How to Install an EGR Blocker Plate: A Complete DIY Guide

Does your pickup truck feel sluggish with poor throttle response? Carbon buildup from the EGR system clogs things up and hurts performance. Installing an EGR blocker plate in your truck can help to cut down on carbon build-up, increase throttle response, and keep your intake system cleaner.

To install an EGR blocker plate, locate the EGR valve, remove bolts, insert the plate with a gasket, and tighten to specs. This blocks exhaust gases, reduces soot, and boosts engine efficiency for better power and fuel economy.

This guide will show you how to install the EGR blocker plate properly with basic tools and clearly outlined steps. We've put together this complete walkthrough because we believe you can handle this job yourself.

Whether you're a seasoned mechanic or someone taking on their first engine modification, we'll make sure you understand exactly what the Chevy/Ford EGR blocker plate does, why it matters, how to install one safely on your pickup truck, and common mistakes to avoid. By the end, you'll know if this modification is right for your truck and how to complete the job with confidence.

What Does an EGR Blanking Plate Do and What Are the Benefits of Installing One?

Struggling with a dirty intake manifold full of soot? EGR systems recycle exhaust and cause buildup that slows your truck down.

An EGR blanking plate is a thin piece of metal that sits between the EGR valve and your intake manifold. Its job is simple: to block exhaust gases from being recirculated back into the engine.

An EGR blanking plate stops sooty exhaust from clogging your intake manifold, cleans your engine oil, speeds up turbo spooling, and can improve fuel economy. Most owners see faster throttle response and a cleaner engine overall.

We remember when our shop truck had constant carbon issues. After fitting a blanking plate, it runs smoother right away. Now, let's break this down further.

How the EGR System Works

The EGR system takes exhaust gases and sends them back into the engine to lower emissions. But in diesel pickup engines, this leads to soot buildup in the intake. A blanking plate stops that flow completely.

We see this most in trucks over 100,000 miles, where the valve sticks open.

Key Benefits of Installing an EGR Blanking Plate

• Cleaner intake manifold and cleaner engine oil
• Reduced carbon and soot buildup
• Faster turbo spool due to less exhaust restriction
• Smoother idle when the EGR system is already failing
• Potentially better fuel economy on some engines

When there are no longer exhaust gases getting recirculated into the intake, hot soot can not enter the intake. This keeps many of the internal components of the engine cleaner and also improves how the engine responds when you press down on the accelerator.

A lot of truck owners are opting to use an EGR plate blocker as an affordable solution instead of doing a complete EGR delete. Some owners report 1-2 mpg better fuel use, but results vary by truck model.

Benefit	Description	Expected Impact
Cleaner Intake	No soot enters manifold	Reduces cleaning needs by 50% or more
Better Throttle	Quicker response	Noticeable improvement in daily driving
Fuel Economy	Possible small gains	1–2 MPG improvement in some cases
Turbo Performance	Faster spooling	Improves acceleration and boost response

While results vary by engine type, EGR blocker plate installation is mainly done to slow carbon buildup and protect long-term engine health.

Potential Drawbacks to Consider

Not everything is perfect. Check the cons here. Without EGR, combustion temps can rise. This might cause knocking if not monitored.

Also, the ECU may throw codes without a tune. We always check temps on long trips after install. In our experience, benefits outweigh risks for off-road trucks, but daily drivers need careful thought.

Overall, blanking plates solve common diesel problems. They keep engines clean and responsive. If your truck shows signs of EGR failure, like a rough idle, this mod helps a lot. We have installed dozens and seen consistent improvements.

Is It Legal to Install an EGR Block-off Plate?

Worried about fines for modifying your truck's emissions? Laws on EGR changes are strict and can hit your wallet hard. Using an EGR cooler block off plate in most jurisdictions is illegal on public roads, and it may void your vehicle's warranty.

Installing an EGR block-off plate is not legal for on-road use in the US under EPA rules, or in Australia for roadworthy tests. It's seen as tampering and can void warranties.

Stick with us to understand the rules and when it's okay.

US Regulations Explained

In the US, the EPA and CARB view EGR blocker plates as illegal for street vehicles. Fines can reach thousands per violation. We know shops that faced penalties for selling kits. Off-road or farm use is often allowed, but public roads are a no-go.

Rules in Australia and Other Countries

Australia requires emissions systems to stay in stock for registration. Modified trucks fail inspections. Many countries follow similar paths.

