Freelander 1 DIY EGR bypass

I had to take off the inlet manifold yesterday so I could fit a Renault thermostat and was disgusted to see the crap building up again already after only a thousand miles or so. So being the tight so and so that I am I decided to have a go at DIY blanking the EGR. I have a spare EGR so figured, what the heck. I could order a nice shiney new bypass kit but where would the fun be in that?
This is what mine looked like before I cleaned it a couple of months ago, the spare wasn't as bad but I'm including this photo to show the valve mechanism which obstructs air flow. Removing this mechanism will probably make little difference to a Turbo car with forced induction but it pleases me so that's good enough reason to do it.


This is what was left after I had a go at it with a hack saw.


After dremelling the sharp edges.


With the valve stem cut away the gate for exhaust gasses just fell out. I was hoping it would stay in place but now there is a big hole left which may or may not cause turbulence, but I'm not taking the chance. I've cut a bit out of an old strut which is close to the right size and shaped the end to more or less follow the inside curve of the EGR. I plan to weld the washer in the photo onto the end of it so it is a tophat shape and will be clamped in place by the normal EGR exhaust connection.

I will have to grind a bit off the exhaust end of the EGR to make room for the washer but not sure how much yet so will wait until I have it welded up then see.

Was thinking about this later on last night and will have to confirm the other side of the valve stem can't come loose, I don't like the thought of random bits of metal floating around the inlet of my car.
It seems to be secure but I need to be certain so will try blowing compressed air into the little vacuum pipe later and if it shows any sign of moving it will either be removed completely or welded in.

Why not line it with an old turbo hose. Epoxy that in place, then weld the stem on.
Mike

Skinny Mike said:

Why not line it with an old turbo hose. Epoxy that in place, then weld the stem on.
Mike

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Hopefully I'll be able to check it thoroughly so I won't need to put a hose in. It would reduce the diameter by the thickness of the hose x 2 so would be reluctant to do that. I've no idea if it would make any difference to how the car drives but having gone to the trouble of cutting out one restriction I don't want to introduce another.
BTW a couple of peeps have suggested some kind of sealant, either exhaust paste or liquid metal but I'd be concerned it would break up and get sucked into the engine so I won't be using any. If it don't work it'll get tweaked until it does or it's going in the bin

Did a wee bit more last night.
Top hat welded on



In situ




I also crimped the vacuum hose pipe to ensure it doesn't cause any issues.
I'm not sure if this will need further adjustment but will trial fit it in the next day or two and see how it goes. Worst case it is a pile of poo and get chucked in the bin. Best case it is totally brilliant and transforms the car adding 20hp.
I suspect it more likely to be the former.

I did one of these back in 2012 added a solid piece of metal topped off with a filling / Fillet of liquid metal, this was fitted to a members car and is still working as it should today, note the vacuum hose pipe was also filled with liquid metal, yours should be ok plus you still get the OEM look of the unit

Arctic2 said:

I did one of these back in 2012 added a solid piece of metal topped off with a filling / Fillet of liquid metal, this was fitted to a members car and is still working as it should today, note the vacuum hose pipe was also filled with liquid metal, yours should be ok plus you still get the OEM look of the unit

Click to expand...

That looks nice and neat. I was going to do something similar but chickened out as I don't trust the liquid metal. If it became brittle, bits could flake off and end up in the cylinders. Hoping to fit it over the weekend to the Doris' 4 door, so will see how it goes. The inlet manifold has already been cleaned out so it is just a matter of fitting it.
Have to admit though I couldn't be bothered doing it again for project Bertie and instead ordered one off ebay for twenty quid. For that money it's hardly worth the bother but was fun doing it.