Another D40 EGR mod

lookskyward1 · Apr 19, 2014

The Aussie guys have been discussing a complete EGR pipe removal kit sold by these guys http://www.yd25.com.au/

[attachment=1:1j8sjjpf]EGR_delete_pipe_kit.jpg[/attachment:1j8sjjpf]

The old flange pipe that introduces exhaust gas into the intake flow is circled in RED. It sits on the intake manifold after the EGR valve. This is replaced by the new flange circled in BLUE.

Surely removing this pipe from disrupting the airflow through the intake manifold is a good thing. :dunno A smoother airflow.

This is a picture posted by Soybean of the old flange, describing it as "The tube itself is sizeable.
It's about an inch in diameter and it sticks about 1.5 inches into the airstream from what i could tell."

[attachment=0:1j8sjjpf]attachment.jpg[/attachment:1j8sjjpf]

Guest · Apr 19, 2014

Re: Another EGR mod

Instant mot failure over here ??? :dunno

lookskyward1 · Apr 20, 2014

Re: Another EGR mod

Biggi said:
Instant mot failure over here ??? :dunno

It would be a fail just the same as the plates we presently fit IF they are spotted. This new plate is of the same thickness and outward appearance as the original part so would go completely undetected unless the MOT examiner was authorised to open up the EGR system which they presently cannot do.

However that said, I have been in touch with YD25.com to see if we could do a bulk buy. I received a prompt reply this morning but the news is not good. The owner has asked me not to publish the price but is in my opinion no where near being worth the bother or expense.

Euro3 and Euro4 plates are available here; viewtopic.php?f=8&t=94097

lookskyward1 · Apr 22, 2014

Re: Another EGR mod

I removed my EGR valve today to have a look at this flange/pipe. The pipe fits into the intake airflow at 90 degrees and must be quite obstructive. There must be hidden horsepower there if this was removed?

karlo · Apr 22, 2014

Re: Another EGR mod

I completely removed the EGR on my Disco when I had it and that never failed MOT?

So cut the pipe off cut a plate out of a bit of tin and blank off the hole.

xzibit206 · Apr 23, 2014

Re: Another EGR mod

Just cut the pipe off the plate on the stock system?

lookskyward1 · Aug 29, 2014

Re: Another EGR mod

Well, to resurrect, this one. :wink:

I have just rebuilt the timing chains on my truck while I am at Gateshead. Yesterday I picked up the blanking plate from Rich.

I fitted it today and reset the ECU (hard reset). The results are so obvious, the engine was pulling smoothly and more readily from a standstill. But the best bit was the instant MPG readout on the computer. Running around the doors when I previously got 21.5mpg has improved to 26.6mpg. Early days yet but this has to be worth doing.

The Aussies are paying over £20 for this plate. Our Rich can make and distribute them at a much lower price. Chase him up now, you will not regret it :bow

lookskyward1 · Aug 29, 2014

Re: Another EGR mod

This is the blank next to the original flange and pipe.

That pipe sits directly at 90 degrees to the airflow of the inlet manifold causing turbulence and obstruction of the fresh air being drawn in.

I'll keep everyone up to date with performance and especially MPG results. The seat of the pants tells me it's well worth doing :rockon

Rich. · Aug 29, 2014

Re: Another EGR mod

Kieths bringing the old plate over to me on Monday so i can do some tweeks to ensure its a perfect fit as a couple of little mods we're needed this time as it was just drawn from a tracing Kieth posted to me a while back. This certainly looks like a very worthwhile mod.

Rich

B10 · Aug 29, 2014

Re: Another EGR mod

Wouldn't make any differenece as the inlet manifold is under pressure from the turbo anyway so the difference in air flow would make no change to anything. Waste of time.

diggerman · Aug 29, 2014

Re: Another EGR mod

I made my own plate and bought another Egr pipe from a breakers and welded the end solid after cutting of the bit sticking into the manifold.

chris vince · Sep 1, 2014

Re: Another EGR mod

B10 said:
Wouldn't make any differenece as the inlet manifold is under pressure from the turbo anyway so the difference in air flow would make no change to anything. Waste of time.

Just read this thread and feel the need to reply to this statement which is so very wrong.
It is not just about the amount of airflow that makes EGR blanking worthwhile.

It is the fact that very hot, dirty, sooty, re-used and inert (lacking oxygen) air is no longer being drawn into the engine.
Recycled exhaust gas is used to replace some of the oxygen content of the air that is drawn into the engine, thereby lowering the heat produced by the combustion process, it is heat combined with oxygen that produces NO2, without this or another system in place these trucks (or any diesel vehicle) could not be sold in many parts of the world.
Hence the EGR system is most definitely NOT there for the benefit of the engine, exactly the reverse!
With it present, the engine will be much less efficient, due to being starved of cool (the reason intercoolers are fitted!) oxygen rich air, this is why owners who have blanked their engines notice a marked reduction in throttle depression to achieve the same speeds, obviously pressing the throttle less equals less fuel consumption!
I can never understand quite why governments allow the unnecessary burning of excess fuel in engines they demand to be inefficient, to try to control emissions, seems counter productive?
Also, consider the very high compression pressures in EGR equiped diesel engines, blow-by past the piston ring seals cannot be totally avoided, this results it the filthy sooty exhaust gases mixing with the engine oil, gumming up and contaminating the oil galleries as well as scouring out plain bearings.
Again, owners with blanked EGR's also notice how much cleaner their oil stays in the long term.
IMO the benefits of EGR blanking speak for themselves.

