Egr Blanking Mod

ming · Sep 26, 2008

REET SO GO BUY ONE FIRST. . . .Strip off these bits[1]

ok take off old egr[four bolts] undo the turbo electrical plug lhs [push metal plunger in and push down to realease] undo rhs electrical grommet with cables ,undo all manifold bolts and pull off ,should end up here [2]

using Slobs idea use oven cleaner to clean plastic manifold ,wash out with water, i did it three times [3]

sorry bout young Porky. . . . .take off all the seals and check um/and clean ,smeer with anti sieze and when dry put mani fold back ,if your not confident on motors use the correct tourque remember this is plastic to ally[4]

fit new egr blanking plate, I found it tight and had to put screw driver in the holes to line it [smeer wiff anti seize on mate faces][5]

put every thing back and double check. . . .put a screw or ball bearing in egr vacuum hose and cable tie it in a safe place [so it wont flap in the fan houseing] last check start motor [mine went first time] then test run . . . . .job done ,refere to heinz manwell un rave fer details. . . . .i wood like to thank Porky fer his tecknickle help un no how . . . . .well he did the whole job really i wez int pub

willo · Sep 26, 2008

Hi Ming,
Sorry to sound boring but you say: then test run.

Did you do that and how was it ?? Noticeable difference ??? (Objective advice please, not a subjectif one such as when an overhaull being done a motor runs twice as good and fast as before......

)

ming · Sep 26, 2008

Well to be fair young Willo its early days yet and a full report wil be forth coming. . . . .but looking at all the ****e that came out ,my report so far confirms that the egr system was total ****e . . .drove it today and there seemed more grunt at lower end, but to early to say really, i went a step further than Jon and polished up the inlet ports, you have to be really carefull doing this as to not get any carbon into the venturias. . . . . .on summing up i do think this is a mod to save the td4 from self destructing, time will tell i think . . . . . .hope yer liked the pics

Ming the Merfiless

Dann · Sep 28, 2008

Brilliant description of procedure. I've done similar but used FLASH to clean. Also being financially challenged I ground out the old egr useless bits and filled with Quick steel. So it still looks original to any nosy MOT blokes etc.

Thanks Ming

jonier · Oct 1, 2008

ming said:
Well to be fair young Willo its early days yet and a full report wil be forth coming. . . . .but looking at all the ****e that came out ,my report so far confirms that the egr system was total ****e . . .drove it today and there seemed more grunt at lower end, but to early to say really, i went a step further than Jon and polished up the inlet ports, you have to be really carefull doing this as to not get any carbon into the venturias. . . . . .on summing up i do think this is a mod to save the td4 from self destructing, time will tell i think . . . . . .hope yer liked the pics Ming the Merfiless

Hi Ming,

My mrs is asking how the vehicle is running after you fitted the EGR bypass & cleaned out all the sh... from the inlet manifold. FYI mine is running better now than it ever has!! wish the same went for the mrs!! Only joking!!

cheers.

Jon.

Chris T · Oct 9, 2008

Hi Ming, Hows it running since you have fitted this mod????

Has it made any difference. Or do you think just cleaning the manifold and
dissableing the egr unit (as you previously had) do just the same???

I ask as I am now thinking of doing this

carcar · Oct 9, 2008

Hello everyone,
Will you please tell me what is the function of the EGR because I,m new to the TD4 engine and could do with some knowledge.Appreciated.And also why was taken off? thanks

Kernow nige · Oct 9, 2008

carcar said:
Hello everyone,
Will you please tell me what is the function of the EGR because I,m new to the TD4 engine and could do with some knowledge.Appreciated.And also why was taken off? thanks

try doin a search on EGR

.........

cremator · Oct 9, 2008

ok in process off fitting one how clean do i ned to get the inlet mainfold its well caked up with crap mr muscle not doing a very good job how long should i leave it soaking done it once left for 2hours on second time now cheers

chromiumuk · Oct 10, 2008

cremator said:
ok in process off fitting one how clean do i ned to get the inlet mainfold its well caked up with crap mr muscle not doing a very good job how long should i leave it soaking done it once left for 2hours on second time now cheers

Try getting a couple of cheap long handle bottle washing brushes & tub of paraffin.

Northern Irelander · Oct 10, 2008

Nice one Ming, proper mod................ good to see Mr.Muscle at work, Porky too

cremator · Oct 10, 2008

ok got it all clean now do the oblong gaskets go back a certain way forgot to see whichway they came out do i need to coat them with anythink
many thanks

discomania · Oct 10, 2008

Nah, they just go back on, with the plate on the top, job done.

cremator · Oct 10, 2008

ah ok thanks you say plate what plate is that dont remember a plate i just pulled them out mind you it was dark have i lost sometghink

TD John · Oct 28, 2008

Hi Folks - My confidence boosted by the wealth of knowlege here, I took off the turbo hoses and had a look into the EGR. TD4's only done 18k but it looked well on the way to becomong a problem. Removed the EGR and cleaned it and entry to manifold, still quite soft crud at this milage. Reassembled with a disc cut from a bean tin in the joint between the exhaust hose and the EGR - effective ehaust gas block? - and all looks bog standard to MOT man. Will post back if I can see any performance difference when it's been running for a while.

Chaser · Oct 29, 2008

Hi folks, interesting thread.

I've just read this on rave cd and wondered if anyone knows if NOx is specifically tested during mot emissions check making it necessary to remove any blanks for the test.

[Exhaust Gas Recirculation (EGR)
During certain running conditions the EGR system directs exhaust gases into the inlet manifold to be used in the
combustion process. The principal effect of this is to reduce combustion temperatures, which in turn reduces Nitrous
Oxide (NOx) emissions.]

Cheers Chaser...

JonFre · Oct 29, 2008

Chaser said:

Hi folks, interesting thread.

Click to expand...

Chaser said:
I've just read this on rave cd and wondered if anyone knows if NOx is specifically tested during mot emissions check making it necessary to remove any blanks for the test.

[Exhaust Gas Recirculation (EGR)
During certain running conditions the EGR system directs exhaust gases into the inlet manifold to be used in the
combustion process. The principal effect of this is to reduce combustion temperatures, which in turn reduces Nitrous
Oxide (NOx) emissions.]

IMHO (and plain English) Definitely not tested at MOT.

Chaser · Oct 29, 2008

Thanks JonFre,

It seems it would be rude not to try it then!

Chaser..

DTO · Nov 7, 2008

I checked my 60k td4 today and the egr valve and manifold were covered in thick soft crud , so i just cleaned the entrance to manifold and cleaned the valve in a parts washer , the valve was not jamed open and was working so after a good clean i just replaced the valve

my options are
1-leave as is and clean again in maybe 2-3 years time .
2-leave original on and blank up exhaust port part with metal disk .
3-replace with the bypass .
what i can report though is it pulls better at low revs with just the clean out , so would recommend anybody with a td4 to clean the valve .

ratty · Nov 7, 2008

Ming. I've made this thread sticky so you don't ave to keep repeating yourself everyday.

Egr Blanking Mod

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