TD5 EGR Blanking Plate Fitting - My Tips

I think I have done it but I had two little pipes (sky blue with 90 degree rubber connectors) on my 03 and blocked them both. one on the main unit and one to a little actuator arm.

I have taken both off and blocked them - is that right? Do I need to block the holes in the egr?

Hi, I presume the reason this is done is to provide cool air only for greater efficiency (cuts-off hot exhaust re-feed). Hmmm, does seem a bit silly to have an intercooler if you are feeding hot recirc air). Should run cooler and more efficiently. Like to know what sort of improvement people get. Cheers, Stephen

Stephen_Aust said:

Hi, I presume the reason this is done is to provide cool air only for greater efficiency (cuts-off hot exhaust re-feed). Hmmm, does seem a bit silly to have an intercooler if you are feeding hot recirc air). Should run cooler and more efficiently. Like to know what sort of improvement people get. Cheers, Stephen

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I've done this on both of our TDi300's and found a noticable improvement in low-down pull, smoothness and economy.

Allied to the De-EGR, I would also recommend cleaning out the intercooler and changing the exhaust downpipe for a non-cat one - big improvement on the 300's !!

Cheers
Dave

Everyone likes pics ...

So here's mine. This is a 300 Tdi, but I'd guess that it's similar to a TD5, maybe, perhaps, possibly, who cares ...

First pic is what the manifold area looks like without the whole EGR system and new top hose without the tee-piece. The arrow points to where the EGR blanking plate is fitted.

Second pic is the whole EGR system removed. I've blanked the pipe end, and just tucked the pipe and wiring behind the airbox. The arrow points to where the EGR blanking plate could be fitted if you wanted to leave the system on, but not functioning .'just in case' ...

Has to be said that there's a great improvement. I also cleaned all the pipework, indeed it was actually all renewed, and cleaned out the intercooler and plenum chamber. Bottle of white spirit, shaken, left 30 minutes, shaken again and flushed out, then repeated. Cost me four bottles of white spirit at 50p a bottle, so well worth it IMHO.

I've also added a de-cat downpipe, can't afford a straight through centre pipe yet, but with these mods on it has to be said that there's a definite jump in performance which can be felt and easily seen. Seems to run smoother as well. Mpg's are about the same, but then I'm still 'playing' with the extra performance ... Towing is a much more relaxed affair, with fewer gear changes. Not been properly off-road yet, just a couple of small green lanes, but the low-down pick-up is definitely and noticeably cleaner, no judders when you get bogged down with too few revs, it now just picks up and revs freely, which bodes well for 'real' off-roading.

So far done 140 miles towing a caravan, about 500 miles solo with full boot and four adults, and about 300 miles short journeys solo, empty. All circumstances drive better and smoother, simple as.

I fully expect that when the novelty has worn off the fuel economy will improve, but I'm still playing with the extra performance ... it's that noticeable ...

The black ****e/goo in the intercooler and hoses (condensed from the exhause gas) is just extrordinary, but then it has gone 200,000Km. Plan to blank EGR, but is there a quick note someone can give on how to get the intercooler out of a Disco Td5 so I can clean it out (as per above post)? It's a wonder the intercooler works. I am keen to have a 100% functional intercooler to get the best out of the ECU upgrade.

Stephen_Aust said:

The black ****e/goo in the intercooler and hoses (condensed from the exhause gas) is just extrordinary, but then it has gone 200,000Km. Plan to blank EGR, but is there a quick note someone can give on how to get the intercooler out of a Disco Td5 so I can clean it out (as per above post)? It's a wonder the intercooler works. I am keen to have a 100% functional intercooler to get the best out of the ECU upgrade.

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There you go...

www.discovery2.co.uk / Workshop / Intercooler Cleaninr

GR8. Looks like about 4 hours work?

Many thanks.

Hi

Just got my EGR removal kit from alisport via ebay £33 plus postage (didnt seem to bad)

Can anyone recomend torque settings for these bolts or just hand tight and back a bit! Didnt get a gasket for the blanking plate but reading this I will probably go for gasket sealer.

