Question About EGR ????

[Swampey]

Sorry for opening yet another post about EGR.. but Ive been looking at this little up grade to my TD5 and I still am losed on this subject.

Diffrent kits.. ie £6 for blanking plates and then £70 for blanking plates and some metal tube and some hoses......

Now I understand the basic concept on why ppl have them on there discoverys... to stop warm are being mix in the engine.. and there are the claims of better MPG and more engine torque.

BUT I AM STILL LOSTED..... what do I remove, do I have to mess with the electrics.. and wheres all that gas that would have recirculated-- wheres is going to go ?????????

Wanna do the conversion but dont wanna screw my baby up

PS - I crap with a screw driver, but Im bloody good with a hammer ....lol

 

[David Pye]

Righty, here ya go:

EGR does what the name implies : recirculates a certain % of the exhaust gas back into the inlet manifold to 'reburn' it to reduce NOx emisions.

If you remove it, the gas that would have been recirculated goes out of the exhaust (taking with it all the dirty oily crap that the EGR would helpfully have deposited in the inlet manifold).

Main reason for replacing it, apart from as you mentioned: Faulty stuck open EGR valve allows recirculation inappropriately, and causes drop in economy and performance. Easier to replace than buy a new one.

What gets removed is as follows: (There are two types of EGR depending on exactly when yours was made as they upgraded it to meet tighter emissions requirements)

Mine is an earlier one (2002) so my instructions apply to that. Full instructions come with the kit though.

1) Undo the two bolts holding the EGR valve metal hose to the exhaust manifold. Spray WD40 on these first, they are often very seized up!
2) Undo the bolts securing this metal hose to the front of the cylinder head.
3) Remove the jubilee clip from the intercooler hose and remove it from the EGR valve
4) Remove the four bolts securing the EGR valve to the inlet manifold, disconnect the vacuum tube and remove it.
5) Fix new plate over hole in exhaust manifold
6) Bolt flanged tube that comes in kit to inlet manifold, and resecure the intercooler hose to it.
7) Stick new rubber tube with blind end over vacuum tube from solenoid.
8) Unplug electrical connection from solenoid.

Job done.

The kit you need for a TD5 consists of a few things:

1) a small metal plate (oval shaped) that goes where the EGR valve connects to the exhaust manifold to plug that hole.

2) A metal tube with a flange on, which goes where the EGR valve sat. The flange bolts to the inlet manifold, the tube takes the hose from the intercooler.

3) A little rubber tube with a blind end to connect over the vacuum tube from the solenoid where it used to plug into the EGR valve. (probably dont need this if you unplug the solenoid anyway but hey..)

Hope that helps.

David

From an electrics point of view, you just unplug the connector that goes to the EGR solenoid valve, and that's the end of that problem.

 

[Swampey]

Anyone got some pics of this process

 

[BrianB]

Try here Mate, A very good write up with pictures.

www.discovery2.co.uk /workshop - EGR removal

Brian

 

[David Pye]

Good link - I used those pics to guide me doing mine

 

[BrianB]

Good link - I used those pics to guide me doing mine

When i can find a decent EGR kit at a good price ill be using them myself

Got to fix my 2 leaking rear ACE pipes first NOT CHEAP!

Brian

 

[Swampey]

Good Pics But Mines Got An Heat Exchanger As Well

Looked At TD5 Live Looks All Very Complex