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Fitting EGR Blanking Plate on a TD5 without removing EGR

Discussion in 'Technical Archive' started by jackstringer, Dec 9, 2011.

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  1. jackstringer

    jackstringer New Member

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    Location:
    Mendip Hills, Somerset
    First HowTo so be gentle.

    The EGR Valve lets exhaust gasses back into the inlet. This was done to keep some EU regulation about emissions happy. But the cost is that power and efficiency is reduced. So plenty of TD5 engine owners blank of the EGR.

    Now I wanted to have the option of getting my EGR to work again just on the off chance that the Discovery fails a MOT. So this guide is not about the removal of the EGR.

    So here we go,
    First Buy a Blanking Kit. Mine came with a gasket and longer bolts. See.
    [​IMG]

    The Next step I feel is one of the most important. But you may think differently. Make a Cuppa. Tea is my choice but your welcome to try different things.
    [​IMG]

    Once you have your cuppa go to your Landrover and using the bonnet release open the bonnet. BTW make sure you attempt this while the engine is cold otherwise you could burn yourself.

    In the image below you can see 2 covers that I have highlighted. Remove these. The fan cover needs only 1/2 turn to release then remove.
    [​IMG]

    Now with the covers removed,

    [​IMG]

    So here is the EGR Valve


    1. This is were the nicely cooled air from the intercooler goes into the engine.
    2. The Valve
    3. Expansion Box
    Hot gases come from the exhaust system and into the expansion box then onto the valve and the into the engine. With the exhaust gases does come some oil/sooty residue. So at some point I will remove this lot and clean. But I will do that when I attempt a Intercooler Clean.

    [​IMG]

    Here is where I chose location for the blanking plate. This was mostly due to ease of access as I never know if I have to remove the blanking plate.

    [​IMG]

    Looking closer at the join it maybe worth noting that these bolts get very hot when the vehicle is in use. So be careful when removing as they can snap. So I suggest some lubricant such as WD40 though don't get it onto the aux belt below otherwise you will have a squeeky start up every morning...:doh:

    [​IMG]

    Its a Allen Key head. Its a little hard to get in there so I didn't use my T-Bar set. Just used a socket adapter.

    [​IMG]

    Comparing the bolts you can see the new ones are slightly longer.

    [​IMG]

    Now make a gap to fit in the new blanking plate. I had to use 2 screwdrivers to lever it apart.

    [​IMG]

    Now the plate will only fit in one way and it can be a bit fiddly. The notch goes at the bottom and on the far side from you. The order should be Expansion Box -> Blanking Plate -> Gasket -> Pipe. I decided as a token gesture to use some copper grease on the bolts as its worth doing as you go around the vehicle doing jobs.

    [​IMG]

    Now its a bit of a pain to get this in and done up but just take your time. Drink plenty of Tea. Now I don't tend to use a torque wrench very often so I just did it up sufficiently tight but don't over do it.

    [​IMG]

    Now that is the pipe blocked off. I decided that to be doubly sure that I don't get any issues I would prevent the EGR Valve from opening and closing as it might shut of some of the air coming into the engine. There are 2 pipes on the 2003 TD5 Disco 2 Facelift.

    In the image below you can see,

    1. The the EGR Valve
    2. Where the vacuum pipes go.
    [​IMG]


    Looking at the pipes where the attach to the valve I couldn't determin whether they are easily removed from that end so I removed them from the other end of the pipes.


    [​IMG]


    You can see the coloured pipes. This is where a junction box for vacuum pipes lives. I removed the 2 pipes then then put 2 bits of sealed plastic tube on the junction box. Otherwise you brakes might not work. I also taped up the ends of the pipes from the EGR to prevent dust and dirt getting in there.


    [​IMG]


    Jobs done. Now go have a cup of tea.


    I saved about ~1 MPG from this mod BYMMV. Not bad for something costing less than £10.

     
    Stookie42 likes this.
  2. Stookie42

    Stookie42 Member

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    An excellent thread. I bought my blanking kit from eBay the other day. Wish me luck.
     
  3. discodrivercumbria

    discodrivercumbria Well-Known Member

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    South lakes
    remove the lot, Far better!
     
    bankz5152 likes this.
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