Hi there, not to sure on the details of weight etc but in regards to more power getting the ECU mapped to suit your own needs/driving style is a good place to start. Getting rid of the EGR should be up there somewhere, not because its a potential issue (in the long run yes) but because it is a relatively simple job and your engine will thank you. The disco has eu3 and eu3, the latter having a egr cooler so a de-EGR kit for an eu2 or 3 will vary slightly. I think late 2001 are eu3 but don't quote me on that. I've removed my catalytic converter for the hell of it really, haven't noticed an increase in power or anything but it's nice to know the engine should be breathing easier. Again only some of the td5's have the cat converter. On another note and your probably aware of the front prop shaft in these things; if not there's a thread with 200+ posts regarding it. I think I've read a few people beefing up the turbo on the td5 by installing another unit though I believe this is a more pricey upgrade. For 10-15k it looks like you'll be getting a v8 unless you can find a cheap td5 out there somewhere; I have a td5 and it's been able to do whatever I ask of it; though in comparison to your plans it's not a lot (towing a 97 Daewoo Lanos for 150k), is the most I've thrown at it, though my godfather whom I bought it off used it to tow his dingo (mini bobcat thingo) on a heavy duty trailer about 3-4 times a week for 6 years. Mines had its issues that I attribute to its working life, the worst being a blown rear diff, but other issues I was able to deal with myself apart from a few niggly jobs like a leaking transfer case.
the RAVE manual I would think should have some specific information your looking for; sorry I can't provide a link but someone will.



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