My EGR Effort

[rangieman]

Well since i got my Td5 Defender ive been reading madly about mods to the Td5 engines , so here,s my effort.

The old not too bad at all and still in working condition ,I just cleaned it up with a bit of wd40 to save getting some of that yucky black crud all over my hands;)
https://www.aulro.com/afvb/images/imported/2009/02/1330.jpg

And the result of some lathe work and welding
https://www.aulro.com/afvb/images/imported/2009/02/1331.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1332.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1333.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1334.jpg
Oh and of course the blanking plate for the exhaust manifold with coupling for thermo coupling for the EGT (pyro) gauge
https://www.aulro.com/afvb/images/imported/2009/03/3.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1335.jpg
And now with the thermo coupling , i got a long coupling 150mm so it will read just near the exhaust outlet into the turbo;)
https://www.aulro.com/afvb/images/imported/2009/03/4.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1336.jpg
The EGR bypass is now painted black with a coat of etch primer underneath ,Ill try and get a pic of the end result after the paint has dried
Then the fitting , next job on the list is the exhaust manifold mod,s;)
Hope you enjoy:cool:

[Sleepy]

Nice work rangieman - Gotta do this myself !

[moose]

That looks great! :cool:

[rangieman]

As stated earlier update of pics of the EGR bypass painted
https://www.aulro.com/afvb/images/imported/2009/02/1302.jpg
https://www.aulro.com/afvb/images/imported/2009/02/1303.jpg

And now the thermo coupling in the manifold
https://www.aulro.com/afvb/images/imported/2009/03/5.jpg
In this pic you can just see the probe of the themo coupling in the second exhaust port from the left
https://www.aulro.com/afvb/images/imported/2009/03/13.jpg

[rovercare]

Nice work, Chris:cool:

[rangieman]

Update time people , Well all the webbing was removed from in between the exhaust ports on the manifold with a die grinder and all holes except the centre 2 on the centre exhaust port were drilled out to 10mm
https://www.aulro.com/afvb/images/imported/2009/02/1204.jpg
The manifold is warped about 2mm id say , when on a flat bench it had a slight movement from end to end but it didnt leak before and i needed the car back on the road so a thin layer of maniseal was used when refitting ,its not leaking;)
Now when refitting i did notice 6 of the 10 studs in the head were loose , I dont know if they came loose when removing the manifold nuts or they were loose before:eek:

So maybe anyone undertaking this task make sure all the studs are tight before refitiing the manifold:cool:
Now to the result no top end performance gains were noticed the only gain i found was turbo spool up is only slightly better:eek:
Now id like to see if there is any gain in fuel economy , maybe not
Would i do this EGR bypass to another Td5 :angel: Only if the EGR was faulty and needed replacement

[disco td5 x2]

hi mate im in the prosess of doing this job at the mo on my disco manual i just have a couple of questions it is obviously ok to cut the webbing between the ports on the manifold i thought this could weaken the manifold ?
and i was wondering what the senser is for that u have put in the blanking plate im trying 2 do everything i can while it is appart so any advise will b great`ly received thanks

[rangieman]

hi mate im in the prosess of doing this job at the mo on my disco manual i just have a couple of questions it is obviously ok to cut the webbing between the ports on the manifold i thought this could weaken the manifold ?
and i was wondering what the senser is for that u have put in the blanking plate im trying 2 do everything i can while it is appart so any advise will b great`ly received thanks
The probe is for a EGT gauge (Exhaust gas tempreture gauge)
Removing the webbing is to help stop the manifold warping;) in turn which can also break manifold studs hence why i also drilled the stud holes out to 10mm all except the centre port holes

[disco td5 x2]

thanks for the info mate i realize that taking the webbing away will reduce the chances of it sheering the studs if u notice the ? i put after my question i was asking u if it can weaken the manifold and cause it to break ? also where might i get a temp gauge and sensor thanks mate

[XSiV]

Can I ask where you got the pyrometer? Have you sourced a guage yet? Or did hey come as a set?

CHeers

Josh

[rangieman]

Can I ask where you got the pyrometer? Have you sourced a guage yet? Or did hey come as a set?

CHeers

Josh
The probe i aqquired from a top secret place;)
This the guage im using , I had it in my old Tdi ,Its neat compact and affordable:D
The probe that comes with the kit was too short for my needs:cool:
DIGITAL EGT THERMOMETER PYROMETER W/ Probe - eBay Thermometers, Test Equipment, Electrical Test Equipment, Business Industrial. (end time 18-Feb-09 02:44:37 AEDST) (http://cgi.ebay.com.au/DIGITAL-EGT-THERMOMETER-PYROMETER-W-Probe_W0QQitemZ190285253370QQihZ009QQcategoryZ5097 4QQcmdZViewItemQQ_trksidZp1742.m153.l1262)

[Rosscoe68]

sell me the probe that came with your kit :) . i have the same kit and broke the probe off while i was fitting my tm-2 so now i have a egt display that reads eeee

[rangieman]

sell me the probe that came with your kit :) . i have the same kit and broke the probe off while i was fitting my tm-2 so now i have a egt display that reads eeee
Pm me your address and ill mail it to you;)

[Rosscoe68]

hey there, thats a bit awkward cos i am currently on the road travelling around aus. i'll work out where our next stop is and get you to send it c/o the post office. will let you know soon where our next stop is.

[Rosscoe68]

where abouts are you, i might be going past on my way round aus :)