experience I have is working on previous cars, this was the first time I've gone near the engine of any car. We spent probably 2 hours trying to clean the thing itself though. Reassembly only took a bit over an hour, the disassembly is oddly enough a lot more complex and time consuming if it's your first time!
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Re: How to clean the D4D intake and EGR sytem

Postby Geppo on Mon, 26 Jun 2017 7:20 +0000

Started this today and was really surprised by how much crap was in there. The vacuum line off the egr cooler
Was actually disconnected, not sure if the previous owner did it but whatever he was trying to do didn't work
Because the butterfly was stuck open, funny stuff.
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Re: How to clean the D4D intake and EGR sytem

Postby Tazlar on Tue, 27 Jun 2017 6:01 +0000

Been looking at cleaning my egr but recently the photos on this step by step guide aren't showing.. is it just me?
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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Sat, 01 Jul 2017 3:28 +0000

Hey guys

Anyone got any advice how I can get the 10mm bolt off the under side of the EGR connected to the heat exchange?

I have a photo but I'm having issues uploading

Cheers Paul
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Re: How to clean the D4D intake and EGR sytem

Postby blatcho on Sat, 01 Jul 2017 5:05 +0000

Paulloz wrote:Hey guys

Anyone got any advice how I can get the 10mm bolt off the under side of the EGR connected to the heat exchange?

I have a photo but I'm having issues uploading

Cheers Paul



I used a 1/4 drive ratchet and with a single hex socket
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Re: How to clean the D4D intake and EGR sytem

Postby DeadlyBeast on Sat, 01 Jul 2017 6:47 +0000

Tazlar wrote:Been looking at cleaning my egr but recently the photos on this step by step guide aren't showing.. is it just me?

No man - not just you. PhotoBucket users who have an unspecified number of hosted images have had their images locked from use on websites. PB is now demanding $399 for such use
If you're going through hell, keep going.
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Re: How to clean the D4D intake and EGR sytem

Postby apSlain on Sat, 01 Jul 2017 7:27 +0000

DeadlyBeast wrote:
Tazlar wrote:Been looking at cleaning my egr but recently the photos on this step by step guide aren't showing.. is it just me?

No man - not just you. PhotoBucket users who have an unspecified number of hosted images have had their images locked from use on websites. PB is now demanding $395 for such use

Have always hated Photobucket...

I managed to find a workaround to grab the images - you can find them (hopefully in order) here.

Image
Image
Image
Image
Image

Image
Image

Image
Image

Image
Image
Image
Image

Image

Image
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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Sun, 02 Jul 2017 1:29 +0000

Guys any thoughts on making my own EGR blanking plate put of galvanised sheet metal?

The thickness is a lot thinner than the blanking plate I got given by Chip Tune in Sydney

I am also going to drill a 3 mm hole in it???

Cheers.

Paul
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Re: How to clean the D4D intake and EGR sytem

Postby TOYZX on Sun, 02 Jul 2017 2:42 +0000

I reckon you'll get an engine light, depending on your year model. Whats wrong with the one you have? Or are you just wanting to try a smaller hole?

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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Sun, 02 Jul 2017 3:33 +0000

It's a march 2015 model,
the one I have doesn't cover the EGR hole completely so I've made my own, is there a blanking plate rule of thumb hole size to let gas through that's best?

Thanks

Paul
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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Sun, 02 Jul 2017 3:36 +0000

It's a march 2015 model and I'm trying to prolong the engine longevity

Thanks

Paul
Last edited by Paulloz on Sun, 02 Jul 2017 3:42 +0000, edited 1 time in total.
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Re: How to clean the D4D intake and EGR sytem

Postby TOYZX on Sun, 02 Jul 2017 3:40 +0000

7mm.

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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Sun, 02 Jul 2017 3:44 +0000

Ok no worries and I assume galvanised sheet will be as good as S/Steel?

Cheers

Paul
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Re: How to clean the D4D intake and EGR sytem

Postby TOYZX on Sun, 02 Jul 2017 4:11 +0000

Thats all I made mine from man.

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Re: How to clean the D4D intake and EGR sytem

Postby Paulloz on Tue, 04 Jul 2017 8:51 +0000

Cheers Toyzx

Im having difficulties physically removing the inlet manifold, any thoughts

Cheers

Paul
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Re: How to clean the D4D intake and EGR sytem

Postby TOYZX on Tue, 04 Jul 2017 1:39 +0000

Got all the bolts out?[WINKING FACE] they can get pretty stuck, a good floggin with a plastic hammer helps.

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Re: How to clean the D4D intake and EGR sytem

Postby frot on Wed, 05 Jul 2017 8:43 +0000

Hi Steve
Your article on cleaning the D4D intake and EGR is excellent. I wonder whether you still have the photos you posted with this article. Call me stingy but I'm not paying Photobucket $400 to view a few photos.
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Re: How to clean the D4D intake and EGR sytem

Postby frot on Wed, 05 Jul 2017 8:47 +0000

Steve, disregard the last. Managed to find another link with your photos thanks to "Deadly Beast"
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Re: How to clean the D4D intake and EGR sytem

Postby cruizzee on Sun, 09 Jul 2017 2:07 +0000

Tazlar wrote:Been looking at cleaning my egr but recently the photos on this step by step guide aren't showing.. is it just me?


Same here, no photos coming up


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Re: How to clean the D4D intake and EGR sytem

Postby apSlain on Sun, 09 Jul 2017 3:13 +0000

cruizzee wrote:
Tazlar wrote:Been looking at cleaning my egr but recently the photos on this step by step guide aren't showing.. is it just me?


Same here, no photos coming up

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Photos available here.
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