darren m · May 26, 2012

hello chaps - i need a little help and advice if you would please.
i,ve got a disco 1 1996 , usually runs A OK , but as been a little slow just lately.
anyway this morning every time i,ve tried to start her up she cuts out straight away ie wont rev and plenty of smoke coming out the back .
ticks over vaguely but thats all.

any ideas what it could be , fuel and glow plugs are all ok

thanks

Pikey · May 26, 2012

Blocked fuel filter, knackered lift pump, water in fuel sedimentor?? I assume it's a doosil as it has glow plugs

Freediscoranger · May 26, 2012

redhand said:
Blocked fuel filter, knackered lift pump, water in fuel sedimentor??

Damit just beat me to it

darren m · May 26, 2012

right heres what i,ve found out while messing with it this afternoon.

the turbo intercooler as a short pipe coming out the top of it this goes into a metal one , then another short rubber one that attaches to the manifold ( i think ) there is a T junction in this which goes to the EGR ( according to the manual ).

anyway while i had someone else trying to rev the engine i notice the short first pipe that comes out of the top of the intercooler crush up like it was being sucked the the engine cuts out.
any ideas what this would mean

thanks

Steve2a · May 26, 2012

Well for a start, bin the EGR valve and get yourself a blanking kit, usually comes with a new rubber hose that goes straight from the intercooler to the inlet manifold.

darren m · May 26, 2012

Steve2a said:
Well for a start, bin the EGR valve and get yourself a blanking kit, usually comes with a new rubber hose that goes straight from the intercooler to the inlet manifold.

whats the benifit though mate
really just want to get it running again

Freediscoranger · May 26, 2012

darren m said:
whats the benifit though mate
really just want to get it running again

benefit is you dont get the exhaust gasses being sent back into the engine instead of nice fresh air. although a fully functioning nice and new EGR shouldn't affect the engine, they might as well be binned as at this age they just make engine performance worse. and for the sake of 20quid you may as well.

And as for the rubber pipe, its normally a sign that its had it. they tend to de laminate when theyre old and crush up like youve described. should be about 8quid for 2 new sections if you want to keep the EGR.

Pikey · May 26, 2012

Yep as said hose is fooked get a noo one might as well do away with EGR at the same timee.

darren m · May 27, 2012

cheers lads - these lamiated hoses are they ridgid then , as all of my hoses going into the intercooler are a bit soft/squishy.

inside the short pipe i,ve removed it is very oily - is that normal.

can it be run with out the intercooler pipe attached

thanks again

Pikey · May 27, 2012

darren m said:
cheers lads - these lamiated hoses are they ridgid then , as all of my hoses going into the intercooler are a bit soft/squishy.

inside the short pipe i,ve removed it is very oily - is that normal.

can it be run with out the intercooler pipe attached

thanks again

Yes the system works by sending the exhaust gases thru the intercooler and into the turbo to try and remove somne of the contaminants and reduce pollution.

They're not rigid but shouldn't crush under pressure.

No you should not run it without the intercooler pipe attached.. :doh:

darren m · May 27, 2012

i,m going to order a set of pipes from rimmer bros or paddocks i think .

but if i was to clean out the intercooler , what would i use and can it be done in place.

thanks again

ps. plus a egr blanking plate.
the little pipe that goes onto the egr -- whats it for and what do you do with it once you,ve blanked off the egr

thanks

Freediscoranger · May 27, 2012

darren m said:
i,m going to order a set of pipes from rimmer bros or paddocks i think .

but if i was to clean out the intercooler , what would i use and can it be done in place.

thanks again

ps. plus a egr blanking plate.
the little pipe that goes onto the egr -- whats it for and what do you do with it once you,ve blanked off the egr

thanks

best to take intercooler out, fill with petrol and swill out, then leave it to dry over night and make sure its completely dry before re fitting. not sure what pip you mean but if your chucking egr away i would just block it up.

darren m · May 28, 2012

orderd the pipes and blanking plate today.
gonna take the intercooler out tonight. think i,ll use a couple of bottles white spirits to clean it through.then soapy water.that sound ok

ALSO
the little pipe that goes onto the egr , the very thing black one , it goes to a little unit at the front wing near where the jack sits -- whats it for and what do you do with it once you,ve blanked off the egr , 3 pipes coming off it 1 to egr , 1 to air filter box , 1 to brake servo

thanks

darren m · May 28, 2012

how to get the EGR off -- looks like allen key bolts , but surely an allen key wont give enough tork , is there a better tool.
currently spraying bolts every few hours with WD40

thanks

Freediscoranger · May 29, 2012

not sure about the pipes, mine looks like its just been taken out of the block completely and just have one going to air box and brake servo.

The bolts will be a pig, constantly heated right up and cooled down day in and day out. think its just the two bolts that attach it to the block not sure what they are exactly

biolandy · May 29, 2012

If you are worried about bolts giving up,I blanked my egr with a 2 pence piece-it fits in the union ,where the stainless steel flexi hose meets the inlet pipe-first union working back from inlet manifold-cheap as chips and all the gubbins stays in place

Diesel Do · May 29, 2012

I've done a couple and always been amazed that the bolts do actually come undone!

Diesel Do · May 29, 2012

darren m said:
orderd the pipes and blanking plate today.
gonna take the intercooler out tonight. think i,ll use a couple of bottles white spirits to clean it through.then soapy water.that sound ok

ALSO
the little pipe that goes onto the egr , the very thing black one , it goes to a little unit at the front wing near where the jack sits -- whats it for and what do you do with it once you,ve blanked off the egr , 3 pipes coming off it 1 to egr , 1 to air filter box , 1 to brake servo

thanks

Depends how you do it. If you're leavin everything intact just putting a blanking plate in leave it all connected then it'll look standard and look like it will work, it just can't!
If you want to take it all off, blank the hole in the manifold, fit new inlet pipe, throw egr in the bin! The thin pipe you can remove, this is what controls it, the thing on the wing is a vacuum solenoid, just a valve that opens and closes to allow vacuum to the egr valve to open it as necessary. The only thing you need to do is blank it off so it doesn't suck air and muck in when it's disconnected

darren m · May 29, 2012

cheers lads - to get access to the bottom bolt , will i have to take the MAF pipes and box off ( at least thats what i think it is ).

cheers

darren m · May 29, 2012

biolandy said:
If you are worried about bolts giving up,I blanked my egr with a 2 pence piece-it fits in the union ,where the stainless steel flexi hose meets the inlet pipe-first union working back from inlet manifold-cheap as chips and all the gubbins stays in place

not quite sure where you mean , do you mean in the actual diameter of the pipe on the T peice , dont suppose you have a pic do you

did you leave the EGR in place ?
how did you block that off
thanks for your help

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