Land Rover Fitting The Bell Auto S Tdv6 Egr Blanking Kit To A My06 Tdv6 Hse Bellautos Manual

Fitting the Bell Auto Services (B-A-S) TDV6 EGR Blanking Kit to a 
2006 model Discovery 3 TDV6 HSE   
Before I describe how I did this, I must first add a disclaimer:  
You do this modification at your own  risk. I won’t be held responsible for 
what I have written here.  
Here’s a picture of the Bell Auto Services TDV6 D3&RRS EGR blanking kit:  
 
The kit replaces the EGR pipes with suitable blanks  fitted to the EGR valves and the butterfly housing. 
You will need all 
4 O-rings – 2 are fitted to each...

 
View of engine with top cover removed – right hand EGR valve shown in inset  
Now unplug the EGR butterfly valve actuator and air box connectors  
 
Butterfly valve connector (lower) and air box connector (upper)  
 
At this point, it’s a good idea to spray some WD40 onto the bolts securi ng the EGR pipes to the valves. 
The bolts get pretty corroded because of where they  are and we don’t want them to shear them off !  
Have a good look at the clip securing the air box to the EGR butterfly valve...

 
Air box to EGR butterfly housing securing clip  
Loosen the jubilee clip securing the air inlet pipe to the right hand side of the air box  then disconnect the pipe 
from the air box.  Note. The jubilee clip is secured to the pipe w ith some sort of retaining clip and will not 
slide down the pipe so just loosen  it enough to clear the lip on the air box allowing you to remove the pipe.  
 
Air inlet pipe to air box jubilee clip   
Completely undo the bolt securing the lower  part of air box and...

 
Air box lower bolt  
Warning. From now on, take great care not to drop anything into the now open EGR butterfly housing. If 
anything ends up in there and the engine  is started, severe damage is likely to result. Not only that, be very 
careful where you put the air box – you ma y not notice if anything falls into it or your kids decide it would 
make a good receptacle for bits of gravel etc.  
 
Air box removed   
Remove the cabling from the right hand and left hand  EGR pipe brackets. On my car,...

 
Tie-wraps – right hand EGR pipe bracket  
Remove the 8 mm bolts securing the right and left hand EGR brackets to  the plastic casings. Note. This is the 
left hand bracket.  
 
Left hand EGR pipe bracket   
Using a suitable screwdriver, unclip the EGR pipe clamps  either side of the EGR butterfly housing. Insert the 
screwdriver under the little  clip across the top of the clamp and twist. Later on we’ll be removing the stub 
pipes and flanges from the butterfly housing when the bolts are easier to...

 
 EGR pipe clamps 
Things get a little fiddley from now on so you need to  take some precautions. Access to the left hand side 
EGR valve is pretty tight and the right hand side is wo rse. It’s a good idea to stuff some rag down beside the 
valves so if you drop anything (I dro pped the gasket!) it can’t go anywhere.  
Remove the 2x8mm headed bolts securing each EGR pipe  to its valve and remove both pipes. Undo both bolts 
completely and carefully pulled each pipe out, with the  bolts in the pipe...

insulation that I had to fold back and tuck behind the dip-stick tube to k eep it out of the way. Don’t forget to 
put it back to where it was.  
 
 EGR valve blank fitted – indent arrowed!   
Once you have fitted both blanking plates, whatever you do,  don’t forget to remove the rags you stuffed down 
beside the valves or your precious  D3 is likely to go up in flames when you take it for a test run! 
 
Right, now for removing the bu tterfly from the actuator shaft!  
First thing to do is remove the...

 
 Removing the actuator. The little black thing (circled) is the bit that links the actuator arm to the butterfly spindle.  
OK, now to get the spindle out of the butterfly! Inserted a screwdriver und er the black part on the end of the 
spindle – the part the actuator arm co nnects to (arrowed in the picture abov e) used that as a lever to pull the 
spindle out of the butterfly. It’s a tig ht fit so you will need to use a bit of force to get it moving .Be careful 
though – the edges of the butterfly...

 
Look at the gunk on it! This is what the EGR valves are making your engine eat on a daily basis! Ugh!  
The inside of the butterfly housing looks very much like this too. !!!  
These stub-pipes also present quite a large obstruction to  the air flow to the engine. When fitted, they meet 
in the middle of the air intake duct. The engine will be  able to breathe much more freely now they are out!  
Fit 2 O-ring seals to each of the 2 blanks from the kit, and then fit each blank to the butterfly housing,...

 
Stub pipe blank fitted.  
Push the butterfly housing back down  into place and secure it in place with the long bolt (see photo on page 
8).  
Refit the air box. holding the  long bolt that secures the bottom of the  air box in place with your fingers while 
you position the air box and push it onto the front of the butterfly housing. Scre w the long bolt in a bit to get it 
started, and then refit the clip that  secures the air box to the butterfly  housing. Ensure that you fit it the same 
way round...