Since I've installed an EGR blanking plate, the car is smoking from under the bonnet and the cabin stinks of diesel fumes. The smoke ain't coming from where the egr valve is. It's coming from lower down somewhere but I can't figure out where. Anyone have any suggestions? Cheers

Maybe the exhaust manifold is cracked, remember that the exhaust gasses are under pressure so even a small crack could allow a sizeable amount of fumes into the engine bay.

I've managed to find the problem. One of the injectors are leaking diesel from the leak off pipe I think but it's only started since putting on the blanking plate. I'm guessing that putting the plate on has added pressure on the fuel side of things causing diesel to leak past the seals on the leak off pipe. Gonna have a proper look tomorrow when it's daylight and see if I'm correct. I'll just get either a new leak off pipe or change the seals and the r clips on the current pipe in hoping it holds

On 01/12/2017 at 5:16 PM, rm9 said:

Since I've installed an EGR blanking plate, the car is smoking from under the bonnet and the cabin stinks of diesel fumes. The smoke ain't coming from where the egr valve is. It's coming from lower down somewhere but I can't figure out where. Anyone have any suggestions? Cheers

If you do have to drive it like that, make sure you drive with the windows down to ventilate & A/c off; diesel fumes can contain carbon monoxide which is lethal!  Best to get it sorted asap.

On 01/12/2017 at 9:05 PM, rm9 said:

I'm guessing that putting the plate on has added pressure on the fuel side of things

There's no connection between the EGR and the fuel system. Fitting the plate can't have changed the fuel pressure. Anyway there's no pressure to speak of on the leak-off side, the fuel is just returned to the tank. If it is a leak from the leak-off pipe then unless you accidentally disturbed it while you were fitting the plate it's just a coincidence.

I think in the end it's just a massive coincidence. Leak off pipe on injector 1 was gushing out diesel earlier today. Took the pipes off and the pipe going into injector 1, the nipple actually split in half and half of it was still in the injector. See pics below.

You can see the seal and the other half of the nipple still in the injector

 

Managed to get it out by using a nail

New leak off pipe coming Wednesday. Might do a guide for anyone else on here who isn't sure on how to replace the pipes

Thank you to everyone for the suggestions

This exact issue is also present on my FF2 2005 1.8TDCi...just discovered it few days ago, but because of the coooollld weather, I'm leaving it to car service to fix it, although it should be an easy fix. Hopefully there is also leak on the leak off pipe, because it could get pretty hard to get out the injectors after all this time, and also with the leaks all over it...

Anyway, good job fixing the leak, if I may throw my piece of advice here, I would (and will) replace all four leak off pipes, because the issue might appear again, so why mess with it all over again.

You can only get the leak off pipe as a set as it's an all in one thing. Luckily it's cheap at £30.15 for the set and it ain't that hard to do either. See the link below to it

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F272939783301