Thread: egr blanking

Originally Posted by bob10

Going to blank off the egr , and after reading the relevant thread, will remove all evidence of its existence. Any one been picked up by Transport after doing this? Interested to know, cheers, Bob

I have a TD5 Alive kit from the UK. Looks factory. You couldnt tell its been done.

The tutorial I read mentions tapping and threading the exhaust blanking plate for an egt gauge.Would appreciate if anyone has done this, could they give me a heads-up on what brand of gauge used, and any pitfalls? Thanks for any input, Bob

DIGITAL EGT THERMOMETER PYROMETER W/ PROBE-NPT

Bob10,
I bought a 'Madman' EMS kit that comes with EGT, water temp, oil pressure and temp as well as an optional temp probe for either gearbox or TC.

It is a very good kit and comes with a blanking plate already pre drilled and tapped for the EGT. You'll still have to purchase the replacement modulator (EGR 'Valve') or if you are handy with the tools, modify the original as I have done and no-one will notice that the original modulator has no internals but looks stock!

Took about 3-4 hours to remove the EGR gear and install the EMS and the engine management and performance benefits are worth the effort!

Cheers

A good egr bypass kit will come with the appropriate plate. Then you just need to get the right thread cutter to match your probe. Most require a tapered thread. If I recall correctly, the Madman EMS website has instructions, and a video tutorial on doing just this.

You then have two paths.

1. You can leave the EGR air cooler in place, and everything else, and to the casual observer, it will all look exactly as it should. Doing this properly means gutting the current EGR inlet of its butterfly etc, and putting the inlet for the arircooler "over" your new sealing plate for the exhaust manifold. (does make it hard to put a temp probe their).

2. Remove all traces of EGR. this means blanking the exh manifold, removing the air cooler, removing all the vaccum lines, redirecting the coolant lines, putting on a new inlet piece. It only takes about an hour to do this....but double that if you dont know what you are doing.

I went option 2. I did this because....i now have lots more room for sticking my hands down the front of the engine (think viscous hub removal), and if ever I was to get nailed by the police, I have the complete system, undamaged or modified ready to put back on if I ever need to. I doubt this will happen, its a stockish looking discovery, not a Nissan Skyline with fully sick wheels and exhaust.

Yeah, I can't see why the boys in blue or the transport guys would have second look at a disco2, or under the bonnet,,, unless.......massive external mods maybe.

I just had my unregistered D2 - with EGR completely removed - pass inspection for NSW plates. What do you imagine inspectors can know and see with all the covers in place.

I have no doubt the EGR was counter productive. Possibly worked for the 1st few kms but cost energy to produce and compounded my TD5 problems by re-circulating crap including metal fragments multiple times through the motor.

JOB DONE !Removed all evidence of an egr, the kit I bought looks like it was there from new, took about 1.5 hrs., luckily I had the right tools [more luck than management] Would have been less time taken if I didn't have to search for dropped bolts. It has made a definite difference to performance at the low rev range, the turbo seems to come in at lower revs.[ could be imagination] With the amount of gunk in the inlet manifold, its a wonder the disco went at all. I wiped as much as I could from it , but was worried about dropping a solid piece into the inlet.I will take it for a decent drive to hopefully bring it up to temp. and blow a lot of it thru. Apart from that, it will be a removal and clean job[ when I get a bigger intercooler, says he, dreaming again] Might be imagination again , but before the job I had a definate vibration at idle,[ like a miss in a petrol engine] now I dont.