I have been wanting to block off the EGR on my Diesel.

I thought about making a couple of block off plates one for each end. Then my EGR unit could be removed and stored away. I decided on a more subtle solution. I made a single block off plate and put it at one end of the flex tubing. I shaped the plate and put it inside the flex pipe at the coupling and just reassembled it.

The engine has much better low end power. Is the turbo spinning faster? Will it help my economy? Might not. After all some of the power that I can get is from the unburned hydrocarbons which are no longer being circulated. I am guessing that the system was not functioning as designed. Seeing how black the intake manifold looks around the egr port makes me realize how much carbon has been blown through the engine.

Here is the disk.

I made it from some 20ga standard steel that I got from a friend who is a fabricator.

I still don't have my boost gauge, it should arrive in the next few days. I don't have an EGT either.

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85 Merc 300D - Unwinding 31 years of wear
86 VW TD
Mahindra Diesel
Iseki Diesel

In 2007 I didn't own a diesel.

There is a kit that is made:

EGR blocking plate kit

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

A Kit?
What fun is that.

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85 Merc 300D - Unwinding 31 years of wear
86 VW TD
Mahindra Diesel
Iseki Diesel

In 2007 I didn't own a diesel.

does anyone know if that plate kit can be used with the egr bolted on top of it so the car will still pass a visual for state inspection?

or would a piece of #10 can work?

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1982 300sd from craigslist $800 greased on one tank with NO CONVERSION in the Hot Texas Sun. (currently dead & awaiting engine damage investigation and/or longblock swap)
new daily: '03 vw 5speed jetta tdi wagon. bagged&chipped

I would think that you could use a plate under the valve or in either of the connectors and keep it all hooked up. My plate is a bit smaller than the ones that I have seen for sale.

Keeping it looking stock is kind of important. Alway when trying to resell or pass inspection.

Edit: A piece of thin can material might work for a while but it will probably burn through. The material that is used for the accordion is a type of stainless steel not very thick but probably well made.

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85 Merc 300D - Unwinding 31 years of wear
86 VW TD
Mahindra Diesel
Iseki Diesel

In 2007 I didn't own a diesel.

You live in Texas. What are you talking about state inspection of an EGR for?

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

It should work, check out the photos of the plate (near the bottom) on this page.

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This car had a history, now it has a future.

Learn more about my Benz here.

To answer the question, yes, you can screw the EGR on top of it with longer bolts. Keep the bottom tube disconnected and the block off plate installed on the exhaust manifold.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

That is pretty much how I made one except for the material. I was worried about leakage and figured that in the event of failure I had the stock system in place and wouldn't be spewing exhaust all over the engine compartment.

I figured that the heat and pressure might distort or crack the plate.

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85 Merc 300D - Unwinding 31 years of wear
86 VW TD
Mahindra Diesel
Iseki Diesel

In 2007 I didn't own a diesel.

?? texas has visual test for all emissions equipment. lots of places are becoming more strict.

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1982 300sd from craigslist $800 greased on one tank with NO CONVERSION in the Hot Texas Sun. (currently dead & awaiting engine damage investigation and/or longblock swap)
new daily: '03 vw 5speed jetta tdi wagon. bagged&chipped

I guess I will find out in December. Worst case, I drive the car without an inspection sticker.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

Why not just put a steel ball in the vacuum line to the EGR valve?

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'83 300D, 126K miles.

Thought about doing that but I could suck air through the valve without air pressure or vacuum on the diaphragm.

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85 Merc 300D - Unwinding 31 years of wear
86 VW TD
Mahindra Diesel
Iseki Diesel

In 2007 I didn't own a diesel.

Remove the EGR valve off the intake manifold, and I bet it is so plugged up with crap it isn`t working anyway.

When I removed the one off my 85 it was so plugged it was hard to push in a screwdriver. your whole intake manifold will have a thick layier of goo.


I have since replaced (I have a Kali Kar) intake/ex manifold, turbo, and down pipe to a Fed spec, more or less. Iam using the manifolds from a 78/79 300SD. no EGR. much cleaner.


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

I had the same experience when I removed my EGR. Be careful not to push that crap into the intake manifold or you might have some unexpected results.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge