 | Home > Maintenance & Modifications > removing egr cooler |
 
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266   
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I think I know the answer to this but it would be really helpful to have a heads up first if I've got it wrong.
I plan to remove the egr cooler tomorrow and I believe (hope) I know where all the fixing points are; 2 studs / nuts where it joins the exhaust manifold another on the corner of the engine near the egr valve and onto the valve itself. sound about right or is there more behind the engine? many thanks. |
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11th Oct 2014 10:05pm |
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| SupraAyf Member Since: 08 Sep 2014 Location: Durham Posts: 142  
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Here we go sir.
All bolts are torqued at 23Nm 
 - Andrew - |
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12th Oct 2014 9:30am |
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| Fifth Horseman Member Since: 08 Mar 2011 Location: Lanarkshire Posts: 322 
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Probably a bit late,
There are two bolts from the cooler to the bracket and then one bolt to the block [URL=] [/URL]
Don't forget the clips around the cooler that hold the coolant pipes. [URL=] [/URL]
Good luck, it looks like access is a bitch. Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  |
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12th Oct 2014 3:03pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19637
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Why are you removing it?
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12th Oct 2014 4:40pm |
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| big steve Member Since: 24 Dec 2009 Location: hertfordshire Posts: 2456 
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I'm removing the cooling element to my 3.2 as its not doing anything 2015 2.2 tdci hardtop xs
3.2 conversion DONE 238bhp and 707nm torque and thats just the start ;-P hybrid turbo in build -done ready to fit ashcroft atb in transfer box 6 speed auto in build |
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12th Oct 2014 6:39pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266
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Kind of a bit late......
I didn't need to completely remove the cooler although I might soon. I needed to disconnect it to fit my egr plate near the exhaust manifold. What a pain the bum....I managed to drop a bolt down by the starter motor and the bracket so I'll be popping out in a bit to try and recover them... any suggestions on how? |
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12th Oct 2014 6:53pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19637
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Try something magnetic?
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12th Oct 2014 6:55pm |
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| big steve Member Since: 24 Dec 2009 Location: hertfordshire Posts: 2456
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Iv always fitted the plates exhaust side
Steve 2015 2.2 tdci hardtop xs 3.2 conversion DONE 238bhp and 707nm torque and thats just the start ;-P hybrid turbo in build -done ready to fit ashcroft atb in transfer box 6 speed auto in build |
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12th Oct 2014 7:21pm |
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| munch90 Member Since: 26 Oct 2013 Location: guildford Posts: 3558
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if you had got a plate that fits egr end ( in between cooler and egr valve ) you could have used a blank with slotted holes , just loosen bolts slot plate in and tighten bolts 5 min job
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12th Oct 2014 7:54pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266
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That'll be an......IF.
Only I didn't. So now have one bolt and one bracket in between engine and alternator 
Getting alternator out looks nigh on impossible....will they find their own way out and I just buy a new bracket? Last edited by Caterham on 13th Oct 2014 8:31am. Edited 1 time in total |
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12th Oct 2014 8:39pm |
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| munch90 Member Since: 26 Oct 2013 Location: guildford Posts: 3558
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oh not quite gone to plan then
have you got a bolt snapped now? have you got it disabled ? if you blank off without you should get the mil light on if your dropping things down by the starter , you should disconnect the battery Last edited by munch90 on 12th Oct 2014 8:52pm. Edited 1 time in total |
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12th Oct 2014 8:45pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266
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No nothing broke thank god.
Foolishly I undid all 3 bolts 1 holding bracket in place (which I didn't need to) plus the 2 from cooler to bracket. Bracket and bolt dropped 
All back together otherwise and gonna go for test drive shortly. |
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12th Oct 2014 8:50pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266
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I was rather worried about the battery thing but not much I can do about it now.
egr is disabled and egr cooler at exhaust end now blanked and all appears to be working well. Just need to see about either removing the cooler all together or replacing the bracket the supports the cooler off the engine near the egr valve. |
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13th Oct 2014 8:33am |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6266
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sorry forgot to say.....thanks very much SupraAyf. very helpful.
not sure where you got the info but that's a far better set of diagrams than I could find. |
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13th Oct 2014 8:37am |
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