EGR blanking plate slight leak

[davidwwc]

I have a slight leak ( showing of black exhaust deposit ) on the EGR blanking plate area. Just wondering does it affect turbo boost at higher RPM ?

DC

[RickJ]

I'll bite. No, this wont affect your boost pressure as the exhaust traveling through the turbine will spin the compressor side fast enough to create more boost than the engine requires to burn the fuel, even at full rack. The compressors waste gate is there to limit the amount of charge air delivered to the cylinders, just so it does not lift the cylinder head off the block. A leak will however, create an awful sooty mess around the engine room if it is left too long. It could also be picked up by your interior heating blower and circulated amongst the occupants within the vehicle creating a fairly unpleasant/unhealthy atmosphere. Ant auto parts shop will sell you a small amount of exhaust rated gasketing for under 10 dollars which you can trace out the shape using the EGR or blanking plate as a guide and cut with scissors or snips. I find what works well is using a contact cement, glue the uncut gasket trimmed roughly to size, to the surface in and apply some pressure allowing it to dry for about 20 minutes or so. After dry, you can take a small ball piene hammer and using the rounded head, gently tap the gasket around the edges of the metal surface which will stress the gasket enough to split it cleanly along the surfaces edge leaving a clean cut gasket. You can also do this to the sections over the mounting flange holes and inside of the pipe which makes trying to get the holes perfectly aligned and easy job. Just my 2 cents

Rick

[davidwwc]

Hi Rick,

Thanks for your detail reply. It was a post back in Aug. and no one has replied yet till now. I did tighten it up and seems working. I will have to fix it the proper way as you suggest. I don't have the unpleasent smell though.

Thanks again, I am sure your reply will help somebody who may have the similar problem.

DC

[Mr. Flibble]

Hi Rick,

Thanks for your detail reply. It was a post back in Aug. and no one has replied yet till now. I did tighten it up and seems working. I will have to fix it the proper way as you suggest. I don't have the unpleasent smell though.

Thanks again, I am sure your reply will help somebody who may have the similar problem.

DC

Actually, it has already helped me as I am going to install blanking plates, but I did not know about the exhaust rated gaskets, so I am going to pick up a gasket and cut it to size.

[RickJ]

Try the ball piene approach. I find it is a really quick and clean way of doing this. you can trace out and cut out the outer diameter first as it is the easy part. After that try gluing it onto the manifold let it sit with something with some weight to it for a little while allowing it to dry. Then use the hammer to tap gently the inside dia and bolt holes out.


Rick

[RickJ]

FYI..

http://www.klinger.co.uk/products/joint ... mperatures

[Mr. Flibble]

I just got my blanking plates, they are 6mm thick steel plates... What are the odds of a leak? They look to be machined quite well. Is a high tempurature gasket required in this instance?

[RickJ]

Some form of packing should be used to ensure a tight seal. I reused my EGR metal gasket without any issues. I simply gave it a light touch up with some 400g emery cloth just to ensure no burrs and to clean the carbon off. Also, ensure you clean off the exhaust manifold mounting flange really well. Use a scraper and again some courser emery ie 80-240g to ensure there are no burrs on the flange or anything else. Gasket maker should not be necessary, but would not hurt if you have it.

[Mr. Flibble]

Given that my blanking plates are 6mm, I probably don't need a gasket. I was considering the copper gasket stuff I have seen around. But then I saw this:

Mr. Gasket 5960 Ultra Seal Exhaust Gasket

gasket_.jpg (26.28 KiB) Viewed 3583 times

I picked up a sheet of this stuff from Amazon. It is about 1 foot square, so I have far more than I will ever need. But this stuff is THICK! It is about 2mm, and I will probably have to cut it with a dremel to size, as this is not paper, but feels more like some sort of carbon-fibre gasket. I am not even sure if I can use my tin snips to cut it!

Here is the description of the material:

Mr. Gasket Ultra Seal Premium Exhaust Gasket has the ability to conform to warped flanges for a tight seal. They have superior tensile strength to resist cracking. The graphite facing withstands heat and allows easy removal. The height of this gasket is 1.360" and its width 1.300". It incorporates a graphite-impregnated facing and a steel expanded metal core that reinforce and increase the tensile strength. It is designed and constructed to improve the sealing of exhaust header flanges. This gives the gaskets the ability to conform to warped flanges giving them better sealing capabilities without deteriorating or cracking under the excessive heat and pressure that is common in the exhaust system.