B10 · Sep 1, 2014

Re: Another EGR mod

chris vince said:
B10 said:

Wouldn't make any differenece as the inlet manifold is under pressure from the turbo anyway so the difference in air flow would make no change to anything. Waste of time.

Click to expand...

Just read this thread and feel the need to reply to this statement which is so very wrong.
It is not just about the amount of airflow that makes EGR blanking worthwhile.

It is the fact that very hot, dirty, sooty, re-used and inert (lacking oxygen) air is no longer being drawn into the engine.
Recycled exhaust gas is used to replace some of the oxygen content of the air that is drawn into the engine, thereby lowering the heat produced by the combustion process, it is heat combined with oxygen that produces NO2, without this or another system in place these trucks (or any diesel vehicle) could not be sold in many parts of the world.
Hence the EGR system is most definitely NOT there for the benefit of the engine, exactly the reverse!
With it present, the engine will be much less efficient, due to being starved of cool (the reason intercoolers are fitted!) oxygen rich air, this is why owners who have blanked their engines notice a marked reduction in throttle depression to achieve the same speeds, obviously pressing the throttle less equals less fuel consumption!
I can never understand quite why governments allow the unnecessary burning of excess fuel in engines they demand to be inefficient, to try to control emissions, seems counter productive?
Also, consider the very high compression pressures in EGR equiped diesel engines, blow-by past the piston ring seals cannot be totally avoided, this results it the filthy sooty exhaust gases mixing with the engine oil, gumming up and contaminating the oil galleries as well as scouring out plain bearings.
Again, owners with blanked EGR's also notice how much cleaner their oil stays in the long term.
IMO the benefits of EGR blanking speak for themselves.

Sorry if you read my statement incorrectly BUT I was obviously or not so obviously taking about the need to remove the stub sticking into the inlet manifold (which the thread is about) NOT the fact of blanking the EGR which is obviously a good idea on any engine, please don't imply your own version of a statement without actually reading the full thread.

Thank you for your input!

Lee21 · Sep 2, 2014

Re: Another EGR mod

I have a 2014 190 and was thinking of blanking the EGR however I have heard this causes and engine management light to come on is this correct?
Has anyone done it on a new one?
I had problems with an Audi A3 and as such I am reluctant to do so again with the Nav. After hours of discussion with two of my colleagues who both had worked at VAG at sometime. The conclusion was that since the control system needed to see a pressure change in the inlet manifold on over run blanking it off would not work with out getting into the source code a changing the parameters. Without doing this the result was that the fuelling was not cut causing the engine to race when the clutch was depressed. This was eventually cured by drilling a 2mm hole in the blanking plate.

lookskyward1 · Sep 2, 2014

Re: Another EGR mod

Fitting this plate possibly could allow the sensor to see the exhaust gasses but not allow any past the egr valve. It might work. :dunno

Monty_Python_X · Sep 3, 2014

Re: Another EGR mod

OK, just to be clear...
I already have my EGR blanked using the circular plate in the original post.
The piece that Rich is fabricating goes on the other end of the EGR pipe to the one i already have installed?
I'll take some pictures tomorrow and mark them up to explain my quesion a bit better

lookskyward1 · Sep 4, 2014

Re: Another EGR mod

Monty_Python_X said:
OK, just to be clear...
I already have my EGR blanked using the circular plate in the original post.
The piece that Rich is fabricating goes on the other end of the EGR pipe to the one i already have installed?
I'll take some pictures tomorrow and mark them up to explain my quesion a bit better

No this plate goes in between the EGR valve and the intake manifold. The manifold intake is about 3" in diameter and the 1" diameter pipe that you take out obstructs the intake at 90 degrees.

Spi78ke · Nov 13, 2014

Re: Another EGR mod

I have a blanking plate I ordered quite a while back. I was planning on doing the mod but kept reading contradicting experiences on the www. When you're no mechanic, it's not easy to work your way trough all the information. So I put it aside and kind of forgot about it all together.
Now this topic has got me reading again. EGR blanking sounds good, even if there is no improvement in fuel consumption. It can't be good to blow the exhaust gas back into your engine. Secondly, I don't want trouble with the EGR in the future because it's clogged up. That said, I don't want trouble with eanything else either because I blanked the EGR.

So, for my questions. Many of you guys have been running your trucks for several years now with the EGR blanked off.
Do any of you have had any issues caused by this mod?
The one blank (driver side) is not going to cause the pipe to get full of soot and eventually blocking the EGR valve so the valve will get stuck?
No turbo problems?

Robgrav · Nov 14, 2014

Re: Another EGR mod

Does this mod improve mpg then.ive read through and seems good. Mpg increase. But nothing much been said since the early days of fitment.

lookskyward1 · Nov 14, 2014

Re: Another EGR mod

Spi78ke said:
Many of you guys have been running your trucks for several years now with the EGR blanked off.

Do any of you have had any issues caused by this mod?

The one blank (driver side) is not going to cause the pipe to get full of soot and eventually blocking the EGR valve so the valve will get stuck?
No turbo problems?

Neither this mod or the standard blank will cause problems. The EGR pipe will not have any flow through it so it is unlikely it will be choked up.

The 'normal' blanking plate will stop the soot getting to the EGR valve, this plate will completely isolate the EGR valve from the intake system. It will continue to work with no effect on the engine whatsoever.

Robgrav said:
Does this mod improve mpg then.ive read through and seems good. Mpg increase. But nothing much been said since the early days of fitment.

Yes, I was hoping Rich. would have a run of these blanking plates made up so others can confirm this. I am seeing about 5mpg better fuel consumption when running about in a urban stop start situation.

Another D40 EGR mod

lookskyward1

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