406 2.0 HPI EGR Removal instructions.
1. Pair of mole grips
2. Philips screwdriver
3. Flat head screwdriver
3. 10ml socket
4. 13ml socket
5. small spade precision screwdriver or similar
6. Hex tool
Take off top engine cover.
unclip top breather hose from the side of the top of the engine.
undo the pipe holder from the side of the air box and release.
you will need your precision screwdriver on this one... on the other ends of the hose there is a yellow clip inside the end which you will need to prize out in order to release the hose, do this on the 2 remaining ends and remove hose entire. WARNING be carefull removing these yellow clips as they are very fragile and break easily!! I chose to replace this airpipe as it was badly gunked up and literally broke in my hand £22 from Peugeot, and yes it comes as all 1 piece.http://img52.imageshack.us/i/dsc03499g.jpg/
Undo the 2 large jubilee clips holding on the main air pipe connecting the air box and butterfly unit, then remove.
You should now be able to takeout the airbox and the funny alien headed thing connected to it!!! it just clips onto the side of the battery tray thing.
If you want to inspect or replace your air filter, just undo the 4 philips screws on the airbox and seperate, when i did this i found loads of old leaves and lots of dirt inside so i just cleaned it all out.http://img100.imageshack.us/i/dscf2961.jpg/http://img153.imageshack.us/i/dscf2968.jpg/
Ok now you should have a good view of the EGR and surrounding areas!!
Disconnect the 3 plugs.. 1 on the Butterfly motor, 1 on the EGR and 1 underneath the butterfly housing, try and move them away from the EGR of you can coz they will get in the way of things.
Next you need to reach under the back of the inlet towards the EGR valve as you will have to take off the retaining clip that hold s on that big metal flexi pipe that goes between the inlet and EGR, if yours is similar to mine you will have a fibre sheath that covers it... just roll this backwards abit so you can get clear access onto the clip and release. NOTE you only need to undo the EGR end as its flexy you just need to give it a yank and slide it off beside the EGR so its clear.
You may also want to undo the plastic water pipe holder to give you abit more room, this is held on by a 10ml nut underneath.http://img442.imageshack.us/i/dscf2957o.jpg/
Now your probably thinking i need to take off that big arm that supports the inlet, well luckily u dont!!!
all you need to do is undo the very top one (nearest the EGR) 10ml socket will do. Take off nut and push the bolt backwards flush with the arm, its just enough clearance to get the EGR out!!!
Next you need your 13ml long socket to undo the 2 nuts on the EGR top n bottom and put them somewhere safe!!
You should now be able to take off the EGR, make take abit of pursuasion and monuvering to get out but it will go! i actually got frustrated with this and ended up taking 2 mil off the end of the right hand long bolt to give abit more clearance on removal.
If you notice in the pics i ended up seperating the EGR in half to try and make it easier to get out but just ignore that, it can be removed in one piece. This is when i discovered a blank plate had been used by somebody!!
step 4: (you dont have to do this step but i decided too and glad i did!)
Removing the butterfly housing
Use the hex tool to remove the 2 top bolts, theres also 2 10ml normal nuts on the bottom remove these and place somewhere safe!
Now you should be able to take off the whole unit with the motor, i decided to clean this out as it was fairly caked up with carbon deposits and oil.
This is what i found upon removal:http://img249.imageshack.us/i/dscf2953.jpg/
Clean up necessary areas, i used a blade to scrape off excess bits of gasket from the inlet / butterfly mounting.
Get your nice shiney new EGR valve and slide down onto the guide bolts ( again this will take abit of manouvering)
By now everything should be all nice and clean to go back onto the car, i used some gasket sealant along with the same rubber gasket on the butterfly housing just for added joining.
In true haynes style.... reversal of removal!! i.e now put it all back together and run the engine for at least 20 mins, your work is now done... hopefully with no parts left over!