Boost/power troubles after EGR and/or new intercooler

[Hodge]

So is the egr blocked or not Hodge

Nope mate it isn't. I took the plate out when I began getting this issue, and as I mentioned above at the same time I started getting the EGR code. Maybe was just a co-incidence.
Removed the EGR blank, code is gone, but it didn't fix my problem. Cars back to normal only after fiddling with the dawes/needle setup.
I got another blank from Mudksi with a hole in it, so I'll drop that in this weekend, and see what happens.

[threedogs]

Don't others drill a 10mm hole in the EGR plate to stop the ECU on
the CRD from throwing up error codes all the time

[Hodge]

Don't others drill a 10mm hole in the EGR plate to stop the ECU on
the CRD from throwing up error codes all the time

Yup. I could have done that too. But I got another plate off mudski with a hole already there, so I don't have to destroy a perfectly good plate, which somebody else can use.
I'm a bit sceptical of the plate with a hole though. I mean you're blocking the EGR but yet opening a hole for it. Surely that hole will eventually cog up with crap anyway ?
Anyhow will give that a go.

[threedogs]

Its only purpose is to trick the ECU into thinking the EGR is unblocked,
maybe periodical cleaning might be required as part of your maintenance .

[Hodge]

Its only purpose is to trick the ECU into thinking the EGR is unblocked,
maybe periodical cleaning might be required as part of your maintenance .

Yeh it's meant to equalize pressure on both sides of the plate fooling the sensor, while still trying to block the EGR flowing through. I'll fit it this weekend and see what happens.
Pain in the rear end to do on the CRD, so I don't want to do it too many times.

You asked about the temps after the IC. Well cruising at 60 on flat roads it sits 250-300. At 100 its about 300-350. Even a slight hill, pushes it past that. Since fitting the dawes and needle valve it has dramatically improved my EGT's. I used to see 500-550 without much effort, ever since then I'm yet to see it go past 400.
New IC dropped my cruising temperatures, and reduced the turbo cool down time. Should also mention that while my EGR was fully blocked, the EGT temps were much lower too.

[mudski]

Great to see it's sorted Eric. Sorry I didn't respond to your text but it's just crazy with work and I just plain forgot to respond.
As for the egr plate. I would put the solid plate in, if you haven't already done so...

[Hodge]

No stress at all buddy, totally understandable. Flat out with work here my self, couldn't spare a daylight hour to put the plate back in, but will definitely do so.
But shes going like it's stolen now. Which is a great outcome. Thanks again for all the advice and the MAF's and plates.

[barbz]

Did you old IC have holes in it leaking boost?

If so did you notice if spool rates in 4th and 5th while better than where they are now still slower than gears 1/2/3?

[Drew]

I get the EGR code popping up every month or so. Scangauge fixes that. I'm certainly not taking it out and drilling a hole in it now.

Just so you don't think you're going silly Hodge, I have had the code reported in the scangauge but no engine light as well once (that I know of).

[Hodge]

Did you old IC have holes in it leaking boost?

If so did you notice if spool rates in 4th and 5th while better than where they are now still slower than gears 1/2/3?

My factory IC had a tiny leak which only became apparent after I installed the dawes / needle valve. Obviously this put more boost through the system, and finally weakest point of the crimped IC gave way.

And yes after the new IC, 4th and 5th definitely changed and lagged in spool up rate.

I get the EGR code popping up every month or so. Scangauge fixes that. I'm certainly not taking it out and drilling a hole in it now.

Just so you don't think you're going silly Hodge, I have had the code reported in the scangauge but no engine light as well once (that I know of).

Thanks Drew. Good to see I'm not the only one. The fact it wasn't throwing an engine light, sort of concerned me, since a lot of other people had it pop up as soon as they got the code. I'll be putting the full blank back in.