EGR blanking with no Intercooler ?

Hello to all, I want to fit a EGR blanking plate only to my 2001 TD5 ES Disco, having read many threads on this wonderful site it seems a straight forword job ! I have noticed that the threads with accompanying photos only show the TD5 with the intercooler attached to the front end, which makes the EGR blanking job a lot easier (accessable). I unfortunetly have the model TD5 without the intercooler which means the EGR manifold looks very awkward to get at right under the aircon pump, ! is there an easier way to get at these two flange bolts or any photo's on this site that I could learn from, Im sure there is but cant find anything, Thanks in advance for any help given.

Steve171054 said:

Hello to all, I want to fit a EGR blanking plate only to my 2001 TD5 ES Disco, having read many threads on this wonderful site it seems a straight forword job ! I have noticed that the threads with accompanying photos only show the TD5 with the intercooler attached to the front end, which makes the EGR blanking job a lot easier (accessable). I unfortunately have the model TD5 without the intercooler which means the EGR manifold looks very awkward to get at right under the aircon pump, ! is there an easier way to get at these two flange bolts or any photo's on this site that I could learn from, Im sure there is but cant find anything, Thanks in advance for any help given.

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There is no such model produced by Land Rover. I think you are confusing the intercooler (large radiator-like thing in front of the coolant radiator) with the EGR cooler which is a cylindrical tube with coolant pipes attaching that goes in front of the head and connects the EGR valve with the exhaust manifold?

If I'm right, can you say clearly whether
1. you want to remove the EGR valve or
2. just block off the flow of exhaust gases back into the engine?


Dave

Steve171054 said:

Hello to all, I want to fit a EGR blanking plate only to my 2001 TD5 ES Disco, having read many threads on this wonderful site it seems a straight forword job ! I have noticed that the threads with accompanying photos only show the TD5 with the intercooler attached to the front end, which makes the EGR blanking job a lot easier (accessable). I unfortunetly have the model TD5 without the intercooler which means the EGR manifold looks very awkward to get at right under the aircon pump, ! is there an easier way to get at these two flange bolts or any photo's on this site that I could learn from, Im sure there is but cant find anything, Thanks in advance for any help given.

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Do these these help? - Instructions for fitting EGR blank.
I think it's the EGR heat exchanger you are talking about and not an intercooler?

There were basically two types of TD5 engine; one with the EGR heat exchanger on the front and the other type had no heat exchanger but a flexible stainless steel pipe instead. Both types are fitted with an intercooler.

As the link from Headtester shows (if you want an easier to see page I've put one on my own website at www.dragonseggs.com/TD5 EGR Removal.pdf) removing the EGR completely is the easiest way of doing the job.

Plenty of releasing oil such as Plusgas, Easol but NOT WD40 will be required to remove the studs at the exhaust manifold end. Once that end is free, it's a fairly simple job to undo the rest of the bolts and completely remove the EGR assembly; it can be a bit of a fiddle to pull it away from the engine.

Once it's all out of the way re-assembly is straight forward using new stainless steel bolts and the only trouble you might encounter then is finding the little rubber bungs after you've dropped them. A dab of Copper Ease on each bolt when re-assembling will help with scrdewing them up again and also with any future removal should it be necessary.

One of the more useful tools will be a correctly fitting Allen key in a socket set to allow easy reach to all the bolts in question.

Thanks for the prompt replies gents, yes BigLad, my mistake I meant the EGR Cooler ! and yes I just want to blank off the egr for better perfomance !!

Steve171054 said:

Thanks for the prompt replies gents, yes BigLad, my mistake I meant the EGR Cooler ! and yes I just want to blank off the egr for better perfomance !!

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Blocking off stops any more exhaust gas gunk reaching the inlet manifold; but blocking off then removing the EGR valve completely will give you the best performance gain.

At the same time clean out the inlet manifold and the MAP sensor fixed to it.

That way you will optimise performance.

Just for info in case anyone reads this in the future, the 10P engine had no EGR cooler/heat exchanger, the later 15P as fitted to facelift D2s had it fitted as standard.

Of course, being a landrover, you'll need to check the engine serial number to be certain of what you've got as engine swaps are fairly common

thebiglad said:

At the same time clean out the inlet manifold and the MAP sensor fixed to it.

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You would be amazed how much crap accumilates in the MAP sensor - I'd recommend this be cleaned annually as the sensor has a very small hole which is blocked by oil crud very easily. I've nicked the image below from the web, this is typical of what you'll find when removing one - the hole I'm talking about is in the recess under the stickyy outy 'probe' bit

Half a can of Halfords switch cleaner later and I too have a clean MAP sensor

Actually I exaggerate - I did use some on the red ECU plug - good old oil in the injector loom phenomenon.

In preparation for fitting the EGR delete kit on my 2001 D2 (10P engine , each day for two or three days I sprayed some silicon oil on the EGR pipe bolts. When I came to undo them (decent allen driver) there was a gentle crack and then they came out no problem.