D40 EGR Blank Mod. (Partly Done) - Nissan-Navara.net
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post #1 of 79 (permalink) Old 18-01-12, 01:41 PM Thread Starter
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D40 EGR Blank Mod. (Partly Done)

I had a go at fitting the EGR Blanking plate that Stainless Dave kindly sent to members.

I thought i would take some pictures along the way to help anyone else like me, who likes to look at pictures before completing a job.

I take no responsibility for anything that you may break or bugger up by doing this, im mearly showing how i did it

Tools : -

Flat Bladed Screwdriver,
14mm Socket
Decent solid ratchet
10mm Spanner
Copper Grease

WD40 Optional but i didn't use it
Hammer Optional but again i didn't use one

Find the EGR Gasket on both sides,
Drivers...

EGR drivers side by StateyD40, on Flickr

Passenger...

Passenger side by StateyD40, on Flickr

Remove top cover for better access, Undo the 2x 10mm bolts

2 x 10mm by StateyD40, on Flickr

Its still held down by 2 rubber gromits at the back so just pull straight up.

Rubber Stops by StateyD40, on Flickr

You can then see the EGR pipe clearly

EGR Pipe by StateyD40, on Flickr

I then removed the Turbo pipe to get a better look at the passenger side Gasket

Passenger Side EGR by StateyD40, on Flickr
(If anyone knows what the item ive starred is, can you let me know? also is it ok to remove as it would be easier to remove the EGR is this was moved?)

As you can see with Turbo pipe removed you can get alot closer.

Birds eye view of Passenger side and the access problems by StateyD40, on Flickr

Now undo the 2 x 14mm Bolts on the drivers side **CAUTION, these are extremely tight, reading over the forum some people recommend tapping your ratchet with a hammer to "shock" it, others a little WD40 (not overly keen on this with it being somewhere that gets hot but let me know)
For this reason i used a 14mm 6 Point socket rather than a multi fitment, and this did job nicely.

18012012418 by StateyD40, on Flickr


This is where i got too... I went to fit the blanking plate i got from Stainless Dave, Its the wrong size and shape So refitted the bolts with some copper grease to make it easier next time

I had a look on the passenger side too and its wrong for that side too.

Not the right shape or size by StateyD40, on Flickr


So when i get the correct size i will continue the write up, but i hope this so far helps someone.
I haven't yet had a go undoing the passenger side but for anyone that has done this before, would it be easier to remove the radiator pipe thats near it and also the part ive put a * on the pictures?

Thanks All
Statey
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post #2 of 79 (permalink) Old 18-01-12, 04:52 PM
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Re: D40 EGR Blank Mod. (Partly Done)

I'm starting to like these how to do with pictures so much easier to follow and understand
Good work so far mate shame about the size

Kc driving lights 150 watts a piece, 2 additional led reversing lights equal to 55 watts each Hankook 265 75 16 pipercross air filter cone type EGR blanked off, free wheel hubs S/S exhaust from the cat back no boxes and twin side outlet pipes
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post #3 of 79 (permalink) Old 18-01-12, 05:00 PM
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Re: D40 EGR Blank Mod. (Partly Done)

I had the same problem with mine bought one from ebay without checking then had to buy another doh. My egr's the same shape as yours new plate cost 4.99 I only removed the two bolts on the drivers side so I could squeeze the plate in, is there a reason for removing the other bolts? mines been running fine since (3 weeks) tbh i haven't noticed much difference, but I had no problems to begin with just wanted to stop all the **** getting into the manifold.
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post #4 of 79 (permalink) Old 31-01-12, 07:39 PM
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Re: D40 EGR Blank Mod. (Partly Done)

this is better than school!

it's easier to undo the driver side bolts, slip in the blanking plate, put copper grease on the bolts, and tighten. job done.

this should lessen unwanted **** back to the engine.

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post #5 of 79 (permalink) Old 31-01-12, 09:13 PM
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Re: D40 EGR Blank Mod. (Partly Done)

the plates i did were for a euro 4 engine
sorry
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post #6 of 79 (permalink) Old 31-01-12, 09:31 PM Thread Starter
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Re: D40 EGR Blank Mod. (Partly Done)

Quote:
Originally Posted by Stainless Dave
the plates i did were for a euro 4 engine
sorry
Not your fault Dave! an extremely kind gesture on your part
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post #7 of 79 (permalink) Old 31-01-12, 11:52 PM
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Re: D40 EGR Blank Mod. (Partly Done)

How hard are those drivers side bolts on the egr to get out? I fancy blanking mine off, but I saw another thread somewhere with what looked like snapped or partly hacksawed off bolts. I can't afford to cause expensive problems on my Nav at the minute.

Mines a Euro 3 same as yours.

Cheers

Simon
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post #8 of 79 (permalink) Old 01-02-12, 09:17 PM
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Re: D40 EGR Blank Mod. (Partly Done)

Quote:
Originally Posted by Si_B
How hard are those drivers side bolts on the egr to get out? I fancy blanking mine off, but I saw another thread somewhere with what looked like snapped or partly hacksawed off bolts. I can't afford to cause expensive problems on my Nav at the minute.

Mines a Euro 3 same as yours.

Cheers

Simon
I did not use a torque wrench so I don't know the exact pressure but they're quite stubborn little fellas.

What I did was sprayed on some WD-40, and used a rubber mallet to hit the handle of the wrench. Let the WD-40 sink in for about 5 minutes since the bolts were a bit rusty.

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post #9 of 79 (permalink) Old 11-04-12, 02:20 PM
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Re: D40 EGR Blank Mod. (Partly Done)

Great pics, I will definitely try this one..Ill do any mod that will gain me some fuel economy!!
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post #10 of 79 (permalink) Old 13-04-12, 08:47 AM
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Re: D40 EGR Blank Mod. (Partly Done)

Quote:
Originally Posted by Stainless Dave
the plates i did were for a euro 4 engine
sorry

Do you have any more of these available?
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