EGR/Butterfly Mod Super Thread

[harri3e]

This post is essentially a collection of all images I found on here that are useful for performing the EGR/Butterfly mod as requested by some.

 

[harri3e]

and more....
enjoy....

 

[rectie]

very helpful but in the third picture do you have to block up just 1 or both 1 and 2?

 

[reddog]

Thanks

Thanks for the updated drawings harr13e. Will have to have a go at it now.

 

[harri3e]

you can put the blanking plate in at either 1 or 2, doesn't matter. I did on the inlet manifold (1).

 

[drew_man]

i was struggling to see what was happening in the real picture but rally great view with the adobe pictures. this is a really good site keep up the good work

 

[drew_man]

was just about to do it and know what to do with the vacuum pipes and say something about unplugging the solinoid or can you just change the vacuum pipes ?????

 

[tweak'e]

changing the vac pipes is the main thing (as well as blocking off the egr). disabling (pulling the plug) the swirl butterfly is an optional extra. some people do, some don't.

 

[drew_man]

true so all i really need to do is block the inlet pipe with a bit of 2mm stainless plate and change the vacuum pipes

 

[tweak'e]

true so all i really need to do is block the inlet pipe with a bit of 2mm stainless plate and change the vacuum pipes

yes thats all it is, fairly basic and easy enough to do.

 

[drew_man]

great thats alot eiser than i thought i got mixed up there some where but is all good now thanks for all the help mate

 

[mariomcarvalho]

this mod is for the D40 engine? why does it needed to change the vacuum pipes. isn't the plate enough?

by the way...how can i get the drawing of the plate? thank's

 

[tweak'e]

this mod is for the D40 engine?

no.
for starters its in the D22 section
its for the ZD30 motor only not any other motor at all. tho the basics are the same for a lot of motors that don't have variable turbo's.

 

[Simonness]

Hey guys,

Anyone selling those Blanking Plates?

 

[tweak'e]

Hey guys,

Anyone selling those Blanking Plates?

mate, have you got a drill and a hacksaw/side cutters? make your own in about 30 seconds.

 

[Simonness]

yer i got the tools.

what kinda materials should i use? i know stainless is the best so far but thats hard for me to come across.

anything else i can use?

 

[Simonness]

btw, what size,type of tubing can i use? is it 6mm(internal) PVC tubing?

 

[will]

I did mine yesturday with a small plate of 2.5mm steel.

i've noticed the car is quieter with better throttle response and i even accelerated up a hill in 5th that i normally had to change down into 4th to climb. havent noticed too much change to getting off the line, but that may change as the carbon buildup burns off. overall it seems very similar but with many small differences that make it well worth while.

This mod is definitely recommended.

here are some pics i took after making the plate.

my plate & the standard EGR gasket.

EGR Gasket width

EGR Gasket length

My handy work - works great.

 

[jap55s]

thankyou for this thread. it makes me understand the mod alot better. ill ive it a go, and if it dont work, ill call nrma, and say " i have nfi whats wrong with my ute "
any wires need to be changed? or is it just hoses? etc

 

[BOOGZ STR]

About to give this a crack in halfa, anyone got a pic of the position of the exhaust manifold blocking point?