Damond Motorpsorts EGR Full Removal Kit Install Guide

Posted on February 01 2017

WARNING: 
By installing this Product, you understand that:
The buyer/user assumes all risk as to quality, performance and use of these products and agrees to hold DD2, Inc. DBA Damond Motorsports (“DM”) and its representatives not responsible for any injury, loss, or damage; including any and all incidental or consequential damages arising from the sale, installation, or use of our products.
Many parts are intended for “OFF ROAD ” and “RACING” applications only. It is suggested that State and Federal emission regulation be checked, to see whether or not this product complies with those laws. Read through the instruction guide thoroughly, before attempting this install. Do not install any components while the engine is running or shortly after the car has been running. Give the car some time to cool down. Failure to install this product correctly, or failure to remove/reinstall existing components correctly, could result in poor running conditions, or even component and engine failure, which the sole user of this product is responsible for. The install instructions are intended to guide you on how to install this product properly.  Only an experienced mechanic should perform this install.  In addition, DM, and its representatives reserve the right to modify and or discontinue parts without notice. If you the user/buyer of this product do not agree with the above, contact DM immediately, to discuss a possible return of our product for a full refund minus shipping costs, and other fees. 


Kit Contents:
1 x EGR Valve Delete Plate
1 x EGR Block Off Plate
1 x EGR Intake Manifold Plug
1 x Coolant Barb Fitting
1 x Tiny Coolant Plug Fitting
1 x Hose Clamps
2 x Mounting Bolts 
 
Tools required:
Pliers
Torque wrench
Adjustable wrench
22mm open-end wrench
Socket wrench:
8mm
10mm
12mm
10mm or 3/8” hex bit
 
Begin by removing the battery and ECU covers, and disconnect the positive and negative battery cables(10mm).

  
Remove the battery from the car, and set it aside. Remove the three 10mm bolts securing the battery tray.
 

 
MAZDASPEED3 ONLY. Remove the harness clips from the ECU. Push on the grey connector(indicated with green arrows) and swing the white harness clip lock(indicated by the red arrows), and remove the harness clips from the ECU.

 
Remove the battery tray and ECU from the vehicle and set aside.
 
Remove the intake, and set it aside. Begin by unplugging the MAF sensor(circled in red). Remove the upper PCV hose from the intake by pushing in the blue clip from both sides, till it clears the black connector of the hose, and pulling up on the hose(blue arrows). Unbolt the intake from the inlet tube(circled in green):


 
The turbo inlet tube can be removed for more access if wanted, but is not necessary.
 
Remove the top mount intercooler(if equipped) and set it aside. Three 12mm nuts(circled in blue), and all clamps(circled in red):

 
 
Unbolt the throttle body from the intake manifold(four 8mm bolts indicated in blue). NOTE: the throttle body may have coolant lines routed to it, do not remove it completely from the car, but instead set it aside in the engine bay, while connected to the coolant lines. 


 
Unscrew the EGR compression nut from the intake manifold, and slide the nut out of the manifold(24mm):
 

 
Unbolt the EGR tube from the EGR valve(two 8mm bolts), and remove the tube:
 
 


 
You have two options now, you can either re-install the tube with the provided EGR plate, or remove the tube completely and use the plate and screw bung.
 
To re-install the plate, for that factory appearance, apply RTV sealant to the back of the tube. Place the plate onto the tube, the factory gasket over the plate, and install the tube back in place(tighten the bolts to 8-10N-M or 70-95lb-in, tighten the tube compression nut to 55N-M or 40ft-lb):
 


 
If you wish to remove the tube completely, bolt the plate to the EGR valve, using the factory gasket, screw the plug into the manifold(apply RTV sealant to the threads of the plug, tighten the bolts to 8-10N-M or 70-95lb-in, tighten the plug using a 10mm or 3/8” hex bit to 10N-M, 10lb-ft, or 95lb-in):
 

 
EGR Valve delete plate:
 
The EGR valve is located on the backside of the cylinder head. Begin by removing the electrical clip on the valve, and setting it out of the way. Place some rags or paper towels under the valve, to prevent coolant from leaking everywhere.

 


Next loosen the hose clamps and remove the coolant hose off the EGR valve and turbo coolant line. Set the hose aside, as it will be re-used.


 
Remove the two 10mm bolts securing the valve to the head, and remove the valve. When removing the EGR valve from the vehicle, be careful as to not get coolant on the paint.

 

 
Inspect the EGR gasket for tears or flaking coating. If bad, replaces or recoat the gasket in rubberized paint. Gasket shown here:


 
Take the Damond Motorsports EGR Delete plate, and tighten in the provided barb as shown using a sealing tape or paste(If you are running a coolant-less turbo, use the provided tiny plug). TQ spec is 8-10N-M or 70-95lb-in. DO NOT OVER TIGHTEN OR DO NOT TRY TO TIGHTEN THE FITTING FLUSH WITH THE PLATE. The fitting is a tapered thread and can break if over tightened.


 
Insert the barb into the OEM hose removed prior, with the longer straight portion onto the barb, use the provided hose clamp on the barbed end after aligning as such:


 
Clean the gasket mating surface of coolant and install the delete plate to the engine using the supplied hardware and the EGR gasket. TQ spec: 20-30N-M or 15-22lb-ft.
 
Put the hose all the way onto the turbo hard line, and reinstall the spring hose clamp.


 
 
Reinstall the remaining components removed from the car. Start the car and check for air leaks. Congratulations! You have installed the Damond Motorsports EGR Block Off Kit. NOTE: blocking off the EGR system can result in a CEL. The CEL will not decrease engine performance, and can be cleared with a scan tool or COBB AccessPort.

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