EGR removal

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RobCSH

RobCSH

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Just woke up after a long night changing all transmission oils and removing the EGR valve...

Sod law say's one bolt broke in the exhaust manufold, but after removing the EGR valve, I was gob smacked at the ammount of ****e in the inlet. So much so, I removed the inlet manufold and blasted it out clean with the steam cleaner. I first though the turbo was passing oil, but it seems to be misting from the breather on the rocker cover (following the trace of oil..)

I've thrown it back together, and I'll go back in for another look in a month or so to see if it's re-occuring.

Anyone else had this, or is it just my usual run of good fortune?

BTW it's a Disco 2 TD5 auto.

Rob
 
RobCSH said:
Just woke up after a long night changing all transmission oils and removing the EGR valve...

Sod law say's one bolt broke in the exhaust manufold, but after removing the EGR valve, I was gob smacked at the ammount of ****e in the inlet. So much so, I removed the inlet manufold and blasted it out clean with the steam cleaner. I first though the turbo was passing oil, but it seems to be misting from the breather on the rocker cover (following the trace of oil..)

I've thrown it back together, and I'll go back in for another look in a month or so to see if it's re-occuring.

Anyone else had this, or is it just my usual run of good fortune?

BTW it's a Disco 2 TD5 auto.

Rob
Click to expand...

What you describe is par for the course.
EGR's have been disastrous failures, whatever it was they were supposed to do.

Dump them soonest.

Some td5 engines have been brought to their knees by the inlet manifold getting more or less blocked by that disgusting black gunge.

But the DEALERS make a lot of easy money from them once the cars are out of warranty ....

CharlesY
 
From the look of it Charles, this one wasn't far off being bought to it's knees... It was starting to suffer with a lack of boost from cold, which with the amount round the boost sensor is hardly supprising. runs a lot better now, pulls a lot cleaner.

Another thing I've got to look at is pull the rocker cover off and check the injector clearances, sounds like a noisy tappet in there, but with them being hydraulic there is no adjustment so I'll check the injectors first before going any further. I know they arn't the quietest engine in the world, but still....


Rob
 
RobCSH said:
From the look of it Charles, this one wasn't far off being bought to it's knees... It was starting to suffer with a lack of boost from cold, which with the amount round the boost sensor is hardly supprising. runs a lot better now, pulls a lot cleaner.

Another thing I've got to look at is pull the rocker cover off and check the injector clearances, sounds like a noisy tappet in there, but with them being hydraulic there is no adjustment so I'll check the injectors first before going any further. I know they aren't the quietest engine in the world, but still....


Rob
Click to expand...

Careful now ...... if it's a td5 with Delphi mechanical injectors isn't it the case that the VALVE followers are hydraulics, but the INJECTOR rockers are adjustable? I had all my injectors out to sort those bloody copper washers, and I recall the good book says to adjust the injector rocker clearances. (As it happens I didn't as I used the same injectors and washers into the same holes).

I also think the good book says use NEW adjusters and nuts on the injector rockers if you need to adjust them. They may think (know?) the adjusters cause trouble if re-used.

Let me know what transpires.

CharlesY
 
Yes, it's the injectors I'm going to check. Can't see why you'd need to repace anything and it doesn't mention it on RAVE.

And true to my usual run of luck, it gained a missfire this morning. Found the injector harness full of engine oil. Just ordered the replacements, given it a quick clean out with brake cleaner at the mo, and it's running OK again.

I'm just hoping this one doesn't turn into a royal pain in the arse, it's doing France the end of this month...

Rob
 
Ah yes, your right, just found the section on RAVE about removal and discard the screws and locknuts. Wonder why?

Me thinks a chat with the lads at JE might be in order...there units an the same estate as ours..

Rob
 
RobCSH said:
Ah yes, your right, just found the section on RAVE about removal and discard the screws and locknuts. Wonder why?

Me thinks a chat with the lads at JE might be in order...there units an the same estate as ours..

Rob
Click to expand...

Rave also says to replace the rocker shaft and injector clamp bolts - are you bothering with that?

I hoping to do my injectors this weekend as they have got very noisy...

Cheers

d.
 
Would have thought you would only replace them if you remove them, haven't had a chance to talk to JE yet.

Rob.

CharlesY, thanks for the advice given, hope I can return the favour sometime.
 
My one is doing well now, and I did not use new bolts on the injector rocker shaft. Fingers crossed!

However, I was VERY careful to clean between the rocker pedestals and the head, and to make sure no injector rocker was bottoming out. Evreything was torqued down progressively. It is always well worth the small amount of extra time it takes to do this. The thing simply goes back together "better" if this is done well.

A point worth noting when working on this area of the TD5 engine is the danger of dropping things down the timing chain passage .... diasaster!

Get a towel ... and press it gently into the space so that nothing can get down there.
 
Re EGR removal and the black gunk, my son in law and I did his Defender TD5 90 yr 2000 and my Disco II 2004, both had the same black gunk in the EGR, turbo pipe and inlet manifold. Our theory is that the exhaust outlet is a hot gas coming into the exhaust end of the EGR pipe then as its going through the EGR valve it meets the cooler air from the intercooler and condenses some of the unburnt/semi burnt diesel/soot to this black gunk. We then thought of the intercooler and sure enough on his 90 there was loads of it in the bottom of the intercooler, flushed out with Gunk numerous times and now seems to run even better.
 
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