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EGR Valve Removal - Mk2 Diesel

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The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
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Totalguy and I had a problem with an air-leaking EGR-valve (the pressurebox on top of the inlet manifold). That's why I've removed the EGR-valve completely, and plugged the remaining hole on top of the inlet manifold... Totalguy mentioned to share this info so in the following piece it's told how this is done... (there are 4 pictures attached)

Here We Go...

(Important! you need to block the flow of exhaust gas also! This can be done by removing the metal pipe (that goes from the outlet manifold to the inletmanifold) and then block the hole... This must be done otherwise the exhaust gas will flow continuously into the inlet manifold...)

EGRRemove 1.jpg

EGRRemove 2.jpg

I first took off the intercooler for better access (also I removed the u-shape tube to the inletmanifold) then i removed the top of the egrbox by hitting the top with a screwdriver (see picture 1 and 2) so it turned bit by bit. This way the metal, which is curved around the bottom of the box, is bent outwards and then when the top has turned 180 degrees you can lift the top with a screwdriver (see picture 3). You can clearly see how the valve works... it's a membrane which is lifted by the vacuum and held down with a big spring (see picture 4, the spring sits on top of the disc-shaped thingy).

EGRRemove 3.jpg

EGRRemove 4.jpg

Inlet Manifold Removal

It turned out I had to remove the inlet manifold as there was no other way to reach the valve... it was a struggle but I found a way to get the inlet manifold off without removing the outlet manifold: I removed that strange looking thread (with a torx-like end - they used 2 of those and 6 normal bolts) in the middle of the inlet manifold, and replaced it with a normal bolt (M8). Now the inlet manifold can be taken off without removing the outlet manifold... Once the inlet manifold was off it was relatively easy to demolish the valve (really demolish... i had to use a hammer and screwdriver etc. to bend it so that I could take it out...)

You can clearly see the shaft in picture 4. I pulled the orange-thing out as much as it would go and then cut the shaft. The valve with a piece of shaft then fell back into the manifold, but the shaft was still too long to get the valve out rightaway. That's why I had to take the complete manifold off to get to the valve, and with brute force bend the valve/shaft to get it out via the first of the 4 holes off the manifold....

Plugging The Hole

To plug the hole I used: - a long bolt (same size as the shaft) - a piece of rubber tube 2.5 cm (inside-diameter aprox. 2 mm) - and a nut.

I pushed the bolt from the inside out trough the hole, then placed the piece of rubber-hose over the bolt and then fitted the nut. Then by turning the nut, the rubber expands and fills the hole on top of the manifold, sealing it airtight....