EGR valve blanking/cheating

So today the weather was a bit kinder so I decided to get the hardest job out of the way. I was right about the bolts, the right one came out with great effort but the same effort on the left one simply rounded out the head. So drilled out and retapped job done. So the blank plate is now in and tomorrow I hope to strip out the front clean the manifold reassemble everything fit the Tafmet gizmo and start up.
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All finished! Job was easier than anticipated as once I stripped the front off I could see the rabbit better. The Intake manifold was only bady coked around the throttle valve flange so realistically not worth the pain of a full strip.
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I have also used self amalgamating tape around the joint twixt the throttle motor and body as there isn't a gasket.
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The pins on the wires for the vacuum control unit are really slack so I doubled them over before inserting
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Then bag'd them up
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http://galeria.123.opole.pl/manuals/emu_egr_06_en_dig-3.0.pdf
 
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I bow to you Andy, always a pleasure to follow your threads, especially with the pics as it really helps understand the root of what your doing - Great job (y)
 
Thanks Martin. I've not gone overboard on details as anyone capable of doing this will manage just fine. and the tafmet instructions are repeated at the bottom of the last post.
Anyone wanting anything specific feel free to ask.
 
Now I have obtained a brand new genuine Fiat Catalytic converter for £80 :D
I will set that aside for future but meanwhile belt the guts out of my existing one (y)
I'm due a new silencer so will speak to local custom exhaust guy soon.

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Hi Techno, I'v just seen this very useful post(y), I'm competent enough to maintain my own plant machinery, and vehicles, I was wondering if the above advice from all posters would apply to my 130 Ducato, MultiJet 2007,63000Km,
I cant work out the engine size from the French log book, (it looks like 8cv(hp)
but could it be a 2.8? The advice I'm looking for is; What general maintenance/ precautions can I take for the above problems. Also I'v had similar problems with our Pilot car, Volvo V70 estate(2 burst heater radiators) with similar symptoms as shown in PaulJags Post WARNING WATER COOLED EGR PIPES (y)
 
Pretty sure 130 is a 2.3 Looks very simple, no electronics

Broken Link Removed

DESCRIPTION
ZU_EGR_33
STAINLESS STEEL
EGR valve blanking block plate with gaskets Diesel engines:
FIAT DUCATO with engines:

2.5 TD, 116 HP (1994 -> 2002) for cars with EGR valve
2.8 TD, 122 HP (1994 -> 2002) for cars with EGR valve
2.3 JTD, 110 HP (2001 -> 2006)
2.3 JTD (Russia), 110 HP (2008 -> 2011)
2.8 JTD, 127 HP (2001 -> 2006)
2.3 JTDM, 120/130 HP (2006 ->)
2.3 JTDM, 130 HP (2011 ->)
 
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my EGR valve stuck open on me when in Italy.

It was caked up with soot. Ended up stripping it outside the Pagani factory in Modena to try and clean it. Still wouldn't work.

I ended up buying a brand new EGR valve in Austria and fitting it in the car park as I had nothing to blank it off with. 472 Euros. Kerching. Ended up getting it blanked back home anyway, and had the EGR mapped out completely.

My van has done over 30k per annum on average in it's life. So it wasn't down to little use either.

They are a pain in the arse, on most vehicles.
 
Techno100 said:
You could pour money down the drain with fuel additives but that will only slow the inevitable.
Click to expand...
Ok, what if prepare a blanking kit and hang it from my int mirror just in case!:D

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Frentchy said:
Ok, what if prepare a blanking kit and hang it from my int mirror just in case!:D
Click to expand...
If you study the listing you'll see it covers a number of engines but they illustrate a picture of each. I would aquaint yourself with the one that compares to yours so you are prepared. It looks so easy given that the plate is slotted and access looks far easier than on mine :cry:
I would identify the specific bolts and try undoing them now and copperslip them.
 
Techno100 said:
If you study the listing you'll see it covers a number of engines but they illustrate a picture of each. I would aquaint yourself with the one that compares to yours so you are prepared. It looks so easy given that the plate is slotted and access looks far easier than on mine :cry:
I would identify the specific bolts and try undoing them now and copperslip them.
Click to expand...
Of course by the time the EGR causes problems it will already have coked up the throttle valve so blanking off at that time is not an instant fix
 
Techno100 said:
Of course by the time the EGR causes problems it will already have coked up the throttle valve so blanking off at that time is not an instant fix
Click to expand...

I hope your not suggesting I Finnish my supper and go out in the cold and do it now!!:eek::LOL:. Seriously; are there no advanced symptoms that could forewarn me?
 
First thing will be a check engine warning on the dash

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Techno100 said:
Pretty sure 130 is a 2.3 Looks very simple, no electronics

Broken Link Removed

DESCRIPTION
ZU_EGR_33
STAINLESS STEEL
EGR valve blanking block plate with gaskets Diesel engines:
FIAT DUCATO with engines:

2.5 TD, 116 HP (1994 -> 2002) for cars with EGR valve
2.8 TD, 122 HP (1994 -> 2002) for cars with EGR valve
2.3 JTD, 110 HP (2001 -> 2006)
2.3 JTD (Russia), 110 HP (2008 -> 2011)
2.8 JTD, 127 HP (2001 -> 2006)
2.3 JTDM, 120/130 HP (2006 ->)
2.3 JTDM, 130 HP (2011 ->)
Click to expand...
Although our 2.8TDi is listed, I'm not sure if it does have an EGR valve. I'll have to have a wee look, and if it's present, then see how easily accessible it is first, before checking on what sort of state it is in.

Cheers,

Jock.
 
I have 3 more drives before having a custom exhaust fitted. This should be enough to become accustomed to it before the change.

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Firstly I would like to commend Techo for this superb thread and his tenacity in completing a hugely beneficial project.
I have a 2010 MY 3.0L that had a fully functioning EGR system until I spotted this post. For some time I have been wondering how to go about blanking or removing this hideous system and now the task is complete. All I would add is you don't need to install the blanking plate if you have a low milage engine as I have, simply fit the "electronic mugging" device remove and blank the vacuum hose. Job done. Provided you EGR valve seals internally you have effectively done the same job.
 
Fenn said:
Firstly I would like to commend Techo for this superb thread and his tenacity in completing a hugely beneficial project.
I have a 2010 MY 3.0L that had a fully functioning EGR system until I spotted this post. For some time I have been wondering how to go about blanking or removing this hideous system and now the task is complete. All I would add is you don't need to install the blanking plate if you have a low milage engine as I have, simply fit the "electronic mugging" device remove and blank the vacuum hose. Job done. Provided you EGR valve seals internally you have effectively done the same job.
Click to expand...

so to be clear i have a Euro 5 2.3 Ducato with approx 9,000 miles on the clock, i could fit " a mugging device" ( which is what? a remap or an actual electronic gizmo ) and blank the vac hose.... job done.

Where do i get one of these "Mugging devices"! please
 
Techno100 said:
No the device is for the 3.0 litre only
Click to expand...


come on Andy! surely you can make one, ive got some bits of wire, a bog roll and an old circuit board..:whistle2:

could be a good little earner :clap2:

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