Thread: EGT sensor in blanking plate

Assuming you're talking about a 300TDI, then remove blanking plate, tap a thread into the plate, reattach plate and screw in probe. The plate isn't overly thick so you don't get many threads, but I did this many years ago and I haven't had to touch it. I'm sure many others have done the same and I don't recall reading about any failures.

The other tip would be make sure you don't snap the bolts off holding the plate on. Mine came off easy, but it is easy to see how they might snap.

Alternatively, I believe you can buy a replacement plate with a thread already tapped in it that is a bit thicker. You still have to remove the old one though (risk of snapping bolts still).

Many thanks Judo, it is a D2, I recently removed the EGR and fitted to new blanking plate. The replacement plates I received are only about 3mm thick so wondering best way to drill and attach the new sensor. Bit out of my comfort zone here. Can I attach a bolt to the 'inner' side with some high temp sealant or will that get too hot ?

I don't know about the D2 sorry. 3mm is enough for a probe thread if it is practical though.

Be aware of the angle of the plate and how much you'll be able to push the probe in. I actually drilled and tapped mine on an angle so the probe goes in straight in the tunnel behind the plate.

How do I tap in a thread to the plate ? Bit new to this ?

Originally Posted by surfingooner

How do I tap in a thread to the plate ? Bit new to this ?

Uhmmmm. First you need to obtain tapping tool that matches thread on your sensor holder. Then you drill appropriate size hole and run tapping tool thorough the hole.
It's not hard to do, but if you never done it before, maybe you better give it to someone else to do. Otherwise you might ruin your plate or have sub-standard installation.

Just went to Bunnings and autobahn and unable to get a single tapper with correct thread without buying a $150 set. Why cannot I simply drill a hole in a blanking plate and fit a nut the other end of the sensor bolt, tighten and seal with high temp sealant and then replace this new plate with sensor incorporated for the plate that is already there ? Am I missing something ?

Originally Posted by surfingooner

Just went to Bunnings and autobahn and unable to get a single tapper with correct thread without buying a $150 set. Why cannot I simply drill a hole in a blanking plate and fit a nut the other end of the sensor bolt, tighten and seal with high temp sealant and then replace this new plate with sensor incorporated for the plate that is already there ? Am I missing something ?

You can use the nut as well maybe. If you have a nut of the right size. Only problem might be if thread on your sensor holder is tappered. Meaning narrower diameter on one end and wider on the other. Then you might run into problem of nut tightening up on the holder but not to the plate. Someone of greater experience with this sort of stuff may provide better answer.

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