This is for the diesel Hyundai Iload, Imax, Starex, H1, van. It wont make any check engine lights appear on the dash :smile:. Basically just buy the Navara D40 blanking plate, widen 1 hole, and stick it in with no gasket.
1. Buy the EGR blanking plate for the Navara D40 ...it should be a diamond shape stainless steel plate 2mm thick. I paid $6.50 This is the title of the ebay one that I bought but there's lots of different listings and even other engines like mitzubishi use the same plate.
EGR Blanking plate Nissan Navara D40 2.5L TD Euro 5 Spec 2011-ON NO HOLE Steel
the link EGR Blanking Plate Nissan Navara D40 2 5L TD Euro 5 Spec 2011 ON NO Hole Steel | eBay
THE HOLES ON THE PLATE ARE TOO FAR APART FROM EACH OTHER AND YOU HAVE TO GET AN OLD DRILL BIT...STICK IT HALF WAY IN ONE HOLE OF THE BLANKING PLATE AND GRIND ONE HOLE TOWARDS THE INSIDE TO ALLOW THE HOLES TO BE CLOSER TOGETHER SO THAT THE BOLTS FIT IN THE ENGINE THREAD HOLES. Make sure to grind off any metal spurs on the blanking plate after modifying the hole.
You'll see if you try to fit the plate that you need to shorten the distance of the holes by 1mm or so.
2. Unbolt the cover shown in the picture. 12mm bolts( 2 short bolts on the front one, 1 long and 1 medium bolt on the back plate).
Don't loose the BROWN gaskets when you take the cover off.
3. Clean the steel mating surfaces where to the plate will go. There may be an elevated ring of carbon baked on. Clean it off with some petrol on a rag and make the surface flat and clean.
4. Set aside 1 of the brown gaskets and put the plate in ...close it up ...no gasket. If the two surfaces are clean and flat it should seal ok.....well it worked for me anyway. The plate should go on the front hole...closest to where you stand....beside the positive battery terminal. The other gasket stays on the other hole.
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The dirty EGR gasses travel from the hole closest to the windshield... and through the metal tube and down the hole closest to the battery, where they mix with the clean air from the intercooler, and then into the manifold, and into the cylinders.
If your going to the trouble of blanking the EGR, then you should also buy a Mann and Hummel, Provent 200 oil catch can to filter the crankcase blow by gasses which are routed from the top left side of the engine through a rubber hose and straight back into the rubber tube which is the air inlet and then down to the turbo. These oily vapours mix with the EGR gasses and make a sticky mess in the EGR valve and engine intake/manifold.
In the Pics, the blank lid is the Provent 200 oil catch can. Its next to the blue lid which is the windscreen wiper fluid. I attached the plastic provent 200 catch can to the rubber inlet snorkel(pictured near the yellow dipstick) using an old rubber bicycle tube .I also wrapped some of the bicycle tube around the white wiper fluid tube. Its a temporary until I find something more secure, but its pretty secure. Before doing all this I removed the bolt holding the wiper fluid filler neck. I rotated the filler neck slightly to make room and zip tied the filler neck to its mounting bracket and discarded the bolt.
Another place for the catch can is on the back side of the battery between the battery and the fuel filter (windscreen side of the battery).
Note there are some knock off copies of the Provent 200 on ebay. If you pay less then $160 its a knock off as explained here. Fake Provent 100 and 200 from CHINA HP Copy
1. Buy the EGR blanking plate for the Navara D40 ...it should be a diamond shape stainless steel plate 2mm thick. I paid $6.50 This is the title of the ebay one that I bought but there's lots of different listings and even other engines like mitzubishi use the same plate.
EGR Blanking plate Nissan Navara D40 2.5L TD Euro 5 Spec 2011-ON NO HOLE Steel
the link EGR Blanking Plate Nissan Navara D40 2 5L TD Euro 5 Spec 2011 ON NO Hole Steel | eBay
THE HOLES ON THE PLATE ARE TOO FAR APART FROM EACH OTHER AND YOU HAVE TO GET AN OLD DRILL BIT...STICK IT HALF WAY IN ONE HOLE OF THE BLANKING PLATE AND GRIND ONE HOLE TOWARDS THE INSIDE TO ALLOW THE HOLES TO BE CLOSER TOGETHER SO THAT THE BOLTS FIT IN THE ENGINE THREAD HOLES. Make sure to grind off any metal spurs on the blanking plate after modifying the hole.
You'll see if you try to fit the plate that you need to shorten the distance of the holes by 1mm or so.
2. Unbolt the cover shown in the picture. 12mm bolts( 2 short bolts on the front one, 1 long and 1 medium bolt on the back plate).
Don't loose the BROWN gaskets when you take the cover off.
3. Clean the steel mating surfaces where to the plate will go. There may be an elevated ring of carbon baked on. Clean it off with some petrol on a rag and make the surface flat and clean.
4. Set aside 1 of the brown gaskets and put the plate in ...close it up ...no gasket. If the two surfaces are clean and flat it should seal ok.....well it worked for me anyway. The plate should go on the front hole...closest to where you stand....beside the positive battery terminal. The other gasket stays on the other hole.
-------------------
The dirty EGR gasses travel from the hole closest to the windshield... and through the metal tube and down the hole closest to the battery, where they mix with the clean air from the intercooler, and then into the manifold, and into the cylinders.
If your going to the trouble of blanking the EGR, then you should also buy a Mann and Hummel, Provent 200 oil catch can to filter the crankcase blow by gasses which are routed from the top left side of the engine through a rubber hose and straight back into the rubber tube which is the air inlet and then down to the turbo. These oily vapours mix with the EGR gasses and make a sticky mess in the EGR valve and engine intake/manifold.
In the Pics, the blank lid is the Provent 200 oil catch can. Its next to the blue lid which is the windscreen wiper fluid. I attached the plastic provent 200 catch can to the rubber inlet snorkel(pictured near the yellow dipstick) using an old rubber bicycle tube .I also wrapped some of the bicycle tube around the white wiper fluid tube. Its a temporary until I find something more secure, but its pretty secure. Before doing all this I removed the bolt holding the wiper fluid filler neck. I rotated the filler neck slightly to make room and zip tied the filler neck to its mounting bracket and discarded the bolt.
Another place for the catch can is on the back side of the battery between the battery and the fuel filter (windscreen side of the battery).
Note there are some knock off copies of the Provent 200 on ebay. If you pay less then $160 its a knock off as explained here. Fake Provent 100 and 200 from CHINA HP Copy