Cheers

Rob

Recently brought a TD5 disco (dream car when younger) and still smiling although sadly being heavily effected by the bolt on bug

Hi i recently fitted a egr blanking plate on my 04 Td5 but i was not aware that i was supposed to block the vacuume pipe. I have found i have 2 blue pipes. 1 from the egr valve to the egr valve modulater and the other from the ILT valve to the ILT valve modulator. Could someone please let me know if i have to block both these pipes or just the egr one and do i leave the pipe or pipes attached at each end with something blocking the pipe in the middle. Thanks...Tony

of course you could just take the whole viscous fan off then you don't have to frig about in between it - lets face it it's on there to keep ur engine cool when its towing a 3t trailer thro the desert - here in Wales heat aint a problem

Tony

Had the same problem today. Had to put it all back together as the guidance note from alisport didnt mention it. I can answer the blue pipes as alisport recomend just connecting them into each other. I too now am wondering what do i do with the other two pipes that only appear on the later model td5's. TD5 alive supply two additonal blanking plates in their kits????. I just knew I should of paid more for their kit!!!

Today i decided to block both the pipes I have pulled the pipes of the EGR and ILT valves screwed a small self tapper screw in each metal pipe on the valves then pushed the pipes back on i have also fitted a stainless steel de-cat pipe and a stainless steel through pipe to replace the center silencer. Sounds more powerfull and performes better in lower gears (mines a automatic) not tried it on the motorway yet. I am now considering cleaning out the intercooler but not sure if that will make much difference as it has only done 45,000 miles hopefully someone will advise me on that....Tony

You should only need to block the pipes if you have removed the egr. If you just blank it off from the manifold, then the egr valve continues to open and close as normal, but doesn't do anything. All the pipes do (I think) is operate the valve. If you remove the valve, you need to block them.

The instructions that came with mine (from JGS4X4) said to remove the vacuum pipe(s) from the EGR solenoid actuator (near the brake servo unit) and then fit the vacuum blanking plugs that came with the EGR kit. Some Discos have one pipe, some have two.

If you didn't get the blanking plugs with your kit you could probably make them up from a piece of vacuum tube with a screw glued in the end of it??

So in theory if you were to just block the valve pipe or in my case pipes that would stop the valve from operating, if that is the case you would not need a blanking plate as it would have the same effect...maybee..possibly F**k i'm more confused now i think

Tony S said:

So in theory if you were to just block the valve pipe or in my case pipes that would stop the valve from operating, if that is the case you would not need a blanking plate as it would have the same effect...maybee..possibly F**k i'm more confused now i think

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Hope the following makes it a little clearer - I'm new to all this and once I'd read up on it I could make more sense of it. This forum was a great help - search through the tech articles from the homepage.

From what I've read:

Removing the EGR itself allows the engine to breath more easily. You could just disconnect the vacuum pipes that open and shut the valve inside the EGR but there would still some restriction to the flow through the EGR.

Some EGR's have a butterfly inside which restricts the flow further, this would be worse if the butterfly was stuck part way.

Blanking the exhaust port prevents the spent exhaust gasses from being recirculated through the engine to be burnt again.

On Discos that have a cooler as part of the pipe work from the exhaust connection to the EGR valve you leave this in place but insert the blank to block the exhaust gasses from being recirculated. On Discos where the the exhaust connection to the EGR valvedoes not get cooled you remove the whole of the pipework, EGR and all.

You have to block the vacuum connection(s) to prevent loss of suction or vacuum - if you didn't block it it would just keep trying to close the EGR valve that you have removed. Some Discos have two vacuum connections some only have one.

Here's a scan of the instructions that came with my kit, they made the whole job a lot easier. The direct url is here

Tony S said:

So in theory if you were to just block the valve pipe or in my case pipes that would stop the valve from operating, if that is the case you would not need a blanking plate as it would have the same effect...maybee..possibly F**k i'm more confused now i think

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In theory I think that's correct. However if your engine has done much mileage the valve may be stuck partly open, which is probably the main reason for blanking it off in the first place. If the valve is not making a perfect seal, then just stopping it from operating won't be as effective as blanking it off completely. In practice, you may want to remove the valve anyway, in which case you need to block the pipes. This would probably improve the performance still further.

Erm i think i get the jist of it now. I fitted my blanking plate at the exhaust manifold and i have blocked the 2 pipes by sealing the bit of metal pipes on the 2 valves and then re-fitted the pipes just not sure if i need to clean out the intercooler...Tony

Cheers Headtester, just the answer I needed. As I dont have any vacum pipe blanks i'll connect them together like alisport have said as it should do the same thing I guess.

Thanks again

Tony S said:

Erm i think i get the jist of it now. I fitted my blanking plate at the exhaust manifold and i have blocked the 2 pipes by sealing the bit of metal pipes on the 2 valves and then re-fitted the pipes just not sure if i need to clean out the intercooler...Tony

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You don't need to, but it may improve performance. I never bothered.