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EGR Blanking plate DIY


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#1 matsmith749

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Posted 06 October 2008 - 10:12 PM

I've just pulled the vacuum hose off my EGR & plugged it with a rivet (nice tight fit).... the car runs much better.

My problem was a slight pulsing/surging when at light throttle & constant speed if the revs were around 1800rpm - seems a common issue.

Anyhow - the check engine light is now on. I fancy knocking up a blanking plate for the EGR & maybe having a small hole to hopefully fool the engine management. Does anybody have a picture of one of these plates / guide to making one yourself?

Also which bit do I need to blank off (which opening on the EGR)?

My car is a 2004 130bhp TDCI, it has what look like a sensor connected to the end of the EGR (but it is vacuum operated - no motor). Is there any point just leaving the connector unfastened?

Cheers!
2004 Ford Mondeo 2.0TDCI 130 horrible bluey green colour, cloth interior (with feature stains) and loads of little gremlins (some under bonnet, some in glovebox, some hiding behind stereo.... allover really).

My Mods so far: Decat, RoverRon tuning box, parking beepers, Colour coded exterior trim, osram nightbreakers, front fogs, Sony 6 cd, front footwell lights, EGR blanked/unblanked, AUX drivetrain comps replaced, MINTEX brakes, 18in ST TDCI wheels


#2 Marty TS

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Posted 06 October 2008 - 11:06 PM

if you ask graemewelch who is often online he will make you 1 for about £5, the bit that gets blank off the the silver pipe that comes horizontal into the EGR valve
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#3 Adi69

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Posted 07 October 2008 - 01:44 PM

There is a common issue with blanking plates being used on Euro IV cars. Not all of them, but certainly some of them. I have a blanking plate in and now the hole in the plate currently at 6mm and still the EM light has come on through lack of EGR flow. There is someone on here that has an even larger hole, and still the light came on.

I had/have the same hesitation problem at around 1800rpm. The only way I got rid of it, was to turn the ignition on, and disconnect the electrical lead to the EGR. That way, the EGR is closed at all time. Then the hesitation disappeared. I have since replaced the EGR valve, connected it back up, and fitted the blanking plate. The hasitation is back......albeit slightly further down the rev range, but its back

#4 philwalker

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Posted 07 October 2008 - 04:33 PM

if you remove the gasket that is between the egr and exhaust...you can use it as a template to make a blanking plate :kaffeetrinker_2:
After 11 years in MK 3 Mondeos...My company have moved me on to a Vauxhall Insignia Sport Tourer

#5 graemewelch

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Posted 07 October 2008 - 06:03 PM

as above and youll end up with somthing like this

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#6 bicolormoth

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Posted 11 October 2008 - 12:23 PM

could you not just use a small clamp on the rubber hose (inlet?).
that way it could be removed or refitted quickly.

i am wondering , though, why Ford went to all the trubble of making this EGR valve, if the engine runs better without it. :eyesup: ?
Mondeo 2.0 TDDi Ghia Diesel Estate 2001 "Y" 145,000m
1st Mod: K&N Air Filter
[color:red]Next Mods: K&N 57i Induction kit ; black eyes ; EGR ; nicer wheels ; oil catch tank[color:red]

#7 bicolormoth

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Posted 11 October 2008 - 08:25 PM

ahhhh i get it now. the EGR is there to minimise exhaust emissions, but it reduces MPG & Performance.
block it off for fun & unblock it for MOT :driving:
Mondeo 2.0 TDDi Ghia Diesel Estate 2001 "Y" 145,000m
1st Mod: K&N Air Filter
[color:red]Next Mods: K&N 57i Induction kit ; black eyes ; EGR ; nicer wheels ; oil catch tank[color:red]

#8 Welsh Dan

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Posted 12 October 2008 - 01:22 AM

How does the sensor inside the EGR work? If anyone knows that then it might be possible to fool it.
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#9 graemewelch

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Posted 12 October 2008 - 12:18 PM

might have a plan for this but need some 1 to be my ginypig (i know my spelling is sh*te).

#10 minneyx

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Posted 14 October 2008 - 03:44 PM

What is your plan?




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