Do you know a good place to get that done in surrey? I would be reluctant to have this done without a recommendation. I dislike garages at the best of times.

In the mean time ill do what you suggested. Thanks for your help. I'll let u know how I get on.

I agree mate,

Most places prefer to cut the pipe and fit a straight pipe but that fails visual inspection,

Im in ireland and traveled 107miles journey each way to have mine gutted instead of chopped, ask around i suppose mate much the same cost to gut it or replace it,

Just if you plant to keep it forever id gut it but if selling on in 2-3 years id replace it.

But when you say it would fail visual inspection, would it fail an mot?

But when you say it would fail visual inspection, would it fail an mot?

If the dpf chamber was removed and replaced with a normal 2.5" pipe or saw to have been tampered with then it would fail the visual inspection on MOT

But if opened on the factory weld then resealed its not evident that its been touched.

The same as EGR removal,

if you remove an egr valve it will fail visual inspection on MOT but if you blank it, the end result is exactly the same but they cant detect its been blanked,

in a word yes, they needed to be visually inspected for mot purposes, if it has been removed then you get a instant fail, and you would have to purchase 1 and fit it, before your 2weeks free test is up.... get it cut open, internals removed, welded back up but then the car needs re-mapping and the dpf software altering with in the cars ecu.. a re-map and dpf removal is around the 400 figure....

in a word yes, they needed to be visually inspected for mot purposes, if it has been removed then you get a instant fail, and you would have to purchase 1 and fit it, before your 2weeks free test is up.... get it cut open, internals removed, welded back up but then the car needs re-mapping and the dpf software altering with in the cars ecu.. a re-map and dpf removal is around the 400 figure....

+1 much the same price as a new dpf which will last you 3-4 years so if planning to sell the car within 3-4 years id just replace the dpf instead of gutting the existing one,

If replacing though, ask them for the old existing one, you can get 50-60 pounds for it,

Someone will buy it and gut it out to replace there own,

Heres the process and how it looks inside:

This is the dpf marked with a C

Then cut open,

Dpf section removed leaving the cat section intact

This is a section of th3 dpf construction thousands of little ceramic channels which are around 8 inches long easily become clogged with carbon deposits and in some cases difficult to break through using exhaust gas pressure alone

Heres two videos of a DV6 1.6TDCi euro4 engine with egr blanked 2.5" exhaust and dpf internals removed,

No smoke and remapped from 90 to 125bhp

I lay in the boot for one of the vids to video the exhaust pipe on the move to show no smoke.

http://s575.photobucket.com/user/lennymanwoods/media/VID_20130923_092316_zps297a067f.mp4.html

http://s575.photobucket.com/user/lennymanwoods/media/VID_20130923_092155_zpsb00a8e8c.mp4.html

Thanks for the info, I'll check that out if I have no luck with simple solutions. I have found a slight air leak on the big steel pipe that goes down into the engine bay. Please see attached links as I cant find out how to attach to posts on my ipad? Would a small leak on this pipe cause my probs?

https://picasaweb.google.com/115120534450023312834/FocusAirLeak?authkey=Gv1sRgCM2LpYKLxs6MqgE&noredirect=1

For info, the main pipe from the air filter to the turbo was fine, couldn't see any air leak.

For info, the main pipe from the air filter to the turbo was fine, couldn't see any air leak.

That black steel pipe is your intercooler pipe, if a hole is in the circuit such as that it will leak off boost pressure causing you to lose power,

Those pipes cost around 70 pounds from ford,

I recommend trying some two part resin to patch it instead of replacing,

This stuff from halfords:

Costs less than 10 pounds,

But leave the car at least 10 hours after applying the stuff.

Doesn't work on exhaust manifolds but intercooler pipes don't get half as hot as manifolds.

Lenny, your a star. Just the answer I was hoping for. I'll give that a go. Thanks.

What am I best cleaning it with to make sure it sticks well?

Lenny, your a star. Just the answer I was hoping for. I'll give that a go. Thanks,

What am I best cleaning it with to make sure it sticks well?

No prob,

Suppose to do the best job possible,

If i was you,

Id unbolt the pipe take it to a workable bench area, give it a light sanding,

Fill it with the resin,

Once dry,

Quick sanding and bit of black paint that has some zinc or rust repellant in it.

Or

You could spare the resin and have it weld but its pretty thin metal so a weld may burn it instead of bonding.

P242F - DPF Filter Restriction - Ash Accumulation

P2458 - DPF Filter Regeneration Duration

P2279 - Intake Air System Leak

Basically your DPF is clogged and not regenerating in the time your ECU expects it to and you have a leak somewhere in the intake system as your mechanic stated.

