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  • Added on: Dec 06 2013 06:47 PM
  • Views: 603
 


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Guide: Fitting Egr Blanking Plate 1.6Tdci Engine

Posted by Lenny on Dec 06 2013 06:47 PM

Hi all,
I 100% recommend if fitting an EGR Blanking plate; that you fit a stainless steel one,
Alluminum plates break through over time with terrible results.

Stainless steel blanking plates are top job a fit and forget item.
Here is a reliable supplier of stainless steel laser cut egr blanking plates.
http://www.ebay.ie/i...S-/170912771190


.Thanks for viewing my Guide and I hope it has helped to achieve satisfactory results.
I have created many Guides all available here on fordownersclub.com all created in my spare time,
in recent times my image host for the guides has began to charge for hosting the images that display within my guides.
So im now paying a monthly subscription in order for these guides to function,
If you would like to help keep the guides full of images,
Donations under £1.00 welcome via PayPal
Address: leonard.woods@live.ie
Thank you.

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Tools Required:
16mm Socket
5/16 Socket
8mm Socket
13/32 Socket (only if engine cover fitted)
T30 Torx screw driver
T20 Torx screw driver

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Time to fit : 02:15 from start to finish, perhaps quicker if you were not stopping to take pictures or search for the required tools since you guys now have a list lol

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The next step is extremly difficult if you don't know how,
But its very simple once you know how; and you will know how to
After you watch this short video from dodge, all wiper arms remove the same way and this dodge wiper removal video video explains it best.

. http://m.youtube.com...?&desktop_uri=/

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Clips removal using flat screwdriver to slide from panel.

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Once unclipped;
Lift the panel free from place and store in a safe place until returning to the car.

Next step is to remove the panel beneath

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also remove the brake fluid resivour from this panel and ensure to place it in an upright position in the engine bay until returning to the panel.

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Store all screws in a cup and place it somewhere safe until returning to the car.

When screws are removed from the panel;
Lift upwards on the front and gently pull backwards to release from the clips that grip it at the rear:

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when removed:
Store in a safe place until replacing on the car

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Now all of these panels are removed, you can gain comfortable access to the rear of the engine,

Your next question may be "where is the EGR Valve located?"

Here are 3 images taken from the front engine bay and leading you to the rear right side of the 1.6TDCi / 1.6HDi engine where the EGR valve joins to the block.

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This round headed barcoded electonic valve is THE EGR!!

This cylinder in the image below is the egr valve cooler,
Helps to cool the exhaust gases that are being sent to the valve for re-entry to the combustion chamber.

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Now to fit the EGR blanking plate;
You first need to loosten the nut on the EGR Cooler tank

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Followed by loosening the two extreemly long EGR Valve bolts.

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Once the nut on the "EGR Cooler"
And
The 2 bolts on the "EGR Valve" have been made loose you can gently pull the EGR Valve from the engine block,
This is a case of trial pulling
Followed by further loosening of the nut/bolts until you have enough space to slide in the plate.

See in the image below this text:
The gap beginning to appear when gently pulling on the EGR valve after loosening

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Their is a gasket seal on between the engine block and egr valve flange,
I kept the gasket on the engine block side; when inserting the blanking plate,

So the gasket now seals the engine block to the egr blanking plate,
This is best for a good seal.

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Now to slide in the blanking plate from the right side of the engine
In to the left.

Very easy,
Just hook on to the top bolt
And
Let the blanking plate swing down; it will hook in to the lower bolt itself.

Just push firmly to the left to ensure it is centre in the valve,
Also ensure the gasket seal is between the engine block and the blanking plate.

Prior to tightening the 2 bolts on the EGR valve back up
Followed by the nut on the egr cooler.

Here is the blanking plate fitted:

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Now to replace the panels

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Ensure the seals are free from dirt
Also check the top panel under the windscreen,
It has a C shaped end that fits the bottom of the windscreen in to the panel for a tight seal.

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..
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All back togeather
You will notice boost comes a lot quicker and increased torque lower down in the rev range,
Exhaust noise is a little louder (just a little)
Engine idle is quieter
Exhaust smoke doesn't exist
Your induction system now takes in clean air only
No carbon in your induction
Less engine oil contamination

All of the above are from my personal experience since fitting,

Other things such as increased MPG have yet to be saw but I'll keep you all updated.
Great surprise with the reduced lag in 1st and 2nd Gear though.

Well worth every penny and more!

By far the best modification on the car to date.