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TD5 EGR Removal


M&S
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I spoke with TD5 Alive at Donnington on Sunday and walked away with an EGR removal kit at a show price . This was the same price as the Bearmach kit but with a few differences.

The TD5 Alive kit has a flared pipe rather than a straight through one so the hose should stay on!

The pipe is also much thinner walled and aluminium unlike the thick walled steel one from BM. Less of a restriction and more suited for the inlet I think.

TD5 Alive also supplied a new gasket and allen bolts, but most importantly, comprehensive instructions on how to fit the kit! These proved spot-on and far more comprehensive than any others I've read or seen.

Anyway, the job was easy. Took 30mins.

1) Remove engine cover and fan shroud (for easier access).

2) Spray the 2 allen bolts on the exhaust pipe with WD40.

3) Remove the inlet hose and vac pipes from the EGR.

4) Remove the EGR valve (4 bolts, 5mm socket).

5) Remove the exhaust pipe (2 allen screws, 5mm). These screws are awkward to reach but a long allen key with a spanner on the end did the trick. An allen socket and extension bar would have been better but I didn't have one handy.

6) Fit blanking plate to exhaust manifold (the one supplied is nice and thick).

7) Fit new pipe to where the EGR valve use to live (new gasket also supplied).

Follow the vac pipes back to two solenoids. Unplug the solenoids.

9) I coiled the wiring and vac pipes up and left them in the engine bay with zip ties. I also put a couple of self trappers in the end of teh vac pipes. Not to stop the vacum (there won't be any with the solenoids diosconnected) but to stop water/dirt ingress. I also used duck tape over the solenoid connectors just to keep them clean and dry. Yes, I'm a bit sad

10) Refit the fan guard etc.

As I say, a 30min job One thing I should say is that I expected my engine to have the heat exchanger fitted (the Haynes book of lies would have me believe this to be the case) but it doesn't. It's a 2004 model so should have, but then it also should have a CDL in the transfer box, and it doesn't

So the bit that you are all wanting to know...how's the performance?

Well TD5 Alive did say that it wouldn't make any real difference to performance, but should improve the fuel economy slightly. I'll let you know after my next tank full. But a test drive has shown a difference in the way it drives.

When cold it pulls better at low revs. The hill out of our street can now be driven in 4th instead of 3rd.

When warmed up it seems to rev a little more freely throughout the range, maybe, hard to tell, could be that it's had a good run only 2 days ago . I'm not convinced that there's any real difference here. But at lower revs it is noticably quicker through the revs (from tickover to about 1500rpm). Pulling out of junctions is that bit quicker

As I say these are negligable differences really, and definiately not a performance increase. But pulling out of junctions is certainly improved and was the only part of the TD5 that I'd wanted to change.

Steph drove the truck today (oh yeah, she passed her driving test a couple of weeks ago ) and asked "if I'd done something to it" as it "seems better when pulling off". It doesn't get sop bogged down at low revs either, so the jobs a good'un.

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If you want to see the difference take off the inlet manifold and look inside! It may pay you to do so, you will need a new gasket though (not expensive). Be prepared to soak the manifold in degreaser for a day or two to get rid of the grunge inside. Whether that will make your engine go better is a matter of opinion, but it will make you feel happier knowing that all that stuff is not in the inlet tract.

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If you want to see the difference take off the inlet manifold and look inside! It may pay you to do so, you will need a new gasket though (not expensive). Be prepared to soak the manifold in degreaser for a day or two to get rid of the grunge inside. Whether that will make your engine go better is a matter of opinion, but it will make you feel happier knowing that all that stuff is not in the inlet tract.

It's on my list of things to do, sometime in the future :ph34r: My gearbox oil leak has got worse so that's the next mechanical job to do. They never get any better do they :rolleyes:

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I fancy Porny's kit for this as it has the new vacuum pump to the servo. Its a job for me too in the not too distant future.

Yeah, I did, but never got any reply to emails <_< so... but as above, if you disconnect the solenoids then no vacuum will be applied to the egr pipes anyway.

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