Region	Legal Status	Potential Penalty
US	Illegal on-road	Up to $45,000 fine
Australia	Fails roadworthy inspection	Registration denial
UK/EU	Strict emissions testing requirements	Fines and possible vehicle seizure

When It's Permitted

These plates are usually only legal for:

• Off-road vehicles
• Competition vehicles
• Farm or industrial equipment

Critically, laws protect air quality. EGR reduces NOx emissions. Removing it increases pollution. We weigh performance against the environment. Always check your local emissions laws before installing an EGR plate blocker.

What Tools and Parts Do You Need?

Frustrated by not having the right tools mid-job? EGR blanking plate installs need specific items to avoid headaches.

You need an EGR blanking plate kit, gaskets, sockets like 8mm-13mm, wrench, penetrating oil, torque wrench, and safety gear. This ensures a smooth install.

Before starting the job, gather everything listed below. Having the right tools nearby makes the installation faster and safer. Read on for a full list and why each matters.

Parts

• EGR blanking plate kit to fit your particular vehicle. It includes the plate and bolts.
• A new gasket (or you can re-use the old one if it is in good shape), but new is better.

We stock kits from EGR Performance for reliability.

Required Tools

• Standard-socket set (8 mm, 10 mm, or 13 mm will be ample), which will cover most bolts.
• Socket wrench/ratchet or a wrench (for stubborn bolts)
• Ratchet/ratcheting sockets again for tight spots
• Liquid wrench (to free up any stuck bolts). Penetrating oil loosens rusty parts.
• Torque wrench (usually around 20 - 25 ft/lbs torque, check the kit specifications). It prevents over-tightening.
• Gloves and eye protection to keep you safe

Using the correct hardware (part and tool) will minimize the risk of leaks, stripping bolts, and mistakes when installing EGR block off plates.

Safety and Extra Tips

Always wear gloves to avoid burns. Eye protection guards against debris. We once skipped oil and broke a bolt – big mistake. Prep tools ahead. If bolts strip, have extractors ready.

Wrong tools lead to damage. Swivel sockets save time in engine bays. Torque specs prevent cracks. We test kits on our trucks first. Good prep makes the job easy and safe.

How Should You Prepare Before EGR Blocker Plate Installation?

Proper preparation will help avoid broken bolts and unnecessary delays.

Park on flat ground, shut off the engine, and let it cool. Disconnect the battery negative. Use penetrating oil on bolts to avoid breaks.

Let's dive into the steps that set you up for success.

• Park the truck on a flat surface. Turn off the truck and wait hours for cooling.
• Shut down the engine and wait until it has cooled down to room temperature. Hot parts burn skin.
• Disconnect the negative battery cable to prevent short-circuiting the electrical system. We do this every time in our garage.

Tips to Avoid Broken Bolts

• Spray EGR bolts with penetrating oil and allow them to soak for 10-15 minutes.
• Use steady pressure when removing bolts instead of using sudden force.
• If a bolt feels stuck, try to tighten and then loosen.
• Use the correct size socket at all times to prevent rounding of the bolt heads.

We broke one once without prep – learned the hard way.

Prep Step	Why It Matters	Tip
Cool Engine	Prevents burns and heat-related injury	Wait 2–4 hours before starting work
Disconnect Battery	Avoids electrical shorts or sensor faults	Disconnect the negative terminal first
Oil Bolts	Helps loosen rusted or seized fasteners	Apply penetrating oil multiple times before removal

Additional Precautions

Clear workspace. Have rags for spills. Check the truck manual for specifics. We review diagrams before starting. If unsure, watch videos for your Chevy or Ford models.

Prep is key to a smooth install. Taking a few extra minutes here can save hours of repair work later. Good habits keep trucks running well.

Step-by-Step Guide to Installing an EGR Blocker Plate

Overwhelmed by engine bay clutter? Step-by-step guidance makes EGR blocker plate installation straightforward, even for beginners.

Locate EGR, remove bolts, insert plate, reassemble, and check for leaks. Use tools carefully to avoid drops or damage.

Continue for detailed steps and tips. These steps will help you to install the EGR blocker plate the right way.

Step 1 – Find the EGR Valve and Pipe

• Pop the hood and spot the EGR valve. You'll often see it near the engine's top, with a metal pipe linking it to the intake manifold.
• Check for the flange where the pipe meets the intake or EGR valve.

On the Chevy LS, it's the passenger side. We mark it first to avoid confusion.

