EGR Blanking off

Hi Guy's was talking to local turbo shop this avo re turbo life of turbo etc on our 06 d22 and asked his opinion on egr mod ,said yes great idea and all they do is put a stainless plate on the exhaust side of egr .Said you don't have to change anything else don't touch vacuum hoses or any sensors .What do you think Chris

Its a good idea Ive done mine. I didnt think twice
it stops all exhaust going into your intake stopping engine problems and turbo

Does anyone know where I can get a stanless plate made up and fitted to my D40 to perform this EGR mod in Brisbane?

Tazz did you do anything other then block off EGR with a plate

No just the blanking plate does all that is needed no engine or turbo problems

is the d40 as simple as block it off too?

not 100% on d40's i have heard of restriting them like putting a plate in with a hole drilled in it say 8mm something like dash lights coming on

FROM ANOTHER FORUM>>>

I have a D40 2.5 since new now has 50000km. I have been searching for a low cost EFFECTIVE way to increase torque at low revs and reduce turbo lag. I have just blocked the EGR line at the hot side of the heat exchanger and it has made a substantial difference and is basically cost free. I have asked many people (mechanics, exhaust specialists, turbo specialists and other D40 owners) and this is the most effective option.
After doing this the turbo spooles up from about 1100 rpm instead of 1500rpm, the turbo spooles much quicker each time you push the accelerator and the car seems to blow almost no smoke compared to the standard d40 cloud every time you accelerate.
Or you could spend 2000-3000 on all kinds of exhaust options which will make the car sound different and do little else.
Or spend 1200-1500 on a 'chip' which will do basically nothing except maybe increase fuel consumption.

1 person suggested removing the rear muffler to reduce backpressure on the turbo allowing it to spool quicker but i have had several mechanics tell me some types of turbos will eventually breakdown from having to force the exhaust through. dunno if this is correct but the egr thing has made enough difference to satisfy me and its tried and tested

The engine will not over boost as the waste gate operation has not been changed, just more pressure input spooling it up earlier creating power at lower revs.

Take the black plastic cover off the top of the motor and look between the main fan and front of the engine block, square thing about 5x5x25cm running horizontal across the front of the motor with flanges both ends joining into aprox 2cm dia. steel pipe is the heat exchanger on the egr line. unbolt the flange at the end of the heat exchanger on the LEFT (exhaust) side of the vehicle and replace the shims with a piece of shim steel cut the same (obviously without the hole for the exhaust to go through). i undid the mounts on the heat exchanger (1 bolt hard to reach under the fan) to allow the new piece to go in with gasket goo on both sides to prevent leaks). I couldnt be bothered finding the shim steel (which is the best idea) so i used a piece of roofing iron. Spoke to a large turbo specialist company and they said they have done this to 6 or 8 d40's without detriment. will try to remember to post pics next week but this is a seriously easy job, took me about 30 minutes.
u need tin snips, sockets i think they were (10,12 and 14 mm) and a piece of tim 10x10 cm will do

look at the facebook link, its got pictures. click next, there are 3 pics of egr removal instructions for d40

Chris T said:

Hi Guy's was talking to local turbo shop this avo re turbo life of turbo etc on our 06 d22 and asked his opinion on egr mod ,said yes great idea and all they do is put a stainless plate on the exhaust side of egr .Said you don't have to change anything else don't touch vacuum hoses or any sensors .What do you think Chris

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YD25 may not need anything but D22 ZD30 certain requires butterfly to be disabled. butterfly blocks off air flow to motor and that air is replaced by egr. if you just block off EGR your left with a motor that is staved of air which is not a good thing for a diesel.
i've seen plenty of reports of motors with similar EGR setups that blow white smoke if they block off egr without disabling egr butterfly. the effective compression drops to low for proper combustion. disable the egr butterfly and it runs fine.

Do you have pictures of how to disable the butterfly tweake? This is what i am after for my d40.

Tommo77 said:

Do you have pictures of how to disable the butterfly tweake? This is what i am after for my d40.

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as mentioned already, its not needed on the D40. it runs variable turbo to shove the egr in instead of a butterfly system. just block off the egr and its all done.

Yeah should of read a bit more into it the thread, thanks for the info mate.

Good Moaning to all,
Still reading with interest re EGR blanking......and still seaching for concrete answers b4 doing this mod to my 09 2:5ltr CRD D22. Im led to believe that the D40 has a variable vane turbo - and that the D22 08/09 model doesnt - therefore -for a D22-D22-D22-D22 - is it a matter of just blanking the EGR pipe or are there other mods / adjustments that need to be made - eg wastegate - (if applicable). Am sorry to be such a pain - I am a NSW Firie.....not a diesel mechanic - - and I come to a site like this RESPECTING other peoples' knowledge and experiences that in this field are obviously more extensive than mine. Thank you in advance for any advice you care to impart re this matter.

as far as i can tell the only thing you need to do on a 2.5 CRD D22 is block the egr. i can't see any mention of a butterfly in the manual. i don't have the 2.5 so i can't go check.

nothing needs doing as far as wastegate etc goes just plate the egr off and its all done.
only thing that concerns me is that they may be running a really tiny turbo to get enough back pressure to push enough egr in. just keep an eye on the fuel economy after blocking egr.
other than that worse possible thing is ecu may pick up that egr is blocked and you get malfunction light come on. however i have not heard of that happening yet.

Just tried to undo the bolts but they are way too tight, might be corroded, any ideas?

wd 40 longer spanner

Yeah but they may break and i dont want to fork out to buy the whole new part.