Jump to content


Show
Photo
- - - - -

Egr Blocking Gone Wrong?

Egr Tdci

  • Please log in to reply
10 replies to this topic

#1 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 08 September 2013 - 04:34 PM

I followed Lennys guide http://www.fordowner...-16tdci-engine/

The 1.6 tdci 90bhp in the fiesta doesnt look the same, but i managed to loosen the two long bolts that holds the egr house to the block.

Sliding the blocking plate in the gap between the block and egr hous was a real PITA, as you cant see the gap, only feel it. And there is not enough room for the blocking plate to slide paralell into the gap, you must wedge it into place.

Well, job was done, took it for a spin. Wow what a difference, to the WORSE!!!
The engine now sounds like its working much harder, and it felts like Im driving with 5adults in the car, its allot slower than it user to be.

I opened it up again, and placed my hand around the egr whilst the engine was running, couldnt feel any laks, my boost gauge still shows 30psi at full throttle, so no boost leaks.

Any ideas?

Have something to contribute?

Sign in or register to start a topic...

Sign up to FOC Premium Membership To Remove These Ads

#2 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,292 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 08 September 2013 - 04:46 PM

I followed Lennys guide http://www.fordowner...-16tdci-engine/
The 1.6 tdci 90bhp in the fiesta doesnt look the same, but i managed to loosen the two long bolts that holds the egr house to the block.
Sliding the blocking plate in the gap between the block and egr hous was a real PITA, as you cant see the gap, only feel it. And there is not enough room for the blocking plate to slide paralell into the gap, you must wedge it into place.
Well, job was done, took it for a spin. Wow what a difference, to the WORSE!!!
The engine now sounds like its working much harder, and it felts like Im driving with 5adults in the car, its allot slower than it user to be.
I opened it up again, and placed my hand around the egr whilst the engine was running, couldnt feel any laks, my boost gauge still shows 30psi at full throttle, so no boost leaks.
Any ideas?

Hi mate,
It has been documented that the fiesta is more difficult to do due to the fuel filter bracket,
I must say your are the first to be experiencing negative results,
The engine may be louder due to increased pressure going down the manifold instead of circulating through the system,
Your spool time will be less now due to increased flow,

Now for my opinion,
I think your dpf could be slightly blocked resulting in loss of power due to restriction of the new faster flow of gases exiting through it,
I think if you give it a week or two, the higher pressure of gasses will blow it through.

Also blanking the egr puts more demand on your induction,
So check your air filter housing for leaves and bugs,
The 20% gasses the egr supplied is now replaced with 20% more atmospheric air taken through your induction filter.

#3 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 08 September 2013 - 04:59 PM

Hey, thanks for replying.

Actually, the bracket for the fuelfilter is not in the way, its the bracket that supports the wiring harness for the injectors that are in the way, that bracket most come off, i dont think you can do this job with that bracket in place :)

I had tossed a blanket over the battery and used that to sit on. Took some pictures, will upload later when Im on the pc.

Im also a bit worried that I may have installed the blanking plate the wrong way, since the plate is angular and not symetrical it can only fit one way right?

The inlet side should be ok. The air filter looks like new. The dpf could be blocked, i dont know. I drive 100km a day, so it should regen quite often?

#4 georgen

georgen

    Too much time on the boards

  • FOC Supporters
  • 952 posts
  • Name: george
  • Ford Model: focus est 1.6 tdci lx
  • Year: 2005
  • Location: Tyne and Wear

Posted 08 September 2013 - 05:00 PM

Hi mate,
It has been documented that the fiesta is more difficult to do due to the fuel filter bracket,
I must say your are the first to be experiencing negative results,
The engine may be louder due to increased pressure going down the manifold instead of circulating through the system,
Your spool time will be less now due to increased flow,

Now for my opinion,
I think your dpf could be slightly blocked resulting in loss of power due to restriction of the new faster flow of gases exiting through it,
I think if you give it a week or two, the higher pressure of gasses will blow it through.

Also blanking the egr puts more demand on your induction,
So check your air filter housing for leaves and bugs,
The 20% gasses the egr supplied is now replaced with 20% more atmospheric air taken through your induction filter.

My focus has the same fuel bracket, its the engines with the square fuel filter that have this clearance problem, I tried without removing but you cant get it in, but once you lift filter out of bracket and leave to the side you then remove bracket completly to get the required space to insert the blank, I would recheck that the valve has re-seated flush as you say you wedged it in, and this might have stopped the valve re-seating fully.

this is the said bracket that causes the problem

008_zps221880f8.jpg

this is the way i fitted my blank

 



#5 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 08 September 2013 - 05:42 PM

Thats not the same bracket as i have, and i have a circular fuel filter, not square :)

But from your picture i installed the plate the same way as you, only that you have arrows point to the top, mine had the two bolts side by side, so in my case the arrows would be pointing to the front front of the engine (away from the fuelfilter)

#6 georgen

georgen

    Too much time on the boards

  • FOC Supporters
  • 952 posts
  • Name: george
  • Ford Model: focus est 1.6 tdci lx
  • Year: 2005
  • Location: Tyne and Wear

Posted 08 September 2013 - 05:48 PM

Mine was bolts one above the other but offset so different, sorry.

 



#7 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 08 September 2013 - 05:53 PM

hmm, ok this is the bolt i could reach easily, i guess its the same on your picture. the one on the opposite side was allot harder.
2013-09-08 16.04.24.jpg
 

#8 georgen

georgen

    Too much time on the boards

  • FOC Supporters
  • 952 posts
  • Name: george
  • Ford Model: focus est 1.6 tdci lx
  • Year: 2005
  • Location: Tyne and Wear

Posted 08 September 2013 - 06:32 PM

I used a quarter inch drive ratchet a 1" extension and a 10mm socket and the bolts were not hard to get at, getting the plate in was lol. the arrows would point at say 10-11 oclock when plate fitted I only put the arrows on because as you say the plate is not symmetrical and once getting it down there didnt want to start second guessing which way, i dont know fore certain this is the correct way but at looking at the egr vale this is the way I decided to fit it and it works. :)  



#9 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 09 September 2013 - 05:46 PM

Drove 100km today to work and back, seems a lite better now, but not as it was before.

It also seems like the idle is higher/stronger.
If I go off the throttle pedal in 1st and 2nd gear it now puls forward on just idle, where it would stutter and stall before.

#10 sambooka

sambooka

    Sam Oglesby

  • True Ford Enthusiast
  • PipPipPipPipPip
  • 1,031 posts
  • Name: sam
  • Ford Model: mk7 fiesta tdci zetec s
  • Year: 2011
  • Location: Lincolnshire

Posted 09 September 2013 - 08:48 PM

Your dpf won't be the problem as I'm fairly sure the 90ps version doesn't have one so airflow would be my guess try fitting a sports panel filter

#11 neps

neps

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 120 posts
  • Name: Espen
  • Ford Model: Fiesta
  • Year: 2009
  • Location: Other / Non-UK

Posted 10 September 2013 - 06:10 AM

I have a dpf on my 90bhp.

I can see it physically, and I have the dpf light in the cluster.

But will replace the air filter today just to be sure.

Have something to contribute?

Sign in or register to start a topic...


Not what you're looking for?

Register now, we have a huge community of enthusiasts to answer any questions you might have




Also tagged with one or more of these keywords: Egr, Tdci

0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users