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  #1  
Old 09-16-2021, 11:45 AM
ngoma ngoma is offline
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Join Date: Nov 2009
Posts: 1,351
Default EGR Blockoff Plates

D24T EGR system offers little benefit of its intended purpose. Needlessly (electromechanically) complex, bunglesome, and generally in the way. After removing the wiring and microswitches, I wanted to further streamline the area by removing the plumbing and installing blockoff plates on the intake and exhaust manifolds.

While making a recycle run at the scrapyard, saw a nice 1/2" thick aluminum plate, looked like it was a emergency snap shut cover for a lab sink.

After removing the EGR plumbing and mounting flanges, the gaskets appeared to be in satisfactory condition for reuse. I used one as a pattern template to cut the plates out of the sheet with a jigsaw.

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I had thought that possibly the different coefficients of expansion between the cast iron exhaust manifold and aluminum blockoff plate would cause sealing problems or excessive gasket wear but it seems to be holding tight.
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1985 744 gle d24t
1985 745 gle d24t
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  #2  
Old 09-22-2021, 09:39 AM
jpliddy jpliddy is offline
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Join Date: Jan 2014
Posts: 340
Default block off plate

hi NGOMA thats one hell of a block off plate NOTHING will never burn through
that . i did mine with a 1.5mm stainless steel plate as i kept everything looking like it came out of the factory the plate was easy to cut and file to the shape of the manifold plate then i put the EGR you can not tell its been tampered with pipe work back
only my personal opinion .you have done a very robust job !
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  #3  
Old 09-30-2021, 10:17 AM
Bob Bob is offline
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Join Date: Mar 2021
Location: united kingdom
Vehicle: 740 wagon, 164 saloon
Posts: 11
Default

I used half a spare egr system however one of the flanges on my d24 differs in size so i had to cut the original system unfortunately. i literally filled the void of the flanges i cut off with weld (off the car obviously) and it looks pretty good to be honest. was a cool little mod.
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  #4  
Old 09-30-2021, 01:32 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
Location: New York
Vehicle: 1986 Volvo 745 TD
Posts: 900
Default Vintage tool for adjusting EGR

Not because anyone cares and not because anyone wants to have their egr functioning... rather for the sake of the memories of those who worked in the early 80`s Volvo dealerships, occasionally had to adjust EGR on a d24 car...

As also mentioned in the Emissions Manual TP31514:
"IP idle EGR adjust tool"
Volvo tool 9995285 (23)
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File Type: jpg Screenshot_20210930-172556.jpg (21.0 KB, 4 views)

Last edited by RedArrow; 09-30-2021 at 01:35 PM.
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