Originally Posted by al_dente (Post 2898693)

I fitted an EGR bypass a couple of weeks ago and then broke down on the motorway last night :cry:

The car had an engine fault light (I think that's what it said) and would only run at about 1400 revs.

Looking under the bonnet, the EGR pipe had split and was blowing hot gasses onto the inlet manifold. You can see from the photo that it's melted some of the plastic.

I think it's melted some of the wire there too, which is the MAP sensor I think. I assume that's what was causing the engine fault.

I bought this type of bypass because I'd read that it puts less stress on the pipe - and I was careful when fitting the blanking plate. I guess the pipe was just getting weak and me messing with it has finished it off.

https://www.the75andztclub.co.uk/for...1&d=1631002437

Originally Posted by Arctic (Post 2898698)

Hi Alistair.
I have reported a few times now that those EGR bypass are not good to fit, they must have the support on them other wise the pipe will flex with vibration and end up splitting as yours did.

It as most likely damaged the wiring to the fuel rail sensor, the MAP sensor is on the other side of the manifold.

If you are going to fit a bypass EGR then use an original one gutted.
https://i.imgur.com/o7rjaJ6l.jpg1

With the support for the rest of the manifold egr exhaust.
https://i.imgur.com/t5SKSdol.jpg2

There are one out there not original with the support which are much better than the one that is fitted to your car, such as this below, but still not as good as having an original gutted one in my opinion.
https://i.imgur.com/KrLavmql.jpg3

https://i.imgur.com/fejsG3Il.jpg4

These are the manifolds cleaned out which i exchange at the Nano meets, some have the EGR gutted others stay original.
https://i.imgur.com/dsEkw8gl.jpg5

To late for you now though, as you know you can 99.9% always find a solution on here.
https://www.the75andztclub.co.uk/for...d.php?t=312649


https://i.imgur.com/mmiaHPZl.jpg6

I have a few of these if you wanted to revert back to original, but it's not an easy job to remove and re-fit the exhaust section.

https://i.imgur.com/W9wRSb2l.jpg7

Arctic

Originally Posted by al_dente (Post 2898706)

Thanks Steve,

I guess I need to start by getting the EGR pipe off and then I can either fit a blanking plate or one of your pipes. I have seen a how-to on here somewhere, so will dig it out. Everyone says it's not easy though, so I'm not looking forward to that.

I'm not sure what to do with the wiring, I guess I'm best to get a second-hand plug from someone with a length of the wiring attached and solder it onto the existing wires.

I will need a new manifold, so will give you a shout for one once I've got the above sorted.

Cheers,

Al