Revision as of 14:35, 4 September 2011

credit to DaveAngel...

With the help and advice from fullfatrr members, i thought I’d document this for anybody else who wants to give their Rangie the full air treatment. Mine is a 2005 L322 - later models may varie.

After the change, the engine sounded better, and was definitely more responsive. Before the change i reset the computer and on one journey achieved ~23.5mpg with a mix of country lane and motorway work, after the change (and the same route home) i am getting closer to 27mpg doing the same journey. Pretty unscientific, but certainly a noticeable improvement.

The kit:- Replacement element - I’ve used a decent green cotton filter, but K&N are equally as good ~£70 http://www.brookwell.co.uk/item/7655/green-cotton-air-filter-rr-l322-td6--o-e--phe000040-

Breather ~£10 http://www.island-4x4.co.uk/breather-filter-llj500010-p-3163.html

EGR Blanking kit ~£40 http://www.johncraddockltd.co.uk/products/da1088_range_rover_l322_egr_blanking_kit_bmw_m57_.php

Tube of Firegum ~£3 http://www.halfords.com/webapp/wcs/stores/servlet/product_storeId_10001_catalogId_10151_categoryId_165625_productId_164909_langId_-1?cm_mmc=Shopping-_-Google%20Product%20Search-_-Car%20Care%20%26%20Maintenance%2FBody%20Repair%2FBody%20Filler-_-Holts%20Firegum%20150g&source=shopping

A screw and a bit of heat shrink.

Disclaimer:- Provided AS IS - I take no responsibility if you do this and cause damage, injury or neglect to tell your insurers.

1) Air Filter change.

You need to remove the plastic covers from the engine. Front piece first (there is an additional screw hidden down to the left of the front panel). The top left cover has capsulated screws. You will need to remove the filler cap, i would put it straight back on once the cowling is removed to make sure nothing falls into the engine.

[img]http://img28.imageshack.us/img28/3610/dscn1921a.jpg[/img]

The Air filter is on the left hand side of the engine, running front to back. Mine was dirter than a weekend in Paris without the wife. Take this out, clean out the airbox, and drop in the new element. The element has a offset lug so only fits in one way.

[img:640:480]http://img703.imageshack.us/img703/2950/dscn1925t.jpg[/img] [img:640:480]http://img845.imageshack.us/img845/6367/dscn1941k.jpg[/img]

2) Breather

This is a cheap little filter that needs to be changed to prevent damage to the turbo. Its located to the right of the air filter at the back of the engine below a sound proofing mat. You have to remove a plastic cover and two rubber gaskets.

Undo the screws holding down the wiring loom, you should be able to unscrew the three screws holding the breather cover in place without disconnecting the loom.

[img:640:480]http://img17.imageshack.us/img17/8291/dscn1936y.jpg[/img]

Replace the breather

[img:640:480]http://img593.imageshack.us/img593/9681/dscn1940b.jpg[/img]

Inside the cover you will find the filter, replace the o-ring at the same time with the o-ring from the kit.

Before replacing, change the gaskets supplied in the kit, these should still be in the retainers on the engine as below -

[img:640:480]http://img534.imageshack.us/img534/9028/dscn1939h.jpg[/img]

You can now replace the left hand sound proofing and engine cowling.

3) EGR Blanking kit.

The EGR recirculates exhaust gases to insure certain chemicals are burnt off before being expelled from the car. the use of this is questionable in a)diesels and b)countries with quality fuel. It appears more as a practice just to appease the Bill Oddie crowd, resulting in warmer (less dense) air, less o2 in the mix and crap being circulated in your engine.

Various kits are available online to blank off this valve. The one i chose completely blocks the exhaust and allows the intercooler air through. Some kits also have place to terminate the control valve (this may cause an engine warning light to illuminate on models newer than an 05.

The EGR valve is located at the front of the engine, you will see the (large) intake from the intercooler, the metal take off from the exhaust and a small control tube.

http://img846.imageshack.us/img846/5637/dscn1923.jpg

The EGR is held on to the head with four bolts. You will first have to remove all the piping. A word of warning that my valve was full of exhaust gunge which far from an elixir of health is probably quite harmful. Protective clothing might be wise.

http://img828.imageshack.us/img828/6996/dscn1927f.jpg Removing the intercooler hose

http://img713.imageshack.us/img713/2609/dscn1931x.jpg My valve was jammed with exhaust tar

I cleaned out as much as I could being careful not to allow any gunk to get inside the engine (which could have been fairly fatal for it).

http://img713.imageshack.us/img713/6642/dscn1928k.jpg This photo shows the EGR removed and the blanking kit ready to be fitted.

Once the EGR was removed, i added a small amount of firegum to the blanking valve and attached the exhaust take off pipe. DO NOT GET THIS NEAR THE INLET. This is purley to help get a decent seal and not get any nasty gases in the engine bay, re-close the jubilee clip with retainer. http://img822.imageshack.us/img822/6250/dscn1929o.jpg

Carefully bolt on the blanking kit and re-attach the intercooler hose and jubilee clip. http://img51.imageshack.us/img51/9513/dscn1930t.jpg You will now need to blank the control tube. I did this by inserting a screw down the tube http://img855.imageshack.us/img855/457/dscn1932y.jpg Adding some heat shrink.. http://img155.imageshack.us/img155/1092/dscn1933d.jpg And cable tying out of the way.. http://img233.imageshack.us/img233/3285/dscn1934d.jpg

Make sure everything is secure and re-attach all the cowling. Start and check all is well.

Below is a photo of my MOST screen, i reset trip 1 on the way to my brothers to perform this operation, and trip 2 on the way back. Once i got home i took this photo.. http://img856.imageshack.us/img856/8936/dscn1942p.jpg

One of the biggest changes is now I can hear the turbo spin down when take my foot off the throttle, a massive improvement.

Hope this helps anybody thinking of making the mod.