EGR Blanking Plate Very Bad Mistake

[savi18]

About four weeks ago made up a EGR blanking plate out a coke can and fitted it to my 1997 Transit 2.5di Smiley, well yesterday coming back from a 100 mile round trip lots and lots of black smoke from exhaust on acceleration I mean it was bad, got home and first thing I checked was EGR blanking plate and as you can see in photo half of it gone no doubt sucked into the engine, so tied open the butterfly valve and took van for a run and almost straight away 90% less smoke and the after around 8 miles no black smoke at all, now I’m hoping the small bit of coke can will have pushed out through the exhaust valves being very thin and soft aluminium and not got stuck down side of the piston, no funny noises or rattle from the engine, it runs really well, what you think guys and I know stupid to make blanking plate of coke can and really cursing myself for doing it, looking to get blanking plate from UK and ships to New Zealand, none available here to buy.

[Altransit]

Disconnecting the operating arm and tying up the butterfly (in the open position) is the recognised way of disabling the EGR valve on these engines.
There's no need for the faff of fitting a blanking plate, but if you must, it should be a thicker piece of steel plate

[g-man]

Spot on Al, I’ve had a blanking plate on since I had to have the Inlet manifold degunked about 14yrs ago

[andz327]

Spot on Al, I’ve had a blanking plate on since I had to have the Inlet manifold degunked about 14yrs ago

Bet it's not a wafer thin Aluminium coke can

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[gotgcoalman]

Made mine from stainless many years ago

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[T350camper]

I'm going to make a blanking plate for my Mk6 tomorrow (135bhp 2.4). I'll use 0.8mm steel, so it won't blow through but wondering about bringing on an EML or causing an issue. The EGR is a simple one with just a vac pipe and no electrics. Some people think it will be fine and others do not. I've also heard that drilling a small hole in the plate to allow for the MAF to detect a differential will prevent a problem. Anyone done this to a Mk6 (2006 RWD 6 speed) ?

[knobby1]

I'm going to make a blanking plate for my Mk6 tomorrow (135bhp 2.4). I'll use 0.8mm steel, so it won't blow through but wondering about bringing on an EML or causing an issue. The EGR is a simple one with just a vac pipe and no electrics. Some people think it will be fine and others do not. I've also heard that drilling a small hole in the plate to allow for the MAF to detect a differential will prevent a problem. Anyone done this to a Mk6 (2006 RWD 6 speed) ?

Just blank it, the Mk6 TDCi doesn't normally throw a fault light/code. Putting hole in the plate defeats the purpose of blanking it in the first place.

Lotf Knobrot

[T350camper]

Thanks. Van pulls well but idle can be erratic and very light throttle is lumpy with some smoke. I'm pretty sure the EGR is opening too much. (no fault codes). Today's job

[T350camper]

Made a blanking plate out of 1mm stainless steel. Then took a 20 mile roadtest (hardly comprehensive, but enough to see how it runs). All the hesitation and harshness is gone. So is the smoke. Pulls very smoothly now, even at low speed on light throttle. No warning lights so far. The idle is still a little lumpy (although better than it was). Maybe that's something else. Anyway...thanks for the advice

[sentenza13]

Hello
I am looking to make a blanking plate before dismantling to close the EGR valve.
Do you know the dimensions and measurements to make this plate?
for MK6 TDDI 125ch
Thanks

[T350camper]

Okay, this is what I did (mine is a RWD 2.4 TDCI). Unbolt the metal pipe that joins directly onto the EGR valve. Use the metal gasket as the template to mark out on a piece of metal. Make sure it's a decent piece of flat metal so it wont blow though over time. Make it nice and neat and use it to replace the original gasket (obviously without the big hole in the middle ). I also used a high temperature sealer to prevent exhaust gas leaks. Wellseal is really good.

After fitting I found the van drove so much smoother and witnessed a drastic reduction in visible exhaust fumes. Don't thousands of miles since then with no EML or other issues except a slightly lumpy idle...which I can live with. I think the later (cleverer?) models need to be mapped out? Mk6 should be fine.

[sentenza13]

egr plaque.jpg

I found it.
works on mk7 too