Thanks for the guide Lenny

Fitted the blanking plate today, took me about an hour and a half, being slow making sure I do It properly but the longest part was trying to get the blanking plate to slot in correctly

One thing I will point out to anyone else is that the screws are long on the egr valve, but the actual threads aren't as long as you'd hope, I undid the top one too much and and gasket fell down

If this happens, get a wire coat hanger, bend it to make a small hook, and you should be able too hook it in the screw hole and get it back into place

Can't honestly say I noticed a massive amount of difference

Maybe slightly less lag low down, but if it extends the engine life then for around £3 it's gotta be worth it

Also, donated to your PayPal (y)

Sent from my iPhone using Ford OC

Thanks for the guide Lenny

Fitted the blanking plate today, took me about an hour and a half, being slow making sure I do It properly but the longest part was trying to get the blanking plate to slot in correctly

One thing I will point out to anyone else is that the screws are long on the egr valve, but the actual threads aren't as long as you'd hope, I undid the top one too much and and gasket fell down

If this happens, get a wire coat hanger, bend it to make a small hook, and you should be able too hook it in the screw hole and get it back into place

Can't honestly say I noticed a massive amount of difference

Maybe slightly less lag low down, but if it extends the engine life then for around £3 it's gotta be worth it

Also, donated to your PayPal (y)

Hi Chris,

Was cringing there at the thoughts of the gasket falling down, but you made an excellent recovery by hooking it back up to position,

thanks very much for your kind donation towards the photobucket fees,

to date your the second person to donate i really appreciate that thanks,

The next time your changing the induction filter perhaps consider upgrading to a Green Cotton Performance induction filter, the guide is linked on my profile page,

can be viewed on a computer by clicking on my aviator picture, doesn't display the same on the app version.

Thanks very much for the guide lenny, even though mines a 1.8 I got there lol

Thanks very much for the guide lenny, even though mines a 1.8 I got there lol

:D no problem cheers,

Wish they were all front facing like the 1.8tdci would been easier,

Or perhaps its the 2.0tdci

I cant fully remember rite now, but either the 1.8tdci or 2.0tdci were pop the bonnet and there's your egr on the front, very easy to blank.

The 1.8 involves removing the wipers and scuttle panel to gain access to the bolts.

The 1.8 involves removing the wipers and scuttle panel to gain access to the bolts.

Thanks Clive mate must be the 2.0tdci then,

Has the egr facing the front,

Thanks Clive mate must be the 2.0tdci then,

Has the egr facing the front,

Lucky bar stewards.

Quick update. Took the intercoler pipe off at the weekend and filled the gaps up with that steel weld epoxy stuff. It's done a good job, is running better now. Still got the dpf issue though. Cheapest quote ive had from a few companies round surrey to remove it and remap the car is £475. Seems a bit steep from what you lot are saying. Anyone else know a good place to get this done?

Cheers

Jimbo

Hi Lenny, i fitted the EGR blanking plate to my car today hoping it would cure my EGR problems, my car is hard to start and cuts out while driving but runs fine with the EGR unplugged but brings up the EML light.

Am i right in thinking that the plate slides in from the battery side or did i do it wrong?

I would love to get my EGR off to clean it if this would fix my issues but i have no idea how to get the Exhaust gas cooler to EGR valve clip off and on without destroying it, here is the clip:-

Any help appreciated from anybody.

Thanks for the guide, i can see the benefits of having the valve disabled, i typically get 65 mpg on the way to work over 30 miles extra urban, with the EGR unplugged i get into the low 70's and the car is more responsive and less laggy.

I am getting a P0698 OBD code http://www.dtcsearch.com/P0698/

I have seen new EGR valves on ebay from transitpartsuk for 88 squids.

It looks like the clips they have on dishwashers

The bit at the top of the picture could be prised upwards with a screwdriver to release the tension on it

And then to get it back together you have to squeeze it tightly so that the 'teeth' slide over the notch and grip it closed

Saying that, depends how much room you've got to get tools in there

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Does any1 know the part number for this clamp/clip, would this 1 fit seeing as my engine it a Peugeot engine.

http://www.ebay.in/itm/PEUGEOT-205-206-306-307-308-405-406-EGR-Valve-Clamp-Genuine-16283J-/280909501280

It looks like the same type of clamp, sort of the replacement you would be expected to use if you haven't got the tools to refit the other

I'm assuming the pipes would be a similar size for most egr's but couldn't say for certain

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