TD5 Mods

[HowardSmall]

I have just carried out the EGR mod, fitted a new injector loom and replaced the MAF in the hope it would fix my intermittent low rev power loss. Sadly it did not...

However it did raise a couple of questions but before I write them I must point out I am not a mechanic so I may well be barking up the wrong tree.

When I pulled out the EGR plumbing it looked to me that the exhaust gas flowing to the inlet manifold is controlled by a vacuum valve. If that is the case why replace the plumbing? Why not simply stop the valve opening by controlling the vacuum? (That would have stopped me shearing off one of the two bolts that now have to hold the blanking plate in place and thus saved me a large bill from the local repair shop)

The flow of oil to the ECU via the injector loom is not going to be stopped by replacing the loom. Looking at the new one it is simply some wires held loosely in a plastic duct in which oil can enter freely. The weakness in the system appears to be the ability of the oil to flow via the plug/socket connecting the injector loom to the external loom. The two O rings stop it flowing past the plug so the oil has to seep past the contacts or flow through the contacts to get to the external loom. Eventually the problem will recur. Has anyone ever tried to address the flow at that point to make a permanent fix?

Final question. When I unplugged the loom from the injectors I saw that the injector socket had heaps of oil in it. Does this have an effect on performance?

Howard

[slug_burner]

I think the effect on performance occurs once the oil makes its way to the ECU. There it has effects such that the engine will not rev to its full range and will not go much past 2500 rpm.

There is not much worth doing to the loom given the oil makes its way inside the individual wires via capillary action.

The reason for removing the EGR valve is to remove the aerodynamic blockage to the inlet airflow therefore improving the breathing efficiency of the engine.

[goingbush]

<snip>

The reason for removing the EGR valve is to remove the aerodynamic blockage to the inlet airflow therefore improving the breathing efficiency of the engine.

incorrect, it is to stop dirty exhaust gasses being passed back through the intake system, stops the inlet manifold and inlet tract being coked up with soot and gunge , improved airflow is a bonus but not the reason.

[HowardSmall]

He was replying to my question as to why it is necessary to remove the EGR plumbing instead of simply disabling the vacuum control and thus stopping the exhaust gases flowing to the inlet manifold.

Howard


incorrect, it is to stop dirty exhaust gasses being passed back through the intake system, stops the inlet manifold and inlet tract being coked up with soot and gunge , improved airflow is a bonus but not the reason.

[nedflanders]

I replaced the injector loom 12 months ago and have regularly checked the plug at the head and seen no oil reappear their, however I am still cleaning the red plug at the ECU as there is still oil appearing there, all I can think of its residual as it is getting less. I take it you have cleaned the ECU when you changed the loom? Also the EGR is removed as any restriction in the intake can't be that good, especially as it isn't being used anymore.

[BilboBoggles]

Another mod to consider, disconnect the sensor on the clutch pedal. Amazing the difference in performance, no more 2nd gear sluggishness.

[djam1]

Another reason to remove the EGR is it falls apart and ends up in cylinder no1
The end result is usually a new block

Are you sure the intermittent low end torque loss isn't turbo lag?
Is it more prevalent on warm afternoons and never there on a cool morning?

[Chilly]

Another mod to consider, disconnect the sensor on the clutch pedal. Amazing the difference in performance, no more 2nd gear sluggishness.

First time I have heard this one...how come this works...and how good

[slug_burner]

incorrect, it is to stop dirty exhaust gasses being passed back through the intake system, stops the inlet manifold and inlet tract being coked up with soot and gunge , improved airflow is a bonus but not the reason.

Might help if you read the answer in the context of the question.

[mools]

Another mod to consider, disconnect the sensor on the clutch pedal. Amazing the difference in performance, no more 2nd gear sluggishness.

Year never heard of this too. How is disconnecting the clutch switch beneficial? I thought the purpose of the switch was to kill the revs once the clutch was disengauged.

Bilbo, can you elaborate?

Also, I have wired up a cruise controll and I know it cuts out if the clutch switch is operated, if the switch is disconnected then will it affect the operation of the cruise function at the ECU?

Cheers,

Ian.

[BilboBoggles]

The ecu cuts the fuel when it senses the clutch, this results in what seems like turbo lag, but is really the ecu cutting fuel. If you disconnect the sensor the ecu defaults to not cutting the fuel. It goes like a rocket after that, none of the classic td5 sluggishness as you go to second after you take off from the lights. Do a Google search on td5 clutch sensor and you will find a technical write up as to why this works.

I was sceptical, but it takes 2 seconds to disconnect, just don't lose the little metal wire clip. I was surprised at the difference it made.