Hi all I have a 2001 TD4, having fitted EGR bypass and Synergy 2 I was well impressed with the results - finally I can zoom along with other more modern kit and with mpg at 38mpg not bad for a 116k motor.

Well I looked at a post here by Biggamehunter ..... what a great conversion!!! But I am not into bling ..... and I just want good airflow.
Looking at the Freelander manifod just prior to the EGR valve reveals a diabolical swirl arrangement.....which if you take off the manifold and examine reveals a horrid metal insert with a nasty stepped edge. With all sharp angles corners and ridges - I summised this was a significant restriction.

So I ordered a new silicone hose .... which is like a smooth 'u' bend - 54mm internal diameter ...... connected to a new length of '2' inch plastic waste and connected this up to the intercooler exit hose (nr water bottle filler). I did some trials as I thought the waste pipe may crush .... but no the good quality pipe is great... I fabricated a steel strap to support
pipe and cable tied the pipe to it . Result ....it works just great. I kept the original LR air intake duct and simply cut the old LR intake supply duct off.
(I even saved the old duct incase I need to refix). To really finish things off I put a new silicone air supply hose on with a new aluminium ram pipe (cheap off ebay)....... This incidentally is 75mm in diameter - compare this with the 40mm diameter std air supply - and you can see how restrictive it is..... Incidentally i kept the old air supply pipe and pointed it toward the new ram pipe to duct some cold air to the new arrangement. I topped the whole lot off with a new K&N filter. Result, vastly better pickup - free reving with a better rev range - I am only on setting 2 with Synergy...I recon this would improve even more with setting 5. See my pic below....
by the way - with a little trimming I was able to refit the orginal engine cover...... hope others try this ....


U bend installed ....

Maybe a nice little mod - but the pics are HUGE!!!

Can you resize them so I can see what the mod is.....

Thanks....

wide screen wide eyes!!! resize em buddy!

Hi I have tried resizing ..... drastically....I thought the pic size would auto change......
hmmm .... here is a trial upload

Hi I have reduced picture size drastically ......... and re uploaded..... according to Photoshop they are 1.2 cm wide and only 33k in size!!!! Hope I helped the viewing......
let me know.... Aside from this ... report back TD4 is going really well definitely more power.....and when driving normally you seem to have to depress the accelerator less for the same speed ..... or at least that's how it feels. Engine is much smoother, free - er revving and a bit more torque. Extreme bottom end around 1200-1300 unaltered. I will be recording MPG ... will keep you all posted...was doing a healthy 38mpg mixed before....

If your having problems with photo size, search for microsoft windows imamge resizer. Install and right click on a photo and select the size you want.

or this image converter/resizer: http://www.mihov.com/sw/en/ir.php

Further testing ..... tried position 5 on the synergy OMG!!!..... this goes really well....... I dont normally give it beans ..... it is really quite easy to hit the rev limiter in 1st 3 gears!!!! This feels like the old GT TDi Golf I had....but a bit gutsy-ier excellent for a bit of safe overtaking .... very impressive.
Next on the agenda is a very discreet decat .... which according to RoverRon should give around 150bhp!! and a good reduction in turbo lag.

I will upload a picture with the engine cover on ..... looks very factory.