Blanking plate comes where the red line is drawn on the picture below its a very thin (cca 2 mm) plate if you use 2 gaskets add another 2 mm so 4 mm in total. Like I said in your case I recommend blanking only for short time as a cheap way to test if this solves the hesitation problem - just as a diagnostic measure. Only then I would go for a EGR/intake replacement since it may be some other problem causing hesitation (unlikely but possible) and replacing the EGR straight away might not solve it.

24 minutes ago, Janzup said:

Blanking plate comes where the red line is drawn on the picture below its a very thin (cca 2 mm) plate if you use 2 gaskets add another 2 mm so 4 mm in total. Like I said in your case I recommend blanking only for short time as a cheap way to test if this solves the hesitation problem - just as a diagnostic measure. Only then I would go for a EGR/intake replacement since it may be some other problem causing hesitation (unlikely but possible) and replacing the EGR straight away might not solve it.

Hi,

I ordered the blanking plate today.

I will use it as you suggest for a couple of weeks to identify if it rectifies the issue.

To be honest, I will only be keeping the car for another 12 months before scrapping - so do you see a particular issue keeping the plate on (if it solves the problem) for the duration of its remaining lifetime?

Out of interest.. would you use sealant considering at this stage its testing? Dont fancy sticking it on a struggle to get it off

Mechanicaly it will cause no issues at all in fact it will keep your engine cleaner and working better/ more responsive as it wont be breathing in any exhaust gases.

If you orderd a plate with two gaskets you should be fine using just gaskets without sealant. To check if it is sealing properly after installation have someone press accelerator pedal to 3-4 k rpm and feel with your hand around where the blanking plate is to feel if any gases are leaking. I had some leakage with just gaskets so I added sealant - but sealant makes it more visible.

2 minutes ago, Janzup said:

Mechanicaly it will cause no issues at all in fact it will keep your engine cleaner and working better/ more responsive as it wont be breathing in any exhaust gases.

If you orderd a plate with two gaskets you should be fine using just gaskets without sealant. To check if it is sealing properly after installation have someone press accelerator pedal to 3-4 k rpm and feel with your hand around where the blanking plate is to feel if any gases are leaking. I had some leakage with just gaskets so I added sealant - but sealant makes it more visible.

Just this - https://www.ebay.co.uk/itm/121106889703

Then you will probably need to use some type of sealant. You can first try your luck without it but I doubt it will seal properly. If using sealant be careful to not use too much so that too much excess selant does not squeeze on the inside of the intake when tightening the plate where it can later break off and fly into combustion chamber. I used thermo resistant acetate silicone that is resistant up to 250 °C.

2 minutes ago, Janzup said:

Then you will probably need to use some type of sealant. You can first try your luck without it but I doubt it will seal properly. If using sealant be careful to not use too much so that too much excess selant does not squeeze on the inside of the intake when tightening the plate where it can later break off and fly into combustion chamber. I used thermo resistant acetate silicone that is resistant up to 250 °C.

Would you advise buying 2? or a seperate gasket?

Separate gasket or have someone cut out 2 gaskets for you using the blanking plate as a mold. 

You need something like this (this if from Poland):

https://www.ebay.co.uk/itm/175019515039?hash=item28bff9dc9f:g:DAsAAOSwTNNhjnEP&amdata=enc%3AAQAHAAAAoOVczM0lWeU9KD4poyZ%2BEYxJI2LUspmwCrIrSz07WeDkZDWU6XtHzKB98kN8VjI3tKb0U3ZLSf7Y0qp55J9EuWDT0EfI1qYeISjy3ks72X%2BEz65oWdY%2BTPiaqwrnnlf%2BYF5HmW%2B1E%2Ffm8pTx0MHuAlDLvrJHspX2euzwu00MPSFS2QDHewKs4MfhD9v%2Fh3K9iIUFffaQuQmvTpj04PhSGp0%3D|tkp%3ABk9SR46I0ZrvYA

Just an update.

Fitted an EGR blanking plate on Saturday 1st October.

Have done 430 miles, mixed driving, morning and night... and no stuttering at all since sitting the blanking plate, so I think it is safe to assume the EGR was the issue.

I do not intend changing the EGR as I am keeping the car for another 12 months maximum, but do you think it will be safe/ok to continue running as is?

So good news overall.. if it wasnt for this forum I would have probably changed the flywheel.. so thank you

Great news! When I heard your problems knew it was an EGR problem. I am very happy that you avoided the major unnecessary cost (DMF). It is perfectly safe to use the plate, only thing to note is the car will take longer to warm up in colder temperatures, due to hot exhaust gases not passing through EGR cooler - and therefore heating up the coolant, but that will do no harm and is nothing to worry about. Regarding the running of the engine it may even run better after some time and a few long highway runs when some of the gunk gets burnt off from exhaust manifold and turbo vanes (since there will be much less gunk passing through them).