Member Since: 07 Feb 2007
Location: Midrand
Posts: 4054
EGR blanking procedure
Hi all
At long last , as promised , herewith the thang . I have found J Moore's original post with pics which I have also included . Between the two sets of pics you should get a good idea of what to do
Member Since: 22 Mar 2008
Location: BURY,LANCS
Posts: 2758
hi
quick question
if your blanking off the egr's do you have to remove the butterfly?
surely by blanking the egr then the butterfly will become redundant anyway
dunc life is tooooo short.enjoy the moment.dont worry be happy
club BSS
14th Jan 2009 11:19 pm
TazDaz
Member Since: 07 May 2007
Location: South East Essex
Posts: 2858
heine
excellent pics
14th Jan 2009 11:30 pm
philhunt
Member Since: 16 Sep 2007
Location: MI5 not 9 to 5
Posts: 1761
Now the pictures have been found again, can a kind mod now make this a sticky please?
14th Jan 2009 11:33 pm
blue meanie D3 Decade
Member Since: 04 Aug 2005
Location: Newbury
Posts: 6861
nicely done Heine going to do mine when the weather improves so will be very helpful, thanksand theeeeennn......???
14th Jan 2009 11:34 pm
Russell
Member Since: 24 Aug 2007
Location: Kent
Posts: 10564
Heine
top man MY17 D5 1st Edition Namib Orange
MY15 D4 HSE Kaikoura Stone
MY12 D4 HSE Nara Bronze Sold and gone
MY11 D4 HSE Stornaway Grey Sold and gone
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Tow bar, full length roof bars, side steps, tow bar storage unit, surround camers.
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14th Jan 2009 11:40 pm
heine
Member Since: 07 Feb 2007
Location: Midrand
Posts: 4054
POINTYED wrote:
hi
quick question
if your blanking off the egr's do you have to remove the butterfly?
surely by blanking the egr then the butterfly will become redundant anyway
dunc
Yes you do - but I can't give you the exact reason why
Hopefully Koos will be along soon
15th Jan 2009 6:50 am
Discoeast
Member Since: 19 Feb 2008
Location: Boksburg
Posts: 800
You must remove the butterfly, now that the blanks are in place and
the butterfly were to close, there will be excessive vacuum created in
the inlet manifold. Some thing will give in and get sucked into the
engine and could be a very expensive repair D3 bullbar-spots-roof rack with spots-ladder-long range tank-swing out spare wheel carrier- upgraded tow bar-dash console-internal water tank-duel awnings-drawer system & T T.
15th Jan 2009 7:46 am
POINTYED
Member Since: 22 Mar 2008
Location: BURY,LANCS
Posts: 2758
cheers
that bad eh?
thanks for explaining
dunc life is tooooo short.enjoy the moment.dont worry be happy
Got a set of plates so am going to do mine when the weather warms up a bit and those pics will help a lot.Now an ex-D3 owner after 7 happy years. Miss the car but not the big bills
Thanks Heine Have a nice day!
2010 Cayenne Diesel with PASM & Off Road Pkg
2005 HSE D3 (Sold)
15th Jan 2009 10:25 am
simonsi
Member Since: 14 Oct 2007
Location: Auckland
Posts: 1264
Discoeast wrote:
You must remove the butterfly, now that the blanks are in place and
the butterfly were to close, there will be excessive vacuum created in
the inlet manifold. Some thing will give in and get sucked into the
engine and could be a very expensive repair
IMHO nothing is likely to get sucked in unless already loose in the intake tract. The inlet between the butterfly and the cylinders is engineering (hard) plastic or metal, nothing that will have any problem withstanding 15psi which is the max vacuum you can ever achieve at sea level.
The butterfly serves to force the necessary pressure differential in order to efficiently draw in the EGR gasses. The trouble with this is that it achieves this by throttling off the supply of clean, fresh air from the turbo. This has two effects:
Firstly it reduces the clean air content in the cylinders and inlet tract/manifold after the butterfly.
Secondly it reduces the overall volume of gases going through the cylinders and out of the exhaust into the turbo turbine side (ie the bit that causes the turbo to spin). This is because there is gas circulating cylinders->EGR->inlet->cylinders but there is a loss of volume of gas down the exhaust to atmosphere hence the volume circulating reduces....This leads to a decline in turbo speed and boost, causing, under the right circumstances, a lag when the throttle is reapplied while normal airflow is restored, the turbu spins back up and boost is restored.
Removing just the butterfly would reduce the effect of the EGRs being open as the necessary pressure differential is much reduced, and the turbo lag would be much reduced also as the supply of boost air through the engine is not being throttled off.
IMHO removing the butterfly is primarily a driveability mod/improvement.
Blanking the EGR valves is primarily a reliability mod as they can't stick open and screw the power the engine can deliver.
Doing both means you get a 2+2=5 effect.
I have both mods on my D3.Cheers
Simon
15th Jan 2009 10:42 am
Tawny Owl
Member Since: 22 Oct 2008
Location: Here and there
Posts: 1645
Thanks Heine , great pictures along with good info
Cheers to simon for his great explanation too , i will be doing mine when the weather gets better
15th Jan 2009 8:28 pm
paxo
Member Since: 11 May 2007
Location: Chepstow
Posts: 21
EGR blanking plates......HELP !
Fantastic instructions on fitting the EGR plates, except they dont account for me dropping the last bolt and gasket from the EGR flange.
It will be under the steel plate benieth the engine .... no !!! Ok it will be forward of that ....no !! on the chassis, wishbone, no,no,no. Eaten by the Disco some where.
Anyone got some bolt and a gasket in exchange for some beer vouchers ?
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and could be a very expensive repair 
