Author Topic: EGR blanking on 2012 GH 2.2 diesel  (Read 3379 times)

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Offline filterlab

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EGR blanking on 2012 GH 2.2 diesel
« on: August 25, 2017, 01:14:03 pm »
I thought I'd put a little guide to anyone who's thinking of, or needs to, blank off the EGR valve on their GH 2.2 diesel.

After several months of absolutely terrible running on my Mazda 6 (hesitation at light throttle and after overrun, surging, occasional poor starting, sound similar to detonation, dreadful acceleration in warm weather etc etc) I boiled the problem down to the EGR valve. I used OBD Fusion on my iPhone 7+ along with a Carista OBD2 bluetooth module and the extra Mazda pack from OBD Fusion (worth every penny). As the EGR valve opened the issues would begin, but as soon as it was closed running was smooth and powerful. Unfortunately the valve is open a lot as one drives, and that really interferes with the feel of the car.

Now, I couldn't find any guides online for the 2.2D, I couldn't find any images of where the valve is located, but I did manage to find a couple of EGRs for sale on eBay, including the handy item picture.

On the 2.2D it's right at the front of the engine, literally right in front of one's eyes as the bonnet/hood is opened. There's not even a need to remove the engine cover. At the top end of the pipe is the inlet manifold, at the lower end the EGR valve.

Top end at the inlet manifold...



Lower end at the EGR valve...



Now, nobody seems to sell blanks for the 2.2D at all, couldn't find a single occurrence of one anywhere. So I loosened the 12mm nuts and had a look between pipe and inlet manifold. The pipe diameter is around 30mm, so I ordered a pack of ten 40mm x 1.5mm aluminium discs from seller Cimlet on eBay. Within a day and a half I had them. I only needed two of course, but I have eight spare in case anyone needs them.



In actual fact there's no need to plug both ends, but I wanted to make sure the inlet side was thoroughly sealed to avoid any potential leaks (and the consequent heat soak). Here's what to do...

1. Loosen the 12mm nuts on the inlet manifold end of the pipe.
2. Pull the pipe toward you whilst sliding the 40mm disc in between the pipe side and the gasket (leaving the gasket on the inlet side).
3. Tighten up the nuts.

4. Loosen the 12mm nuts on the EGR valve end of the pipe.
5. Pull the pipe toward you whilst sliding the 40mm disc in between the pipe side and the gasket (leaving the gasket on the EGR side).
6. Tighten up the nuts.



That's it! Ideally if you have the necessary equipment it's worth clearing the codes, or more importantly the ECU adaptation which should clear with the codes. Start the engine, let it idle for a few minutes, then head out on the road.

Just something to finish up, if you're wondering just what crud comes through the EGR valve and into the inlet manifold. This was a temporary plate I put in whilst waiting for the discs to arrive, it was in the car for a couple of days (around 550 miles)...



That is literally a 1mm deep, burnt on pile of soot and crud and cr@p. That's what goes into your engine to be burned off. You have clean air in, clean fuel in, clean oil to lubricate - and then the car throws this much filth into the mix. Nice eh?

Anyway, hope that's helped someone.

Offline Willpower

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #1 on: August 25, 2017, 02:22:25 pm »
Excellent write up and pictures.  I have stickied this posting.   

Thank you :)
 
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Offline filterlab

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #2 on: August 25, 2017, 06:44:57 pm »
Thanks old bean, hopefully it'll help someone out.  :)

Offline Steve Walsh

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #3 on: August 30, 2017, 05:35:52 am »
Thinking of blanking mine off, Does it need an ecu mod or anything else.
Thanks

Steve

Offline Cee-Jay-Cee

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #4 on: August 30, 2017, 02:59:42 pm »
Shouldn't you be using some form of instant gasket also to ensure a proper seal?

Offline filterlab

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #5 on: August 31, 2017, 10:37:43 am »
Shouldn't you be using some form of instant gasket also to ensure a proper seal?

You could do, but the original gaskets are in place anyway.

No ECU mod on mine. All is good.

Offline filterlab

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #6 on: August 31, 2017, 10:55:49 am »
Just checked on my EGR, no leak at all.

Offline Steve Walsh

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #7 on: September 26, 2017, 06:39:15 pm »
Blanked mine off yesterday, just done a 250 mile trip. after 220 miles, engine check light came on and wont go off, do they go off after a set time if no fault present


Offline mareng73

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #8 on: May 31, 2018, 04:33:11 pm »
I would suggest removing EGR blanks and just clean the EGR and piping at service time. If the EGR is vacuum operated , drop it in some soapy water, it will come out clean.
If they are not meant to be used then mfrs would not fit them.
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Offline alfaboy155

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #9 on: August 28, 2018, 12:30:30 pm »
Really appreciate this post with pictures!. Got a EGR 'delete' the other day and have the blanks now to go in this evening. :)

Offline apav

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #10 on: August 28, 2018, 04:08:28 pm »
Try to clean it. If you blank it, you will lose the benefits of the EGR and you may be looking for a problem further down the line.

The EGR reduces the amount of oxygen in the cylinders resulting in lower combustion temperatures which means lower levels of NOx. NOx is what drove mad the government to ban diesels. You add to this the removed DPFs and you have the full picture.

https://www.eta.co.uk/2015/06/10/mot-test-to-get-tougher/

By playing up with the EGR, you go beyond the legal limits and so you make the car illegal. Not that somebody will check or cares but this is the official line.

https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/676700/in-service-exhaust-emission-standards-for-road-vehicles-19th-edition.pdf

Offline alfaboy155

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #11 on: August 29, 2018, 02:52:46 pm »
This is the crud going back into the engine via the egr system. Removed pipe, cleaned both ends and reattached with blanks in place.


Attachment removed.

Please read this
  http://www.mazda6forums.co.uk/index.php?topic=1846.0
« Last Edit: August 30, 2018, 07:11:50 am by Willpower »

Offline apav

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #12 on: August 30, 2018, 12:09:16 pm »
I suppose you had some photos there.

I am not saying that there is no dirt involved.

But this is how the engine is designed.

It is now illegal and more polluting.

It may need more cleaning than without it, like the DPF needs cleaning, but there are benefits.

Anyway, the latest predictions are that electric cars are set to sell more than diesels.

So, out with the old DPF, EGR, injector seals, oil pick up and in with whatever new ideas will come up to bypass the regulations. Maybe a diesel non DPF, EGR generator in the boot charging the batteries?

Offline alfaboy155

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #13 on: August 30, 2018, 09:23:11 pm »
This is the crud going back into the engine via the egr system. Removed pipe, cleaned both ends and reattached with blanks in place.


Attachment removed.

Please read this
  http://www.mazda6forums.co.uk/index.php?topic=1846.0

Apologies to Admin




Offline alfaboy155

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Re: EGR blanking on 2012 GH 2.2 diesel
« Reply #14 on: August 30, 2018, 09:34:39 pm »