Hi all. Got a blanking kit winging its way to me as we speak after seeing some of the other posts and walkthroughs that have been posted here over the last week or so. Had a quick poke under the bonnet last night just to make sure I know where everything is (admittedly in the dark) and just had a question about the easiest way into the exhaust manifold. Instructions seem to suggest taking off the airbox, but I was wondering if it was reachable from the underside and I could therefore save the job of taking everything off? Also, anything to be aware of with this job on a Td6, all the good write ups I've seen are for the bigger engine. Cheers!

1. Remove front engine cover
2. EGR valve is top right of engine at the front.
3. Pull off the rubber vacuum hose
4. Undo the jubilee clip to the EGR cooler
5. Undo the 4 torx/allen bolts holding the EGR in place
6. Remove EGR

Replacement of the blanking EGR should be roughly the reverse of the above. If it doesn't provide a place to refit the vacuum hose, use a golf tee or similar to plug it. .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

Thanks Joe. I was pretty comfortable with that bit (useful to know I'm not missing anything though!), but the bit I'm less sure about is the diamond shape blanking plate (pic attached). Assume this needs to go on the exhaust manifold, but it doesn't seem easily accessible. Is it an unnecessary step, or am I just missing something obvious

Hmmm, it is for one of two things:

http://www.fullfatrr.com/gallery/displayim...amp;pos=34 (big effort)

or

http://www.fullfatrr.com/gallery/displayim...amp;pos=28 (little effort but unlikely it is this)

Suggest review my photo howto for thermostat which pulls all EGR parts off. You will see it is a bit of a job!

http://www.fullfatrr.com/gallery/thumbnails.php?album=380

FWIW my EGR blanking kit was quite different to yours with just the rounded "pennies" to block off the gas flow into the EGR, and a spike to put the vacuum hose onto. Never bothered with blanking off further down .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

The one you bought seems too much mucking around, you can get them which are simpler, just remove your exisiting one, fit this type in its place exactly how the old one was fitted. it looks O.E so inspectors won't know you have removed it.as pipes are still there, no blanking plates required like yours.'
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Done this to my TD6 a couple months ago very easy job no fault codes.
Used the same as @lounge_on_wheels img.

Its Vacuum controlled so just plug the hose from the controller to the EGR valve.
you can just stick a screw in the hose.

would the EGR still operate on pressure difference from exhaust to atmosphere (where vacuum hose is no longer)?