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Technical EGR maintenance. (video)

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Technical EGR maintenance. (video)

Shadeyman

Shadeyman

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Due to a boost valve problem I decided to remove the EGR for a bit of maintenance and to reposition the blanking plate I have installed. Took a few photos and made a quick video in the hope it will be of help to some of you.

I gave everything a quick wipe then noticed the 2 venturi where completely blocked so I gave them a good clean. You'll see them towards the end of the video.

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I just did mine over the weekend and thats where I chose to put my blanking plate so that the EGR can't get clogged up again, I also had the throttle body / Inlet valve off and scrubbed it clean. Once it was off I cleaned as much of the manifold as i could reach and I've acetone cleaned the MAP & MAF sensors (i am gob-smacked at the amount of carbon + oil sludge there is going back into the engine). No Wonder I'm getting appalling MPG :bang:

Hopefully I will see some improvement now all of this has been done.
 
My daughter has Fiats Restrictor Plate fitted and still the crap caused her EGR to stick open. I stripped and cleaned her EGR then blanked it off. The exhaust gases and the crap it contains is now blocked from entering the EGR. You can see the difference in the amount of crap when you look at the photos of both sides of my blanking plate.
 
This is the first time I've blanked off an EGR and that was my thinking, if you put it before the EGR then it absolutely can't get clogged up again. If you put it either end of the corrugated 90 deg. elbow like fiat say then the EGR is the "dead end" where all the carbon and soot will end up.
 
I think thats what happened to my daughters car. When Fiats Restrictor Plate is fitted after the EGR the flow of gases before the plate slow down causing crap to be deposited in the EGR. I think if anyone is considering fitting Fiats Restrictor Plate they should fit it before the EGR to help keep the crap in suspension so less is deposited in the EGR, hopefully most of it will continue into the engine to be burnt.
 
I'm hoping that the soot & carbon dust will just start to gather in that off-shoot of pipe from the exhaust. The next thing I want to do is what Stuart_89 has done and redesign the oil catch tank so that oil from the crankcase breather won't get sucked into the turbo and then cover everything in the air flow system with smears of wet oil.
 
The blanking plate I purchased will also fit between the exhaust and the pipe leading to the EGR intercooler/heat exchanger. I did think about blocking off the whole of the EGR system so the exhaust gases and the crap it contains stays in the exhaust pipe and no where else.
 
Is it possible if someone checked my post out to see if it is the same issue
2006 stilo jtd sporting turbo not working
Regards
 
Shadey, what do you mean by the EGR "intercooler/heat exchanger"? does the off-shoot of pipe from the exhaust T-off to somewhere other than the EGR valve?
 
Item 1 is the intercooler/heat exchanger that cools the exhaust gasses before they enter the inlet manifold.

Item 6 is the gasket that is used throughout the EGR system.

Bottom left of the diagram is where the EGR pipework connects to the exhaust manifold. As you can see there is a gasket there(item 6). As my blanking plate is a basically a thick version of this gasket I could install it next to the exhaust manifold blanking off the whole EGR system. I think steel blanking plates would be perfect in this position.
 

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Ah yes, that thing. It's basically just a small back box of an exhaust system. You wouldn't happen to know what the pipes "SRG 10402" connect to would you?
 
Ah thats ok then, I was concerned that blanking off the EGR where we have might have shifted the soot build-up into a component connected to one of those pipes, but since the gases don't flow through them then I'm happy enough with where we have chosen to block off the EGR. (y)
 
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