HELP!Disco 300, Injection Pump and EGR valve

I would appreciate some help regarding the FI pump and EGR Valve
I have rescued a 1995 Discovery 300 for a few hundred quid and propose to refurbish it and give it a life extension;
I started with a quality replacement engine. Not sure of source or model of donor but unlike the original engine it does not have an EGR valve nor the Bosch micro switch on the accelerator spindle on the pump.
The original pump and turbo ran great, but underpowered, so I re fitted the original turbo&manifold and FI Pump with switch. The result is masses of unburnt fuel spuing out of the exhaust. I have re checked the timing and its fine.
Do I need the EGR system, what does it do, is it a benefit. What does the Bosch micro switch do on the pump is it essential, can I put this on my original pump. Any contribution, comments, would be appreciated

Hi mate with regards to the EGR valve. As far as I know (and someone with MUCH more experience will be along shortly I'm sure) the EGR stands for Exhaust Recirculator Valve, basically it does what it says on the tin.

As the exhuast gas is emitted from the engine, this little gizmo takes some of the exhaust and pushes it back into the combustion... I can only guess this was done to help pass emissions tests as to me putting hot dirty air back into the mix can only hinder the combustion process.

Others have bought an EGR blanking kit to actually prevent this happening (I have just picked the blanking kit up but not fitted it yet).

Seems to be two main ways of stopping this process. Either just fitting the EGR blanking kit to stop the air going back in, or a slighty more expansive kit is a blanking plate and new hoses which is what I think you have on the new engine.

From what I have read there seems to be a basic three step process to give your Tdi a bit more kick and make it pull better/more smoothly and this is one of them:

1. Blank off EGR valve (Cheap as chips)
2. Fit bigger intercooler (expensive but I've seen posts about using a 7.5tonne LDV or Iveco intercooler, apparantly a good fit?!?!)
3. Fit a de-cat pipe (less resistance for the engine getting rid of the exhaust)

hope this helps.

steve drewery said:

I would appreciate some help regarding the FI pump and EGR Valve
I have rescued a 1995 Discovery 300 for a few hundred quid and propose to refurbish it and give it a life extension;
I started with a quality replacement engine. Not sure of source or model of donor but unlike the original engine it does not have an EGR valve nor the Bosch micro switch on the accelerator spindle on the pump.
The original pump and turbo ran great, but underpowered, so I re fitted the original turbo&manifold and FI Pump with switch. The result is masses of unburnt fuel spuing out of the exhaust. I have re checked the timing and its fine.
Do I need the EGR system, what does it do, is it a benefit. What does the Bosch micro switch do on the pump is it essential, can I put this on my original pump. Any contribution, comments, would be appreciated

Click to expand...

not sure about the pumps? are you saying the 1 you have fitted is the hot wire type and the other 1 the older version? 1 needs air flow meter and 1 dont if im correct.. throw the egr in the bin lol

User manual LAND ROVER DISCOVERY - User guide LAND ROVER DISCOVERY - Operating instructions LAND ROVER DISCOVERY - English - Diplodocs

Download the works manual from this site, tells you all about the engines and egr valve

Regards Pete