EGR.. Should have done it ages ago.

D2 TD5. Bit the bullet this week and got an egr kit from JGS 4X4. Went to my mates this morning to get it done, just in case of any problems.
5 Studs out ok..... 1 broke off in Manifold. (Good job I had gone to him).

What should have been a 20 minute job turned into 3 hours, and Big Al getting rather annoyed.
Anyway, as usual , he persevered and won the battle. I gave him the price of a drink and set off home, not knowing what to expect.

I have often heard from you Guys on the forum say how it can transform a motor, Now I believe it. It just felt as though somebody had taken the handbrake off. I can't wait to check the mpg on the next tankfull.
I usually do a check when I do a brim to brim fill. It has been running on average at 20mpg. 23mpg. on a good long run at around 60mph on cruise.

I will keep you posted on my findings. Looking forward to driving my NEW Motor now.

Sounds good! Still got to get round to mine. Bought the kit in August and it still sits here under my desk!

20 to 23 mpg.. crikey are you constantly towing something or do you drive it like your on GTA. You should get much more than that.

Did you clean out all of the sooty/oily mess that the EGR valve creates in the inlet manifold?

Well worth doing it at the same time for the best improvement.



While not ideal, my TD5 wasn't too bad as you can see. A high milage Mundane-o I did recently was terrible with 5mm thick sludge all round the manifold. Inlet ports must have been down to 50/60% of their original size!

Also clean the MAP (Manifold Absolute Pressure sensor) in the inlet manifold. If the manifold is clarted this sensor will be also, giving duff info to the ECU.

I clean all ours with aerosol brake and clutch cleaner and allow to dry. DO NOT POKE ANYTHING DOWN THE SENSOR - you'll damage it !!!!


Dave

I will be doing mine in a few weeks. Got the kit, but waiting for the silicone hoses which I will put on at the same time.

Can the inlet manifold be cleaned without being removed? It seems like it might be an absolute sod to get off.

johnboy6 said:

5 Studs out ok..... 1 broke off in Manifold. (Good job I had gone to him).

Click to expand...

I'm curious as to why you had to take the manifold off. When I fitted a delete kit on mine, I just had to remove the two allen bolts holding the egr pipe onto the exhaust manifold and 4 allen bolts at the other end where it attaches to the inlet.

DIFFLOCK66 said:

I'm curious as to why you had to take the manifold off. When I fitted a delete kit on mine, I just had to remove the two allen bolts holding the egr pipe onto the exhaust manifold and 4 allen bolts at the other end where it attaches to the inlet.

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I assume when he says studs he means the allen bolts. Especially seeing as he said it broke of "in the manifold" not "in the head"

5 out ok plus 1 snapped = 6 total which is how many allen bolts there are.

JordanTD5 said:

I assume when he says studs he means the allen bolts. 5 out ok plus 1 snapped = 6 total which is how many allen bolts there are.

Click to expand...

Makes sense.

DIFFLOCK66 said:

I'm curious as to why you had to take the manifold off. When I fitted a delete kit on mine, I just had to remove the two allen bolts holding the egr pipe onto the exhaust manifold and 4 allen bolts at the other end where it attaches to the inlet.

Click to expand...

Sorry to mislead you. It was an Allen stud that sheared off, not a bolt.

Tks Biglad & Jordan for that advice. The short answer is that we didn't get time to do what you suggested, but hopefully We will get round to it in the near future.

Can anybody tell me if the removal of the inlet manifold is easy,normal, or hard to get off and on again.

Inlet manifold isn't hard but is a pain in the arse as space is limited.

wipe as much as you can with a rag and something to poke the rag inside, remove sensor first!

discodrivercumbria said:

wipe as much as you can with a rag and something to poke the rag inside, remove sensor first!

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Really? I would have thought there is a high risk of introducing debris into the engine. Fairly new to this so this is a question rather than a quip.

Also worth doing the inter cooler at the same time?

Have just removed my EGR over Christmas break but have now bought inlet manifold gasket so I can do a complete clean up

i wouldnt bother removing manifold or intercooler, once egr blocked it will clean itself

MrTox said:

Really? I would have thought there is a high risk of introducing debris into the engine. Fairly new to this so this is a question rather than a quip.

Also worth doing the inter cooler at the same time?

Click to expand...

depends how **** up it is? mine was sort of ok, so i did it carefully, cleaned MAP sensor twice now, once when i did it and 2 months later, i took intercooler right out and cleaned that out too!, but now have an uprated 1 on, a big difference since remap!

Ive just had mine blanked off and drove it last night. And its a loads more smoother running engine now and the power has increased. Im veryim pressed next job for me is remap.
When more pennys come

Was going to blank mine off, however, jus got replaced under warranty, so will see how it runs with a brand new one in for a while.