Installed EGR Blanking Plate - Sputtering - UPDATE - FIXED!

[gsaruk]

So I just finished installing the EGR blanking plate per the instructions posted on the site (very helpful), and have noticed a significant improvement in performance. I installed both plates. The only problem is that I am now getting intermittent sputtering at full throttle.

Did I screw something up?

Thanks.

**********UPDATE**************

Thank you to everyone that provided suggestions. I am happy to say the sputtering has stopped. It seems like the sputtering was the pop off valve (thanks, Luna-Sea). When i had reinstalled the metal pipe, I believe I had somewhat pinched the hose to the wastegate actuator. I basically undid everything and put it all back together, being sure to let this hose run freely, and viola! Problem solved.

Thanks again.

[mararmeisto]

Did you plug the vacuum hose?

[gsaruk]

Did you plug the vacuum hose?

Yes, a few minutes after pulling it off though.

[legionnair]

Full throttle under load or or in neutral?

[gsaruk]

Full throttle under load or or in neutral?

Haven't tried in neutral. It sputters when I floor it and when climbing at a decent speed. Pretty much anything around 3000 RPMs.

[Luna-Sea]

Hey,
My guess would be you have a bad seal on the EGR intake block plate or a somewhat clogged fuel filter.
I used some high temp sealant around my block plates.
Please post what you find.

Good luck!

[gsaruk]

Hey,
My guess would be you have a bad seal on the EGR intake block plate or a somewhat clogged fuel filter.
I used some high temp sealant around my block plates.
Please post what you find.

Good luck!

Which one is the intake?

[legionnair]

If you look down in the hole where the intake hose is it is the plate to the right. I would also check the fuel filter (like above post suggested),wastegate opperation, and double check the vaccum line

[gsaruk]

Just a few details to add...

The sputtering does not occur in neutral.

It only seems to occur during high RPM's and stops as soon as the vehicle shifts.

It is a very rapid sputtering.

I switched the screw in the vacuum hose, no change.

Question - Several of you have suggested a clogged fuel filter. Why would this have started in conjunction with installing the blanking plate?

Somewhat stupid question - Where is the fuel filter, and what size do I need to replace it?

Thanks.

[tonydca]

Rapid sputtering sounds like fuel starvation. Now that your engine is getting cleaner air without the EGR, it might be running too lean (if it was "tuned" to run as well as possible before with the EGR).

Maybe fuel (IP) calibration if not filter? I'm no diesel expert, so if it were me, I'd take it to CVI or similar for a tuneup. Really works wonders on my L400.

[gsaruk]

So I picked up the high temp sealant and reinstalled both plates yesterday. Let it sit for 2 hours and took her for a spin... and the sputtering was still there (May have been a bit less, but that could also be wishful thinking).

The sputtering sound sound definitely seems to coming from the well under the driver's seat (as confirmed by my wife sitting in the back).

Question... Should I try sealing the plates up a bit more with a bead of sealant around the outer edge? Is this still a possible fuel filter issue?

Another possibility... there is a hose approx. 3/4 inch that passes around the end of the metal pipe removed during installation (towards the rear). When I reinstalled that pipe, the hose was running beneath it rather than around the end. I tried to check that the hose wasn't being pinched under the pipe, and it didn't seem to be. Any idea what that hose is and if this may be the source of my sputtering?

Thanks.

[yojimbo]

Dude, I think you're bouncing the overpressure relief valve on and off, it's at the back left corner looking from the front and is designed to vent turbo pressure if you exceeded about 15psi.

Have you pulled the turbo boost pipe from the wastegate off instead of the egr vacuum, or both? The wastegate, if its not given boost pressure will not open and will boost to infinity, and hence the the relief valve will cycle.

FWIW a diesel can't run lean, as it has no mixture needs, less fuel just equals less power.

[gsaruk]

Dude, I think you're bouncing the overpressure relief valve on and off, it's at the back left corner looking from the front and is designed to vent turbo pressure if you exceeded about 15psi.

Have you pulled the turbo boost pipe from the wastegate off instead of the egr vacuum, or both? The wastegate, if its not given boost pressure will not open and will boost to infinity, and hence the the relief valve will cycle.

FWIW a diesel can't run lean, as it has no mixture needs, less fuel just equals less power.

How do I recognize the wastegate and if I pulled the turbo boost pipe off?

[Luna-Sea]

hey,
Can you post some pictures?
Your turbo and fuel filter are more under the drivers panel which you have to unbolt.
If you can sneak over to CVI it would be a great benefiet as they are pretty dialed in for
what to look for. Also its my understanding that they are nice about showing you what to look for
in terms of common problems.

Your Pop off valve is on the intake at the back a round disc looking thing,
makes a hissing noise when it pops on and off.
I am not sure if you can test the pop off at a stop or no load. (anyone?)

The wastegate actuator is attached
to your turbo and opens/closes the wastegate depending on how open/closed the valve and
rod are. There is a hose on the actuator.


Here is a fun info link on how those work
http://www.delica.ca/forum/turbo-wasteg ... -7786.html

Hope this is helping,not just confusing you more.
I suggest the fuel filter because its easy to check/change,would be due for a change if
its last change-out is unknown. It can contribute to your symptoms in that
the fuel consumption goes up significantly at around 3000 rpm on my L300
and a restriction off fuel flow(filter getting clogged)would cause a sputter.





Right On!

[BushRatt]

Ok...so I have a question...I was told that you can just cut the hose on the EGR valve and plug it. Is this correct? If so why install the blanking plates?

Thanks, BushRatt.