Step 2 – Take Out the EGR Pipe or Valve Bolts

• Loosen the bolts that hold the EGR pipe in place. Most trucks have two bolts on the side of the manifold or valve.
• Remove the pipe gently and put it to the side.
• Keep the old gasket if you can still use it. We use a mirror to see hidden bolts.

Tip: If the bolts won't budge, spray some penetrating oil and give it a few minutes before you try again.

Step 3 – Insert the Blanking Plate

• Place the blanking plate between the EGR valve housing and the intake manifold.
• The gasket usually goes on the exhaust side of the plate. If necessary, adjust the plate's position using a screwdriver. Avoid letting the plate fall into the engine compartment – tape if needed.

Step 4 – Put Components Back Together and Secure

• Put the bolts back in and tighten them by hand first.
• Use a torque wrench to tighten bolts to the kit's specs, 20–25 ft-lb.
• Hook up any hoses, sensors, or vacuum lines you took off earlier. We double-check connections.

Step 5 – Last Checks

• Reconnect the battery.
• Turn on the engine and let it run.
• Pay attention to any hissing, rattling, or weird turbo noises.
• Look around the EGR area to spot exhaust leaks and check nearby hoses and wiring.
• Drive short to test.

If everything looks and sounds okay, you're done with the install.

Step	Action	Caution
1	Locate valve	Check service manual for exact position
2	Remove bolts	Use penetrating oil for stuck fasteners
3	Insert plate	Ensure proper alignment before tightening
4	Reassemble	Torque bolts to manufacturer specifications
5	Final checks	Start engine and listen carefully for leaks

Steps prevent mistakes. We installed it on our Ford, and it took an hour. Critically, torque avoids leaks. If codes appear, tune the ECU. This guide works for most pickups.

What Can You Expect After EGR Blocker Plate Installation?

Curious if your truck will run differently post-install? Changes in performance and maintenance are common.

Expect quicker throttle, faster turbo spool, and cleaner intake. Fuel economy may improve, but monitor for codes or rough idle.

Explore what happens next. After you install the EGR blocker plate on diesel engines like Ford Mustang or Chevy LS, here's what most truck owners see:

Performance Changes

• The gas pedal might feel more responsive. We noticed this on our Chevy – acceleration improved.
• The turbo could spin up faster
• Some trucks get a bit better gas mileage, while others stay the same

Engine Behavior Shifts

• The idle should remain smooth if the engine is healthy.
• But ECU might cause rough run or misfires without tune.

One thing to keep an eye on is how hot the engine gets inside. Blocking the EGR can make the cylinders hotter. Watch gauge.

Maintenance

• The intake system stays cleaner, oil lasts longer. Listen for any knocking sounds and check your oil more often on long drives.
• Less soot builds up in the engine oil

Expectation	Positive	Potential Issue
Throttle	Quicker response	Typically none
Fuel	Possible efficiency gains	Results vary by truck and driving style
Maintenance	Reduced carbon buildup	May experience higher operating temperatures

After installation, the benefits show quickly. Our truck had no codes at first, but we tuned it later. Critically, higher temperatures stress parts if untuned. Balance gains with care. This mod suits tuned off-road trucks best.

Common Installation Mistakes to Avoid

Afraid of leaks or broken parts during install? Avoiding these mistakes helps make sure your EGR cooler block off plate setup works as it should.

Avoid wrong side placement, bad torque, and missing gaskets. These cause leaks or codes.

Learn from others' errors below.

Putting the Plate on the Wrong Side

Placing the plate on the intake side of the EGR valve doesn't solve the problem. The valve can still get stuck open and let exhaust in.

Correct placement:

Install between the valve and the manifold. Wrong side lets exhaust in still. We saw this once – no benefits until fixed.

Tightening Bolts Too Much or Too Little

• Too loose → exhaust escapes
• Too tight → threads strip or parts crack

Always use a torque wrench and stick to the kit or service manual guidelines.

Forgetting or Reusing Bad Gaskets

No gasket or the wrong one can lead to leaks and check engine lights. Use the right gasket and put it on the correct side, the exhaust side.

Crushed or torn gaskets won't seal. Always swap out damaged gaskets before you tighten the bolts. Reuse only if perfect. We replace them every time.

Skipping Leak Checks

Even a tiny leak can cause:

• Rough idle
• Error code P0401
• Turbo performance problems

Start the engine and listen for hissing sounds. Hiss means issue. Smoke test if needed.

