EGR STUCK FAST. E270cdi W211

[james2747]

The car has recently gone in to 'limp home' mode a couple of times especially when I put my foot on the gas.
It was suggested I remove the EGR valve and give it a thorough clean, including the operating lever.
Looked easy, a couple of bolts to remove, then wiggle it out.
2 days later and after numerous attempts ... with lots of 'expletives' and grazed knuckles the EGR valve is still in situ.
I can just about rotate it back and forward about 30 degrees but that requires lots of turning force, including levering and hammering on the flanges (near the bolt holes) which is taking its toll on the bolt holes and alloy body.
Have tried revving engine a few times to 3,000 revs and 'blowing it out' as shown on a YouTube video ... didn't even budge 1mm ... or even a hundreth of a millimetre!
To prevent any damage to the valve, I even considered unbolting the motor bit from the valve so I can get a better purchase on the valve section in the hope I could generate more leverage and turn it further but can only get at 3 of the 4 bolts, due to operating lever being in the way.
Any ideas on where I can go from here? It really is 'stuck tight' and rotating it the little I can, seems to make it tighter ... not looser.
I would add that I am reasonably competent with the spanners so it's not a case of being a complete plonker, it is just being held in there 'tight'!
At the moment its, EGR 1 v James 0.

 

[alexanderfoti]

I had had to hammer them round with a chisel before, they can often be really stuck. Have you tried penetrating oil?

 

[Wighty]

As above penetrating oil then a wide chisel gently tapped into the gap till it opens then a wide screwdriver to lever up . If you hit it to turn it use a piece of wood hit by a hammer it will cause less soft metal damage

 

[james2747]

I had had to hammer them round with a chisel before, they can often be really stuck. Have you tried penetrating oil?

Hi
Yes, tried lots of penetrating oil sprayed regularly over 2 days.
After struggling for so long, think I'm left with few options so I'll try driving a steel wedge in to the joint and then repair any damage with file or similar afterwards.

 

[james2747]

As above penetrating oil then a wide chisel gently tapped into the gap till it opens then a wide screwdriver to lever up . If you hit it to turn it use a piece of wood hit by a hammer it will cause less soft metal damage

Hi Wighty
Tried lots of penetrating fluid and to minimise damage I tried to hit it with wood to start with (an old hammer shaft) but it just chewed the wood up quickly as there was no movement of the EGR (well only a few mm of turn).
I think your idea of getting something in to the gap is the best (& final) option as I'm sure it will knacker the flange a bit but hopefully it can be 'cleaned up' with a file afterwards.
Thanks for your suggestions ... much appreciated.

 

[Westheath]

Don't break the EGR cooling assembly whatever you do.

Stop hammering, use diesel and carb cleaner mixed together then soak-soak-soak over night..

Don't rotate it but try lifting it upwards wiggling firmly bit by bit applying diesel and carb cleaner mixed as you go.

 

[bembo449]

and when you finaly get it off , blank it and have a remap

 

[Wighty]

and when you finaly get it off , blank it and have a remap

Can you still do this with the new Mot rules pal ?

 

[mattkh]

......
use diesel and carb cleaner mixed together then soak-soak-soak over night..

How does the diesel help ?

 

[Westheath]

How does the diesel help ?

Dunno but been using it to remove stuck injectors glow plugs and EGR's for years.

 

[Wighty]

Probably stops the carb cleaner evaporating ?