Thread: EGR valve mods + other jobs

this weekend did a couple of jobs on the disco the first one was to splice a new plug into the existing external injector harness this is the plug on the outside of the timing cover it was split in two,also replaced the injector harness but I had stripped the plugs the weekend before and sealed them up.

The last two jobs I did at work sunday night as it was very quite I removed the egr valve that bolts to the manifold and cleaned it up removed the carbon from the exhaust side of the valve then inserted a 25mm core plug (welsh plug or what some people call frost plugs),then using a hacksaw cut the shaft on the valve and removed it,then using a die grinder removed all that metal on the inside of the throat so it is nice and round.

Then using a soldering iron plugged the small tube that the vacuum line connects to and there is also a small hole under the vacuum diaphram housing tapped a thread into this (4mm)and loctited a bolt into this. from the outside everything looks normal I think this should improve airflow,the next task is the pipe between the turbo and intercooler it has a flat section in it this probably would act as a restriction as well.

The third job was to mount a trailer plug in the bumper using a hole saw I drilled a hole where the O is in the rover the last plug got torn off as it was mounted below the bumper

I have now modified the pipe that goes between the turbo and intercooler the pipe measures 49mm outside dia. where the crease is it drops down to 40mm so I cut the pipe past the nipple for the waste gate tube and welded a short length of exhaust tube on and refitted it.

It seems to have a bit more get up and go but this could all be in my head as well but any restictions in the inlet system can't be good need to do these mods using a dyno to prove if these things make a difference and I have all so taken out the centre muffler as well.