Can anyone direct me with a link to a 'How to' on blanking off the EGR and cleaning the inlet manifold. I won't be too clued up on where it is etc so anything detailed would be amazing.
Once I've blanked EGR, is a remap required right away or at all? Can any garage do this (remap) or does a specialist need to it, if a specialist required, how can I find one? I'm in Swansea South Wales. How much should a remap cost approximately?
All your help n advice is fantastic guys. Really good members on here and I've just signed up. Thank you
Also, if the water pump has never been change, on the 100k motor. Will there be any long term damage? Would changing it now not be fine?
I think the service history shows one cambelt change at 82000 miles. I know Alfa state it around 65-70k to change, but most in the know change it at 45-55k. Is there any issues with 1 change at 82k?
Sorry for the onslaught of questions.
Blanking the EGR is quite easy, it sits at the back of the engine attached to the manifold, remove 4+2 screws, don't loose the gaskets, slide the blanking plate in, tighten everything back up.
You will either need a remap (it doesn't have to increase power, just remove the EGR bits from the map) or use fixitsan dongle. any remap place should be able to do it.
Realistically it should not cost you more than £300 if you go for the full works, just EGR removal will be cheaper, there are people that charge a lot more but they are not worth it, unless you go into serious modding and fit different intercooler/turbo/injectors/stuff, but then you are talking about £1000s (day at the dyno will cost you £600 to start with).
Inlet manifold has to be removed to be cleaned - it's best to do it when you are doing the timing belt and the water pump as the timing belt has to be removed to remove the manifold.
Water pump will not cause any damage just because it wasn't changed - water pumps tend to fail with no warning and take the timing belt with it. Actually just yesterday someone at work had a water pump give up on 1.9 8V CDTi (same water pump and belt and everything) at just over 100k miles.
Late change of cambelt is not a problem just like the water pump - as long as it did not snap before the change you are ok.