TD5 EGR Blanking Using TD4 Kit

Hello,

I was wondering if anyone could offer some advice on blanking the EGR of my Defender TD5.

Basically I have the proper blanking kit from Paddock Spares, but for the life of me I cannot undo the two allen head bolts connecting the pipe tot he exhaust manifold. The allen head has now rounded, so I tried knocking in a star drive, but no joy, so I then chopped slots in the heads to try using a flat head screw driver to undo, but still no joy. I have been soaking the bolts in WD40 at every opportunity but the damn things refuse to budge.

Aside from chopping the pipe out then chopping the heads off and trying to drill out the bolts (which I am loathed to do as I fear I won't be able to get a drill in place - given the space constraints in the engine bay) I had though about using the TD4 kit. This kit has an extra section attached to the body of the replacement for the EGR valve section which fits into the pipe work effectively blanking it off, just much closer to the valve itself as opposed to straight out of the manifold.

I guess my question is, has anyone attempted this method and/or does anyone thin that it would not work?

And also does anyone know how to solve the current predicament of the stuck bolts?

All thoughts and opinions welcome.....unless they are mean

Thanks in advance
Tom

I had to remove my exhaust manifold to fit mine! Same issue.

Mine was blanked off on the flexi pipe that comes out of the exhaust manifold but shortly after the pipe split.

Yeah I think the pressure build up in that pipe is too great for the wall thickness, which was my fear.
I've got a feeling the exhaust manifold will also give me grief to remove!

Did you drain the coolant and remove the coolant hoses going in above the manifold?

Get some proper heat on the allen bolts then grab them with molegrips. They will come out.
A normal plumbers blowlamp using MAPP gas will do the job if you don't have an oxy torch.
A butane or propane torch wont get hot enough as they need to be red/orange hot.
Also make sure the manifold is nice and warm before waving the torch around.

Doh! I just bought a butane torch to try and shift them....guess I'll be getting a refund on that and going for a bigger version

I blanked mine by fitting the blank between the flex pipe and the exhaust gas cooler on the front of the engine, the flex pipe should take the exhaust gas pressure OK that's what it normally has to do all the time that the EGR is closed.

TElsworth said:

Doh! I just bought a butane torch to try and shift them....guess I'll be getting a refund on that and going for a bigger version

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Don't mess about with DIY blowlamps. Get a Rothenberger from a plumbing supplies shop and then you can switch between butane and MAPP (has some acetylene in it) as you wish.
They are also good for lighting the bbq and bonfires.