It perhaps seems possible just to squeeze it in there without removing the EGR, by looing at this video for example (different car though) https://www.youtube.com/watch?v=deZriENJWWs

I found a video of the same engine i have though, of what the EGR looks like... https://www.youtube.com/watch?v=9-iPiWrmo-8&t=239s
But should the EGR blanking plate be inserted between where he screws at 14:20 or where he screws at 15:05?

The place at 14:20 is where the difficult bolt is, the place at 15:05 would be easier to do. Does anyone know where the EGR blanking plate should be fitted, i guess at 14:20 before the EGR?

Maybe a much more relevant question though; As you mentioned before, the throttle body is built into the EGR valve, like one piece, does it then work to blank the EGR? Doesn't the function of the throttle malfunction then too?

Kind Regards
Jonathan

Hi Jonathan

I think you have the EGR inlet and outlet mixed up.

Looking at the diagrams I posted, the gas flow is in this order:

7 Exhaust Manifold
5 Gas Heat Exchanger (Cooler)
10 EGR Valve
"Red Pipe"
9 Air Temperature/Pressure Sensor
8 Intake Manifold


The inlet to the EGR valve is on the right as you look at the engine, and is the side shown at 15:05 in the video. This is where the blanking plate should go, between the Gas Heat Exchanger and the EGR valve.


The outlet from the EGR valve is on the left/lower down, and is shown at 14:20. It connects to the smaller "red pipe" fitted with a flexible "bellows" section. You shouldn't need to disturb this.

If you prefer to replace or clean the EGR, maybe you could remove the EGR complete with the red pipe, and deal with the damaged bolt when it is on the bench and easier to get at ?

Be also aware that with fitting the plate you may now also eml coming on [ mot fail ..!!], there are also 2 types of blanking plate, one is solid and the other has a small hole in the centre, trial and error to which works , loads of info on the ford transit forum.

Hi,

Thanks for the reply!

So if i understand correctly (just to confirm before i start doing anything), at number 4 of this picture is where i shall insert the EGR blanking plate? https://www.fiatforum.com/attachment.php?attachmentid=216495&d=1616750881

That is, between the ''gas heat exchanger'' and ''exhaust gas inlet''. Is this correct?

If so, this may become a quite simple thing to do for me by just laying below the car. There appears to be only 2 bolts holding it together which i perhaps could screw out slightly and then press the blanking plate in there.

However, i did notice that there is some type of black silicone, quite much of it, at this place. I guess so that no air should come out between the two parts, or so that less heat should be transferred perhaps? The only way for me to separate the two parts and placing an EGR plate there would be to cut this silicone. Isn't this a bad thing to do?

And, i have an EGR plate with a small hole in it - if i understood correctly this should not make the check engine light come on? And just placing this blanking plate seems much easier than trying to remove the whole EGR and buy a new one or clean it.

Many questions here... But i appreciate alot you taking the time and answering them, the idle has became quite rough lately and i think it could be due to the EGR - if i could fix this myself it would be great.

Kind Regards
Jonathan

Hi Jonathan

Yes, the blanking plate should go at the point labelled 4

I think the Black Silicone is probably non standard. Often thin metal gaskets are used which are pressed with a slight ridge which deforms to seal. So (in theory) they must be used only once. You would need a parts diagram from a dealer (Fiat or Ford) to identify the correct gasket. These metal gaskets are not very expensive.

Hi,

Thanks. Great, then i know where to put it.

Regarding the black silicone,

Do you think it's fine to cut this silicone so that i can put in the EGR plate there, or may i risk something then?

And if i understood you correctly, you think that original there is a one-time metal gasket that's supposed to be there, but that someone has removed that and put this silicone instead? And that it would be good to buy that one-time metal gasket again?

What do you think about, for now, just to cut this silicone and put new heat-resistance silicone again after putting the blanking plate? And do you know what's the purpose of this, just to seal for air leakage or not to transfer heat from one part to the other?

After having read a bit, i get the impression that i could cut the current silicone and put the EGR blanking plate, then to make it 100% well i could go and buy some heat resistant silicone and finish off with? I found one silicone which can stand about 250 celcius, that should be enough or?

Or can it be a large mistake to cut the current silicone you think?

By the way, i remember you said there is no separate throttle body on the Puma 4hv 2.2 engine which i have, rather instead, it is build in with the EGR valve. Would't it be bad then for this reason to blank the EGR valve? I.e. that it would stop other functions relating to the throttle working properly?

If i for some reason wouldn't manage to mount the EGR, at least i perhaps would be able to spray the Wynns EGR cleaning spray directly into the EGR while the engine is working if i'm lucky. Hopefully it will work to mount the blanking plate though.

Thanks once again for all the answers you provide by the way. Thanks to the diagrams you sent and comments you made i've understood much.

Kind Regards
Jonathan

Thanks for the reply.

Kind Regards
Jonathan

Hi

You will need to remove all the old silicone, to leave a clean flat surface.


In the UK the gaskets are available for a few pounds. The picture shows the input and output gaskets from a supplier called Coastal Motorhomes. I think using the original metal gasket is best, as long as you can take out the two bolts to slide it in. Place the gasket on the input side of your blanking plate. Ideally you would use a second gasket on the other side of the blanking plate too.

You could use silicone sealer instead. The temperature isn't that high because it is after the heat exchanger. There is no heat insulation property required. Be careful not to allow silicone to squeeze out and enter the pipes or EGR, as it could break off and be drawn into the engine. Only a thin coat on each side of the blanking plate is required.

Don't worry about the throttle body, this engine is not designed to use one and there is no need to replicate its function.

Hi,

Ok Thanks alot. Thanks for highlighting the need to be careful not getting any silicone into the pipes neither.

Kind Regards
Jonathan Johansson

Hi again,

I mounted the blanking plate and went for a test run, what a difference. It accelerates much better and when i release the gas on 1st gear it no longer engine breaks roughly. Neither vibrates like it used to do...

One of the bolts however did not work to tighten back completely, just spins... So i applied a little bit of blue loctite on it. Perhaps it's also leaking a bit since the old silicone gasket was separated. I can buy some more gasket silicone tomorrow and apply.

It is a blanking plate with a small hole in the middle... I drove about 10 minutes and the check engine light did not come on... I guess it should be fine and shouldn't come on since the blanking plate has a hole in it?

Kind Regards
Jonathan Johansson

The check engine light still hasn't come on and hopefully wont.

But, i was thinking, i guess the EGR valve is still quite dirty and it is in use since the blanking plate has a small hole in it. So, does a blanking plate with a small hole in it completely solve the issue with a dirty EGR, or is it just a matter of time until the EGR will be clogged up i wonder... I should read some on this topic.

I also wonder whether there is a difference in effect between a clean EGR valve + a blanking plate with a small hole and a dirty EGR + a blanking plate with a small hole in it. I.e, could the engine get even better if replacing the EGR for a new one or clean it and then place a blanking plate?

Kind Regards
Jonathan