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Thread: Vectra C 2.0DTi EGR Blanking...

  1. #1
    Regular Member TonyP2020's Avatar
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    Vehicle : Mokka

    Trim : SE - Orange Rock 's !!

    Engine : 1.7CDTi

    Year : 2014

    Default Vectra C 2.0DTi EGR Blanking...

    .....yes another one.
    I took the cover above the EGR/Inlet manifold of today.
    It must be the easiest thing in the whole car to remove.
    I last did this at the end of April, and had cleaned it out as best as i could without dismantling it further.
    Anyway inside was sooted up again.
    Looking inside the manifold and figuring out the airflow, I think that the exhaust flow into the inlet manifold can take 2 paths.
    One is the half round cut-out in the Inlet Manifold, and the other way is up into the cover and the exhaust flog joins the clean air in the cover.

    So how to block the exhaust gas flow.
    I have fitted 4x 40mm repair washers (40mm diameter, 6mm hole in the middle, about 2mm thick, mild steel, BZP) loosely into the area just above the EGR outlet. They do not fit properly.
    I choose 40mm washers because that is the size (width) of the opening.
    They do not in any way completely block the exhaust gas flow, but they must slow it down.
    The 40mm washers cannot be sucked up into the inlet manifold, I checked.
    The next step is to bend some 6 more 40mm washers at an angle of about 30 degrees just above the centre hole.
    Then they might fit the shape of the inlet a bit better. I will do this at work next week.
    Just before re-placing the inlet manifold manifold i sprayed some Brake Cleaner onto the sooty deposits.
    When the engine finally started, it rev'ed right round into the red zone on the tacho'.
    I switched the engine off, but it continued to run for about 10 seconds, with the rev's falling and then stopped.
    Thankfully it started again with no nasty noises.
    Driving it shows a small improvement, and it seems a bit more lively, but I have only done about 20 miles.
    I will report back when I can, and include photo's.

    Next step is de-cat. Anyone on the Wirral had it done, and if so, where please??? Thanks in advance.

  2. #2
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    Vehicle : Vectra

    Trim : Design

    Engine : 1.9CDTi

    Year : 2005

    Mileage : Lots

    Default

    I got mine de-catted by Peco Exhausts in Birkenhead and paid £70. Seems if I'd shopped around a bit and gone to Powerflow in Wrexham I think I could get it done for £30 or somewhere around that. It really can't have liked the brake cleaner!

  3. #3
    Regular Member TonyP2020's Avatar
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    Vehicle : Mokka

    Trim : SE - Orange Rock 's !!

    Engine : 1.7CDTi

    Year : 2014

    Default

    1. General view of engine bay, showing the inlet manifold.
    2. Inlet Manifold cover removed, showing the 4 straight washers i put in there on Saturday.
    3. 6 new washers, bent at about 30 Degrees just above the centre hole.
    4. Close up of washer shape.
    5. 6 bent washers in place. There are still some gaps around the washers, but hopefully about 90% of the gap is plugged.
    In my first post I said that the washers were about 2mm thick, this is incorrect, they are about 1mm thick.
    Last edited by TonyP2020; 25th July 2011 at 18:52. Reason: extra info

  4. #4
    Regular Member TonyP2020's Avatar
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    Vehicle : Mokka

    Trim : SE - Orange Rock 's !!

    Engine : 1.7CDTi

    Year : 2014

    Default Part 2

    1. Old washers showing soot deposits, after less than 100 miles.
    2. Back together again.
    30 Minutes to do, not including bending the washers.
    Disconnect the Boost Sensor cable to avoid straining the conductors.
    E10 Torx socket and a bit of grease for the metal gasket.
    The inlet manifold cover had to be pushed gently to go down all the way with the bent washers in, as the bent washers touch one side of the inlet manifold cover.
    Hopefully this means they wont rattle or move about.
    Last edited by TonyP2020; 25th July 2011 at 18:57.

  5. #5
    New Member melvyn8181's Avatar
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    what does putting them washers in there do?

  6. #6
    Regular Member TonyP2020's Avatar
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    Vehicle : Mokka

    Trim : SE - Orange Rock 's !!

    Engine : 1.7CDTi

    Year : 2014

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    They block the flow of exhaust gases into the inlet manifold when the EGR is open.
    I hope.

  7. #7
    New Member melvyn8181's Avatar
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    excuse my dumbness but why would you want to do that ?

  8. #8
    Regular Member TonyP2020's Avatar
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    Trim : SE - Orange Rock 's !!

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    Default

    Quote Originally Posted by melvyn8181 View Post
    excuse my dumbness but why would you want to do that ?
    Well I thought I would start yet another "Blank off the EGR on a 2.0Dti" thread but this time actually put forward a simple idea to actually try and (partially) blank off the EGR on a 2.0Dti engine in order to try and cut down on the amount of exhaust gases getting into the inlet manifold and which, over time, causes the inlet manifold to soot up and cause poor running.
    Last edited by TonyP2020; 26th July 2011 at 23:02.

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    Vehicle : Golf 7

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    Quote Originally Posted by TonyP2020 View Post
    Well I thought I would start yet another "Blank off the EGR on a 2.0Dti" thread but this time actually put forward a simple idea to actually try and (partially) blank off the EGR on a 2.0Dti engine in order to try and cut down on the amount of exhaust gases getting into the inlet manifold and which, over time, causes the inlet manifold to soot up and cause poor running.
    Make yourself up a plate m8. Don't put loose bits of metal into the manifold - yeah they probably won't go anywhere but I'd imagine they'll make a racket. Plus the exhaust gases will still get round them.

  10. #10
    Regular Member TonyP2020's Avatar
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    Year : 2014

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    Quote Originally Posted by Gazza4 View Post
    Make yourself up a plate m8. Don't put loose bits of metal into the manifold - yeah they probably won't go anywhere but I'd imagine they'll make a racket. Plus the exhaust gases will still get round them.
    Hi gazza, thanks for the reply.
    Yes I am considering the idea of making a plate the shape of the gasket but leaving the bit above the EGR solid, plus a folded down half round bit to cover the cut out in the inlet manifold itself.

    First step is to scan the gasket and make a drawing, then see if the laser cutters, who do a lot of stuff for my workplace, can make it in 2mm thick steel.

    I do realise that the washers seem a stupid idea at first look, but they are simple, cheap, easily available, they are held in place by the top cover, are too big to be sucked into the engine, and cut out about 90% of the exhaust gases.

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