The EGR is at the back of the engine on the top. 4 bolts are easy to see and remove, 2 of the bolts fix the EGR to the engine block and the other 2 bolt the EGR to the EGR cooler. There are 5 other bolts you need to remove as well. These are for the metal pipe that goes from the EGR to the inlet manifold, 2 at either end and 1 bolt that secures this metal pipe to the side of the engine.
The one bolt I couldn't find was underneath the EGR itself. You cant see it at all. I ended up going out to buy one of those dentist style mirrors which helped no end. This last bolt is an allen bolt that requires a 5mm allen key, the allen key needs cutting down somewhat in order to fit as space is very limited. Once this bolt is loosened (you dont need to remove it) the EGR can be removed by sliding it back towards the windscreen area. This whole precess took be about 2 hours plus to figure out and then about 10 minutes to put back together.
After all of this my EGR was nothing like I was expecting. My car has covered 80,000 miles and it was clean, a bit of soot but other wise there was nothing. My MK3 was caked at this mileage and to the point that you could scrape it out. It seems the MK4 runs muh cleaner.
I certainly wont bother removing it again unless it is to replace it. I was hoping this was the cause of my poor fuel economy but it now seems it's my MAF sensor but a full diagnostic on Tuesday will confirm this for sure.
I'm working for the next few days but if I get a few spare minutes I'll take some pictures that might help others out and save you time trying to figure out how it comes apart (Haynes manual was next to useless)
- sparkymark75 likes this