Thread: Out with the old, in with the new TD5 rad

One more thing........and this will highlight my noviceness: How do I check if my EGR has been blanked off? I believe there are pros and cons for its removal. Can someone point me to an explanation so I can see if mine's done or not? If not, I might leave ithtat way. Good? Bad? Help!
Thanks,
Pete

How can there be a bad side to stopping your engine injesting burnt stuff??

Originally Posted by Tinggu

Well, the rad and intercooler are out and also most of the hoses. Thanks Rob for the lend of your viscous fan tools. Made that bit of the job a cinch. Belt is off and spinny items all seem quiet and run true. Strangely, the Haines manual says the tensioner turns clockwise to release........mine goes anti-.....??? Spraying kero around to hose off the gunk tomorrow. Anything else to check before the bits come and I (try) and reassemble?
I noticed some soot on the top hose where it comes out the head, and here is a photo of the bits behind, looking sooty, and it would seem a manifold bolt gone AWOL. I've heard about this little problem but intend leaving it for now as I'm hoping it's not going to cause a stuff up for a wee while. I'd guess it's been like it for a long time. Is it a biggie to fix? Right now I just want to get the old girl back on the road again.

Looks like the pic is rotated. Left hand side should be at the top.
IMG_2556.jpg

The soot will be from the manifold warping like a banana, this snaps the cylinder 1 and/or 5 studs. Plenty of info on the forum about this. Are you getting a whistle under heavy load? You’ll be loosing power as any exhaust escaping isn’t getting to turn the turbo!
Repair involves removing manifold de-webbing/cutting the sections between each port then having it machined flat. Then renewing the manifold studs with upgraded ones and new gasket etc. Can also have the manifold ceramic coated at the same time to help with heat soak and prevent the manifold from warping again.

As for the EGR blanking if it’s done you’ll see an extra plate between the EGR cooler pipe work and manifold?? Usually if EGR is removed the whole thing is taken out and a new section of pipe added in its place and blank plates put over the manifold port.
Here’s a video YouTube

Hope this help!

Lemo

Thanks Lemo.....not exactly wot I was hoping to hear, but thanks anyway! Yes, a whistling sound under power. Had it for longer than I care to admit and I think I asked here some time back what it could be but don't recall this as being a suggested possibility. Can't find the thread right now. Sigh.......how often does it happen that fixing one job leads on to a whole bunch of new sagas? Job for next week. Right now we have to get rolling again.

As for the EGR I read this:EGR expained very nicely and watched the video you suggested. My setup is different from the vid in that there is a cooler with hoses and an additional thin vacuum hose attached to an actuating lever on the side of the EGR unit. I've always thought our beast pulls like a train and has a whole heap of "go" I would not expect from such a small engine in such a heavy car........but more would always be nice. I have reservations tho' about a roadworthy test which would likely test emissions. Would I be in trouble there? Also, with the emphasis these days on reducing emissions it's surely going against the tide to reducing pollution.

One thing in the story EGR expained very nicely (mentioned above) it mentions a custom computer chip to fool ECU into thinking that nothing has changed otherwise it may trigger a "check engine" light.

Right now, while waiting for the rad and hoses to turn up I'm cleaning up all those behind the radiator concealed places and still tackling a couple of recalcitrant hoses. I'm also going to rebalance the viscous fan which has a couple of chipped blades.
Cheers friends,
Pete

Fan blades trimmed and now seems in perfect balance, spins and stops randomly, rather than same chipped blade at the top each time it stops.

Originally Posted by Tinggu

Thanks Lemo.....not exactly wot I was hoping to hear, but thanks anyway! Yes, a whistling sound under power. Had it for longer than I care to admit and I think I asked here some time back what it could be but don't recall this as being a suggested possibility. Can't find the thread right now. Sigh.......how often does it happen that fixing one job leads on to a whole bunch of new sagas? Job for next week. Right now we have to get rolling again.

As for the EGR I read this:EGR expained very nicely and watched the video you suggested. My setup is different from the vid in that there is a cooler with hoses and an additional thin vacuum hose attached to an actuating lever on the side of the EGR unit. I've always thought our beast pulls like a train and has a whole heap of "go" I would not expect from such a small engine in such a heavy car........but more would always be nice. I have reservations tho' about a roadworthy test which would likely test emissions. Would I be in trouble there? Also, with the emphasis these days on reducing emissions it's surely going against the tide to reducing pollution.

One thing in the story EGR expained very nicely (mentioned above) it mentions a custom computer chip to fool ECU into thinking that nothing has changed otherwise it may trigger a "check engine" light.

Right now, while waiting for the rad and hoses to turn up I'm cleaning up all those behind the radiator concealed places and still tackling a couple of recalcitrant hoses. I'm also going to rebalance the viscous fan which has a couple of chipped blades.
Cheers friends,
Pete

Hey Pete

I’ve removed the EGR cooler and all the associated cooling hoses back to the oil cooler, if removing the EGR it removes a lot of hoses no longer require and my view less things to leak

Not sure on the EGR and ECU programme change but someone will chime in with a response? Mine was done prior to me purchasing.

Road worthy test would depend on your location etc, I’ve rarely seen an inspection mechanic look under the bonnet when doing a road worth in all the times I’ve taken my cars in, for the pittance they get for the inspection time required for a complete job I think a lot of things get missed, plus if they’re not a land rover mechanic and knew it had an EGR I think it’s not going to get picked up???

And as for the l’ve fixed that problem and found six more.... you’ll eventually get it all done and just enjoy the driving

Lemo

I was enjoying the driving just last week - the future seems distant..........even my spare parts are distant!

Well, it's job done and everything is back in its rightful place and no bits left over, apart from a couple of heater hoses that are no big deal to change at my leisure. There was a delay with bits as Australia Post "lost" my hoses etc for a few days, but thanks Mario and heather for chasing them up and helping out with a couple of queries. We were on the road Saturday but after so long in the shed other jobs had to be attended to before I could come back here for an update. She now runs at 81/82 C rather than 88/89 which must be due to the new 78C thermostat.
It was not a fun job. When dismantling I found the Transmission cooler did not want to separate from the Rad/Intercooler lump. I had to lever it out in the end and guessed correctly it would be a bugger to put back. The various workshop books don't mention the that the trans cooler has a peg that slides into a slot in the rad on the passenger side.. It would not go until I carved 3mm off the plastic housing after some hours of fruitless knucklebusting. Another mistake I made was to fit all the lower hose, including the thermostat before wrangling in the rad/intercooler lump. I had to backtrack, remove the thermostat to get the space I needed.
Having done the job I can see that that the radiator I have removed has the updated mods with the restriction for the fuel cooler and it seems a shame to trash an otherwise very serviceable rad for a decent rad with a stuffed sidetank. I had new a new sidetank fitted on our EA Falcon when that crumbled.........is that a viable option for my old rad? Does anyone put new side tanks on? It would make a decent 2nd hand option.
Next job is the exhaust manifold, but that might have to wait till we've spent a couple of weeks on our boat. Lucky us old farts!

Thanks to the community for all the help with this job. Rob lent some tools, Mario some knowledge and patience and Lemo and others for showing me I'm not alone!
My thanks to you all and this forum.
Pete