Well, an eventful journey has terminated prematurely at sedgemoor services with a small fire. The events leading up to this were - driving along towing a caravan with my td5 (99) and a smell of burning paper wafted in. I don't know if it's related but after a few minutes it sounded like the exhaust was blowing. Stopping at the first safe spot I took a look and the exhaust sound appeared to be around the manifold. It was at that point I noticed a small fire, I disconnected the battery and put the fire out - this turned out to be molten plastic from the positive battery leads. So I have no idea where to start. Ive taken the engine cover off and it looks like an egr? Valve might have been by passed as there is a sawn off pipe at the front - I think this is where the blowing sound might have come from? Could it be sending out fumes that would be hot enough to melt the cables? If not how do I track down the short? Many thanks

Exhaust gasses while towing can have around 500*C or even more temperature so investigate in that area cos an electrical short would have blew the main fuse IMO

Hot day and hilly so I'm with you on that - I have attached a photo of the pipe that looks like it. Also a picture of the melted cables.

Having done a bit of reading it looks like someone has bodged the EGR blank job and I'm guessing the gasses coming out are HOT. Ordered a blank plate and will fit, hopefully no electrical problems actually exist but I will get some new cable sheaf.

That's the first thing I thought of, a badly executed EGR removal.
If you follow that open ended pipe back it should connect to a flange on the exhaust manifold. That's where you should really be blanking off the EGR on that version of the Td5 engine.
Regarding the burnt and melted wiring, the first thing to do is to carefully cut away all the melted plastic so that a full examination can be undertaken. Where the insulation on the wires isn't too badly damaged, about a quarter to half inch of bare wires showing you might be able to get away with insulating tape but any more damage that that and you should consider either cutting and slipping replacement insulating sleeve over the damage or in the worst case, cutting the damaged wire out completely and soldering a new length in. It's unlikely or not even economic that you'll have to attempt to replace the entire damaged harness.
New split flexible conduit, the black sheath can be bought on the bay in various diameters and lengths.
Once you've got all that done, check for any fuses which might have blown while the damage was being done.
With luck all should work out OK.

http://www.ebay.co.uk/itm/Flexible-...hash=item4ad6359869:m:muEBVIGupUkz0TPX0P9-fvQ

Wow, thats really really bad! Nice hot exhaust gases being fired right at the cables, I'd check that the intake pipe isn't torched too!

Glad that your ok and found the issue though.

All sorted now - thanks for the advice. The intake pipe was fine, cleaned up and put new flexi conduit on the battery cables and attempted the EGR pipe removal - thats a tricky job. It seems my allen bolts are pre knackered for me, so rather than snap them I have crimped the pipe and welded up the end. If I take the manifold off ever I will do a neater job.

ant_harvey said:

so rather than snap them I have crimped the pipe and welded up the end. If I take the manifold off ever I will do a neater job.

Click to expand...

Yep, that'll do it. Somewhat unconventional though. Glad you got it sorted.