Always inspect around the EGR flange for leaks.

Mistake	Consequence	Fix
Wrong side	No blocking effect	Reposition plate correctly
Bad torque	Leaks or component damage	Retorque to manufacturer specifications
No gasket	Exhaust leak	Install a new gasket

Avoiding mistakes saves time. We over-torqued once and stripped threads – costly. Critically, the gasket position seals properly. Follow guides closely. Good habits lead to reliable mods.

Should You Chip or Remap the ECU?

Bothered by check engine lights after mod? ECU expects EGR flow and may limit power.

Without remap, expect codes like P0401. With tune, disable EGR checks for no lights and full power.

See why tuning matters.

Without a Remap

ECU detects no flow and lights up. Some trucks go limp.

Installing EGR block off plates might cause the system to store fault codes like:

• P0401 (not enough flow)
• P0402 (too much flow)
• P0403 (EGR circuit problem)

This often turns on the check engine light. Some trucks might go into limp mode or lose power. Others might run, just showing a warning light.

With a Remap or Tune

• A good ECU tune can turn off EGR monitoring.
• This stops fault codes and keeps normal power levels.
• For daily-driven trucks, tuning works best in the long run.

Option	Pros	Cons
No Remap	Simple installation, no tuning required	May trigger fault codes or limp mode
With Remap	Prevents warning lights and drivability issues	Higher overall cost due to tuning

When to Choose Each

Daily drivers need to be tuned. Off-road can skip if the codes are okay. We tune all our modded trucks.

Tuning completes the mod. Without risks arise. Critically, sensitive ECUs cause problems. We recommend professional tunes for safety. This step maximizes benefits.

FAQs

Q: Will an EGR blocker plate damage my engine?

When you put it right, it doesn't. But it can make things hotter inside, so monitor temp, keep an eye on how your engine runs and check your oil often.

Q: Can I remove the EGR blanking plate later?

Yes. Just make sure to put the old gasket and parts back in so nothing leaks.

Q: How long does EGR blocker plate installation take?

Most people who like to work on cars themselves can do it in 1–2 hours, depending on how the engine's set up and how easy it is to reach the bolts.

Q: Solid plate vs. plate with a hole – which is better?

Solid blocks are all for the best cleaning. Stops all EGR flow, cuts down on carbon buildup, works best for off-road or tuned trucks, but you're more likely to see error codes.

Plate with a small hole lets a tiny bit of exhaust through. It will be less likely to trigger codes, still helps with carbon, good for everyday drivers.

Q: What are the risks of using an EGR block off plate?

Legal fines, breaking emissions rules, and losing your warranty. Engine/electrical: hotter burning, knocking/pinging, check engine light, or limp mode. Extended heat exposure can cut down engine lifespan.

Q: Can I install a Chevy/Ford/BMW/Toyota EGR block plate myself?

Yes, with skills. It can be somewhat tricky, since the intallation involves working in cramped engine areas. Requires careful tightening and leak testing.

Make sure to follow instructions for your specific car model. If unsure, consult a trusted diesel mechanic.

Final Conclusion

EGR blocker plate installation is a very simple method to eliminate carbon buildup, boost throttle response, and keep your intake system cleaner than before.

The installation consists of removing the 2 bolts that secure the EGR valve & pipe, inserting in the blanking plate with the gasket, and then careful installation of parts once again. EGR Performance offers the best EGR block off plate kits for reliable results.

Who should install the EGR blanking plate?

• DIY truck owners with basic mechanical skills
• Individuals who feel comfortable using sockets, torque wrenches, or who have worked in tight engine bays
• Owners of pickup trucks who are looking to maintain the cleanliness and performance of their engines

Follow the below Safety & Reliability Recommendations

• Make sure the correct gasket is used & that the bolts you torque meet OEM specifications
• Be sure to inspect the installation to ensure there are no leaks or misalignments
• Make sure you understand any possible legal restrictions or emissions laws that may apply in your local region
• If your Cummins EGR block off plate is completely solid, you may want to consider an ECU tuning in order to eliminate any check engine light codes caused by removing the EGR system.

Following the above steps will help ensure that installing the EGR blocker plate is safe, effective, and will last a long time.

More Reading

• Exhaust Gas Recirculation
• Will EGR Delete Cause Diesel Engine Damage
• The Pros and Cons of an EGR System Delete