EGR blank

[nbuuifx]

I'm interested in this, I've ended up blanking off nearly every EGR I've had, usually too late (ie when it's causing a problem and has already gummed everything up)

I've got no EGR issues at the moment but would prefer to get rid before I do get any issues.

I believe I have a EURO3 model (8th digit of VIN is a 3)
I have a 2004 2.0d

So can I blank away?
Where do I need to blank?
The last couple I have done I just removed the EGR then used the gasket as a template to draw around on some sheet alloy, then cut out with aviation snips and drilled the holes then put it all back together with a bit of instant gasket applied - will this approach surfice on the volvo?

[EricMe]

I'm sure it would, but this eBay seller
http://www.ebay.co.uk/itm/1108187289...ht_1899wt_1390

suggests that loosening the connection at the exhaust manifold end of the connecting pipe and sliding his plate in before retightening would be much easier. Not quite as easy as he suggests though - his picture is of ame engine in a Peugeot but a V50 has engine mounted a bit further back so something of a knuckle scraper to access those bolts (but removing EGR completely would be even worse).

[nbuuifx]

Thanks for that, looks more awkward than previous cars and doesn't have a gasket for me to trace around! I may just get one at that sort of price.

So is that all that I need for a Euro 3 model and it will stop it without bringing up any errors?

[v40bart]

Yep, all you need. Yours is a dumb version which is vacuum actuated and there is no feedback from it so ECU is no wiser. Euro 4 is a tree-hugger wet dream, if you blank it for long enough it will stop you from enjoying your car.

[grin factor]

Originally Posted by VenomS40

Yeah I guess your right in what your saying about, I do like the idea of a 3mm hole to start with and go from there.

Going back to the solid plate, does anyone know if a remap will be enough to stop the light coming on once fitting a solid plate?

If you are getting the car remapped ask about this, I would think they may be able to alter the ECU to suit

[EricMe]

Originally Posted by EricMe

I'm sure it would, but this eBay seller
http://www.ebay.co.uk/itm/1108187289...ht_1899wt_1390

suggests that loosening the connection at the exhaust manifold end of the connecting pipe and sliding his plate in before retightening would be much easier. Not quite as easy as he suggests though - his picture is of ame engine in a Peugeot but a V50 has engine mounted a bit further back so something of a knuckle scraper to access those bolts (but removing EGR completely would be even worse).

I've finally got round to fitting my blank. It was indeed a knuckle scraper to access those bolts but not quite as bad as I'd feared. Two of them - both 10mm heads. That nearest front of engine loosened easily with a socket on a long extension bar. The other is a bit harder but would probably loosen OK if you used a flexible drive (I have one but couldn't find it today !). By groping about with a 10mm ring spanner it was possible to loosen it a couple of flats, thereafter the straight extension fitted at a bit of an angle was able to undo it further.


With blank plate installed 'as is' I went or a test drive but had to abort after 100 yds with “Engine System Service Required” message
Tried again with 2 holes each 3mm diameter
Also aborted after 100 yds – same error message
Drilled one hole out to 6mm
“ESSR” appeared after approx 7 miles of test drive but no real ill-effects; still able to rev to 400rpm (not that I often need to)
Drilled another 6mm hole
Went for 15ml test drive with no warning message.

Very difficult to measure internal pipe diameter at first although measuring the 'sooty circle' after the 10 ml test drive showed it to be around 25mm.

Area of whole pipe is therefore 25 x 25 x Pi / 4
A 3mm hole has area 3 x 3 x Pi / 4
Each 6mm hole has area 6 x 6 x Pi / 4

I'm therefore allowing exhaust gasses to flow through holes totalling (9 +36 +36) x Pi / 4 instead of Volvo's 25 x 25 x Pi / 4
i.e effective area of pipe is now 81/625ths (= 13%) of original spec so around 87% of gasses that would have ben recirculating aren't. It won't be quite that effective of course as throttling it down at one point isn't quite the same as using a tube of that size all the way but it's a reasonable approximation.

Now commencing a series of comparative mpg tests but it will probably be another month before I can decide if it was worthwhile.

[VenomS40]

EricMe - Great little review there thumbs up to you! So you think around 13% of the gas' is only getting back into the manifold now then if I'm reading that correctly?

[EricMe]

Originally Posted by VenomS40

EricMe - Great little review there thumbs up to you! So you think around 13% of the gas' is only getting back into the manifold now then if I'm reading that correctly?

Probably a little bit more than 13% but gas flow modelling is extremely complex and I wouldn't even want to try calculating an exact figure. Doubt it would be as much as 20% though.

Consensus of opinion here seems to be that not recirculating is going to improve mpg, performance etc. Recirculating 13% of the pipe's capacity must be seen as better than recirculating 100%

N.B. the %ge I'm quoting is of the designed recirculating load and that's going to be nowhere near the toatal exhaust gas generated

[v40bart]

I am now running 8mm hole blank, no problems so far.

[VenomS40]

Originally Posted by EricMe

Probably a little bit more than 13% but gas flow modelling is extremely complex and I wouldn't even want to try calculating an exact figure. Doubt it would be as much as 20% though.

Consensus of opinion here seems to be that not recirculating is going to improve mpg, performance etc. Recirculating 13% of the pipe's capacity must be seen as better than recirculating 100%

N.B. the %ge I'm quoting is of the designed recirculating load and that's going to be nowhere near the toatal exhaust gas generated

As long as the ESSR message stays away then I may go and give this a little try. Interested in hearing your findings on MPG after a months use Will be keeping an eye on this post.