84 Euro 300TD Turbo EGR/Turbo Help

[hcubed]

Ok, so I have an 84 300TD Turbo that has a bogus, rusty and leaky EGR system that I'd like to remove. It looks like it was added during federalization of the car (kinda like this guy's: euro 617 turbo and EGR? how do I patch the intake manifold). After doing some searching through the forums, it looks like I'll have to figure out a way to plug the hole on the intake manifold, then the hole on the exhaust manifold where the EGR valve flex pipe goes, and also the vacuum line to the EGR valve. Does that sound right? Here's a picture of the current EGR setup (I circled the leaky parts):


Second, there are these two devices under the turbo and I'm not sure what they do. One of them is pretty leaky and I think it's part of the EGR system. I circled them both in the picture below. Any idea what they are and if they can be removed? Any idea what else might be leaking that could be replaced - maybe the turbo seals? Thanks in advance for any help.

[JimmyL]

WOW! Now that is some rust! What is the rest of the car like?
#2 looks like your wastegate line, but it is hard to tell. Doesn't look like my style of turbo.

[hcubed]

What does the rest of the car look like? Someone recently said it looks like it has chicken pox (hehe - pretty rusty). But...it's great for hauling around bikes/skis/climbing gear/people and for sleeping in. Yeah, it is pretty amazing that so much under the hood could end up that rusty. It was a Massachusetts/New Hampshire car and now is in Connecticut. I'll post a pic tomorrow when the sun comes back up.

[JimmyL]

Cool. I certainly didn't mean my post as rude, but upon re-reading it might not have been my most polite. Sorry.
I guess luckily, we just don't see rust like that down here. Now, we will cook the heck out of a dash, though......

[hcubed]

No offense taken at all! The car is a bit of joke, but if it's going to be rusty, I'd at least like it not to be leaky...

[Brian Carlton]

That entire setup is unlike any of the configurations on the vehicles shipped to the US. The EGR valve is completely different and the supply of exhaust is completely different.

You can remove the vacuum from the EGR valve and plug the hose.............or you can remove the valve and manufacture a suitable plate to cover the opening.

I've made some of these plates in the past for other forum members, however, they don't appear to work with such a valve.

[hcubed]

Yeah, that's what I was afraid of...something entirely unique. Any ideas on the components in the second photo?

[Brian Carlton]

Originally Posted by hcubed

Yeah, that's what I was afraid of...something entirely unique. Any ideas on the components in the second photo?

#1 appears to be an exhaust pipe routing to the turbo.........can't be sure because it's just one section.

#2 is the wastegate actuator. The black hose that's attached goes to the manifold and provides manifold pressure to open the wastegate. The oil on the actuator is typical of older units..........they do collect some oil in the housing.

[hcubed]

Aah, the wastegate actuator. I see that in the diagrams now. I thought it was part of the bogus EGR stuff. Thanks Brian. I suppose I should replace that if it's possible. Maybe the part number is in the new EPC...