I sent you a PM Sam. There might be some issues with the CA engine.

Lemme know when they're available.

They've been available for years..........LOL.

Send me an e-mail (not a PM) and I'll give you the details.

Email sent you you BrianC

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2005 Accord Hybrid (Wifes)
1995 Subaru Impreza L AWD (Snow car)
1984 GMC Sierra 1500 (Mine)
1983 300CD Best $ I ever spent. (Mine)
1984 190D (sold and glad I did)
1983 300D (sold and wished I hadn't)

OMG OMG OMG i was reading this whole tread since its one of the first thing i do on a older car is deleted the focking P.O.S. EGR valve's but i noticed the first post was back from 2004!!!! lol omfg i didnt know it was that old! i am soo late lol anyways i make custom plate blockers everytime but i gotta admit if brian still had some of thoses i would probably be interested! ......... cya

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1991 560SEL AMG "Jap spec"
1989 560SEL Euro spec

They are still available.

Just send an e-mail for details.

B.C.

What is the benefit of getting rid of the EGR, and how significant is the benefit? Will I get better performance, better MPG, both, or what? And how much better?

Yes, yes, yes, yes, and not a huge amount... I'd estimate maybe 1mpg? The other benefit is keeping nasty soot out of the intake tract, which also has a habit of clogging the ALDA plumbing fittings. Check out the photos below... those are from EGR soot mixing with oil vapor to create a tar-like sludge.

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Check out my website photos, documents, and movies!

1 MPG and it will keep extra soot out of my engine? For 30 bucks?
SIGN ME UP!

One thought. What would you think of the idea of only installing one or the other of the two blockoff plates (whichever is easier), with two gaskets (a gasket on each side of the plate)? Basically just blocking off one end or the other of the EGR without removing the EGR assembly?

The main reason I'd want to do that is to maintain the stock look and to keep it from being obvious that a piece of smog equipment is missing (removed) when I go for my emissions test. Sometimes the emissions testers take a look under the hood, you know...

1 MPG is probably optimistic... figure that as a maximum.

And yes, you can leave the EGR valve in place, with the plate sandwiched in between, to pass a visual inspection - no problem.

Well, THAT was one of the quickest and easiest mods I've done in a while.
Scrounged up a scrap piece of heavy gasket material and a scrap piece of heavy galvanized sheetmetal.
Unbolted the EGR at the upper end, and pulled the stock gasket out to use as a template.
Cut out two gaskets (using scissors) and one metal plate (using tin shears) - without cutting out the center hole in any of them of course.
Sandwiched the metal plate between the two gaskets and put it all back together.

35 minutes start to finish - including 10 minutes spent scrounging the materials.
Cost - $0 since the materials were just scrap I had lying around anyway.

If that even gets me 1/2 mpg it will be the most cost-effective economy-enhancing mod of all time!

FYI, this is an excellent kit, and well worth the $. Brian supplies a VERY nicely finished plate and good looking hardware, plus a MB gasket, the necessary copper disc to plug the EGR port in the exhaust manifold, and thorough directions. VERY easy install. I drilled and tapped the EGR plate to accommodate a hose barb for a pressure port to run my pressure-type wastegate actuator (a mod I had been working on with the help of gsxr's excellent thread).

Thanks for providing this kit. I COULD have scraped together the raw materials to do this myself, but the finish would not have been nearly as nice and I'd have spent a lot of time coming up with the right pieces.

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

I am very curious about the mods necessary for Cali 617 turbo. I just blocked the valve today, but ended with an exhaust leak b/w the trap ox / cat and exhaust mani.
If you remove the valve completely there is no elegant or effective means of blocking off the cat.

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The easiest way to accomplish your goal is to simply disconnect and plug the vacuum line to the EGR valve. The valve cannot open without vacuum and there is no need to install another blocking piece of aluminum beneath the valve.

The kit is only for those that prefer the look sans valve.

Yes, that is a problem. AFAIK, there is no easy way of blocking the exhaust outlet from the cat. The copper disc that I provide with the kit won't work at that location. You'd probably have to weld it shut with a steel plate.