Sluggish after EGR removal.

Having exact the same problem on ours, egr is blanked a few weeks ago by the garage dude, sorry to break in just wanting to know what is the solution

I’m pleased about that as I thought it could have been worse. Unfortunately I didn’t get time to look over the weekend but I’m hoping it’s cleaning the small valve type thing pictured above. I’ll be checking this Saturday. As I have a few jobs to do before towing my caravan. Hopefully with the help of the guys on here I will get there.
I was expecting a big power difference with the EGR not the other way. Fingers crossed. Wat h this space.

A potential issue with EGR blanking and silicone hoses is that it can be very difficult to get a reliable seal on the hose from the intercooler to the new intake manifold pipe unless there is a large overlap. It can slip off very easily due to oil contamination, rob you of most of your boost and as it is covered by the plastic engine cover it can go unnoticed. If the clamp is too close to the end of the hose the oily silicone can squeeze from under the clamp and the tighter you clamp it the faster it squeezes out. Also many EGR replacement intake pipes have very little knurling on the end to prevent the clamp from slipping off. The bottom line is that unless you have a large overlap of hose over pipe it can be very difficult to prevent the pipe from being blown off by air pressure and spilling all your boost.
When you did the EGR blank did you remove the intercooler and flush the oil out? Did you do the same with the intake manifold? If not you can assume that this pipe will be significantly oil contaminated.

Hi Si and others. Well had a interesting day to say the least yesterday. I cleaned the little black sensor as shown In an earlier post. took the disco for a drive. all seemed ok but foot hard down and no more than 300 revs and 50MPH. took foot off and slowly accelerated and 70 80 no problem. Bloody baffled. Oh and it wouldn't kick down a gear either. so I googled this and it said gearbox oil level. I took out the 8mm level plug and oil ****ed out everywhere. so its stood with no oil in the gearbox and a gearbox service kit on order. Bloody hell!! Holiday in 3 weeks, will it be ready???
Oh and Si I never took the intercooler off. I may just put the bloody EGR back on and have done.

You better find somebody with nanocom to record a live data log cos it ca be a coincidental management issue then refitting the EGR would not help at all... what about F2 though, did you check that?

sierrafery said:

You better find somebody with nanocom to record a live data log cos it ca be a coincidental management issue then refitting the EGR would not help at all... what about F2 though, did you check that?

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Hi, I did check the F2 fuse and it was ok but i'm going to go through all of this again when I have the gearbox done at the weekend. I was wondering if that little sensor was or is damaged as I blew it out with an air hose. I cant find one second hand anywhere.

If you can get a Nanocom or similar, it would be useful to compare the live readings from the Mass Air Flow (MAF) and the Manifold Air Pressure (MAP) sensors under hard load. It may be that the turbo is drawing in plenty of air (MAF reading), but the engine is not getting the boost it produces (MAP reading).
Did you check the security of the hoses, especially the one from the intercooler to the EGR replacement pipe? It can look fine with the cover on, but you may find it comes off with a stiff pull, in which case you are effectively driving with minimal turbo boost.

Si Click said:

If you can get a Nanocom or similar, it would be useful to compare the live readings from the Mass Air Flow (MAF) and the Manifold Air Pressure (MAP) sensors under hard load. It may be that the turbo is drawing in plenty of air (MAF reading), but the engine is not getting the boost it produces (MAP reading).
Did you check the security of the hoses, especially the one from the intercooler to the EGR replacement pipe? It can look fine with the cover on, but you may find it comes off with a stiff pull, in which case you are effectively driving with minimal turbo boost.

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Hi Si I have checked them all. Tight and very secure. I’m baffled. Going to go through it all again at weekend then I’ll have to bite the bullet and take it to the garage. (Don’t want to but it may come to it.)

This really needs a diagnostic tool as there could be a number of reasons. One thing you might try when the auto box is sorted is disconnecting the MAF sensor plug. Without it the engine goes to a default setting and if the performance improves it is a reasonable sign that you need a new MAF sensor.
Talking to the guru, sierrafery, could this be fuel starvation? Dodgy fuel pump or FPR, blocked filter?

For some complete different story, this was on the loose at our d2 gave same result. But unmistakable to obvious, it sits in plain sight. See picture, (valve on the turbo don't know its name, stil learning

I think you mean the pressure line to the wastegate actuator.

Elmur Thud said:

Hi Si I have checked them all. Tight and very secure. I’m baffled. Going to go through it all again at weekend then I’ll have to bite the bullet and take it to the garage. (Don’t want to but it may come to it.)

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have you also checked the connection between EGR replacement pipe and intake manifold? In my case, even I put gasket between them , I had leak.
The mating surface of the pipe was not perfectly flat so it was removed and re-machined. It seems to be ok now.

Si click, that's the one.

Elmur Thud said:

Oh and it wouldn't kick down a gear either. so I googled this and it said gearbox oil level. I took out the 8mm level plug and oil ****ed out everywhere. so its stood with no oil in the gearbox and a gearbox service kit on order. .

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I'm assuming you opened up the filler plug with the engine turned off. If you are doing the service yourself this weekend make sure you understand the technique before you start. In essence, it is designed to be filled with the engine running and, as you found, will overflow massively once the engine is off and fluid is free to return to the sump.

Well guys.
This weekend I managed to get the gearbox serviced. not to bad to do. On the EGR fault thing. I purchased a mew MAP sensor, so I just replaced the old one and BOOM she is running like a dream and kicking down gears too. MAP sensor £20 so not worth buggering about with cleaning and recleaning the old one. I'll be on again in a few weeks when its onto the next project. Sunroofs!!
Cheers for all the help.

Good to hear you got it sorted. You should think about getting a diagnostic tool though (iCarsoft, Hawkeye, Nanocom) as connecting one of those would have led you to a faulty MAP sensor straightaway and saved you a lot of head scratching.

Si Click said:

Good to hear you got it sorted. You should think about getting a diagnostic tool though (iCarsoft, Hawkeye, Nanocom) as connecting one of those would have led you to a faulty MAP sensor straightaway and saved you a lot of head scratching.

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Thanks Si
It still running fine but today the windscreen wipers have started going and won’t turn off lol.
Just chilling as it’s doing my head in. I’ll start with that when I get a minute.

Si Click said:

You should think about getting a diagnostic tool though (iCarsoft, Hawkeye, Nanocom)

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I agree with getting a tester but i strongly discourage everybody to buy iCarsoft for Td5 cos it's useless with the engine management.

sierrafery said:

I agree with getting a tester but i strongly discourage everybody to buy iCarsoft for Td5 cos it's useless with the engine management.

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But you told me last week or so that icar soft would work? Saved me some beers. Didn't order it yet though.

Good the disco is running again, bold now?

Little art said:

But you told me last week or so that icar soft would work? Saved me some beers. Didn't order it yet though.

Good the disco is running again, bold now?

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show me the link where i said that iCarsoft works for Td5 engine management please...IIRC i told you about Foxwell so better check again instead of making me think i' was drunk