TD5 EGR Removal/Blanking

I am Ok with the EGR blank now after a long and crappy session fitting it. I also managed to find a nice man from DWlandrover who sold me a second egr clamp just in case i have to use it to refit the old egr for an mot reason etc etc. My problem fitting the Alisport pipe kit could have been a lot simpler and quicker had i opted to undo the two exhaust bolts but i was scared of them shearing off and being left in no mans land. I adapted the old egr clamp with a longer bolt and a packer so i could do it up and i retapped the two dodgy bolts into the manifold. Fitting the egr blank was a bugger to do because of the clamp. If i had a choice to fit the egr to the corrugated pipe OFF the engine it would have been much easier as there is no way with the new Alisport pipe bolted in place as there is no space and you cannot see what you are doing.. I have seen a few videos and none of them show the clamp being fitted with the two pipes in place and all of them just show the egr with the corrugated pipe and clamp all in one piece being removed as one.
So, i am now ready for a Storm remap with no egr, straight though exhaust centre and no cat, a completely fee wastegate arm, new wastegate and a ITG filter. I just hope its all worth it.

Def90man said:

Do you not put a blanking plate at the manifold end so there’s no fumes in the feed pipe?

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You dont need to add a blanking plate as the new Alisport pipe that replace the EGR comes with a big mushroom type thing that the old corrugated EGR feed pipe then clamps onto. There is then no need to remove the two rusty old blots and have the risk of snapping them. Trouble is though the refit with the new pipe and then trying to connect the clamp on the mushroom thing to the small egr feed pipe is a right bugger to do as there is little room and its under the new pipe so you cant see the clamp or its nut and bolt. I got there in the end with mine but add that taking off the egr feed pipe and adding it to the new Alisport pipe before you fit it means you can do up the clamp easily out of the motor. A much easier job and one i recommend.
On egr's it must be better for engine breathing if you remove the egr valve. Look inside one to see the muck in it and the restriction the rod and mechanism make to the airflow through the EGR body. After removing mine i can clearly now hear the turbo whistle much more clearly.

Def90man said:

Do you not put a blanking plate at the manifold end so there’s no fumes in the feed pipe?

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You dont need a blanking plate as the Alisport tube/pipe comes with the feed to the EGR corrugated pipe blanked off already. It has a mushroom like pipe that the old EGR clamp fits onto to hold the old egr pipe to the Alisport pipe even though no fumes can pass through it. Its their way of avoiding having a blanking plate or having to try and remove the old rusty two bolts into the exhaust manifold. Trouble with doing it this way is its expensive to use the Alisport version and it makes replacing the clamp a real pain as there is limited space and its underneath the pipe where you cant see and can easily get a spanner onto the bolt. See pic,

What happened to the changes in MOT regulations that said modifying emission control systems was an MOT fail?

Al2O3 said:

What happened to the changes in MOT regulations that said modifying emission control systems was an MOT fail?

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Well, strange to relate, a number of us on here have been submitting TD5 Land Rovers for MOTs and nobody's said anything. I have my EGR system somewhere in a shed in case it's ever needed but so far I've never been asked for it. I suppose a tester would be within their rights under the legislation to ask for it to be present in order to issue a pass, but in practice it just doesn't come up. All they do is the smoke test.

Brown said:

Well, strange to relate, a number of us on here have been submitting TD5 Land Rovers for MOTs and nobody's said anything. I have my EGR system somewhere in a shed in case it's ever needed but so far I've never been asked for it. I suppose a tester would be within their rights under the legislation to ask for it to be present in order to issue a pass, but in practice it just doesn't come up. All they do is the smoke test.

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Same here, but mine's a 96 300Tdi. Some had the EGR and some didn't. I removed mine when I rebuilt the engine. I've been thinking I'm getting away with it because with my age vehicle some did have them and some didn't, so a pain for the MOT bod to chase up. On the other hand, I would have thought all TD5's would have an EGR and so easy to check.

Mine's from 2006, so firmly in the emissions control era. A few people on here have been apprehensive about taking Land Rovers for MOTs without the EGR, but as far as I can tell, I don't think anyone's been told to come back with one fitted for a retest. I keep an eye on people's comments about TD5s because that's what I've got, but haven't been following what anyone's got to say about the later Ford-derived engines.

Def90man said:

Do you not put a blanking plate at the manifold end so there’s no fumes in the feed pipe?

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You dont have to if you reconnect the old corrugated egr feed pipe from the exhaust using the original clamp to connect it to the new Alisport tube. You can add a blanking plate in place of the pipe but then you are risking the two bolts snapping off so i left it one and used the clamp again. This caused me an hour or two wasted plus i found two of the four bolts on the alloy pipe that the old EGR bolted to were stripped so more time wasted on these. I didnt risk snapping the two egr pipe bolts and am going to have a LR repair shop remove them and replace them with two new ones from 3 rd March so they can re-drill the holes if they snap them. Then i might use a blanking plate and keep the old corrugated pipe and clamp bolted onto the old EGR unit just in case i need to refit it. The EGR itself is now gleaming as its been totally cleaned and the caked on crud from the internal shaft etc is now all gone.
I have no centre exhaust box, a new sports ITG air filter , a new wastegate actuator and freely moving wastegate now. I have also had a Storm Tuning Stage 2 remap done and the old girl flies now and accelerates up hills unlike before. Its also getting a LOF clutch kit fitted , a new power steering pump and pipes on the 3rd March and a transfer box rebuild as well.

Hopefully after all this it will last a while longer and have no oil leaks.


Update. I had the local 4x4 garage try to remove the two egr pipe bolts where the currugated egr pipe connects to the exhaust manifold and they snapped one. SO i should have done it myself and been careful ..... Now i only have one bolt left holding the pipe on!!!!!!!

Has anyone thought of removing all the internals of the old EGR to make it a straight through unit? Taking out the internal shaft and plunger and blocking off the vacuum pipe does the same and will fool a mot tester. If it looks like it is still in place maybe thats what is needed....... I might get a used EGR and try it especially if i can get the internal hole though it bored to the same size as the bigger in or out pipes it bolts to. Even just cutting out the central shaft and plunger thing will improve airflow through the old EGR unit and you can retain just a blanking plate on the corrugated egr pipe to/from the exhaust manifold too to stop the filthy fumes getting through.

Tim4x4 said:

In summary, modern EGR systems are beneficial for the reduction of harmful NOx emissions, improved throttle response, and increased engine longevity, particularly in diesel engines.

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ls the TD5 EGR system classed as "modern"?

lightning said:

ls the TD5 EGR system classed as "modern"?

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Yes