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grivas · 12th October 2021, 12:51

[QUOTE=al_dente;2903334]Hi folks,

I posted on another thread about some issues that have been caused by an EGR bypass that I recently installed (https://the75andztclub.co.uk/forum/s...&postcount=427).

Photo...

I have fixed the broken EGR pipe by removing it and fitting a blanking plate on the back of the engine where the EGR pipe was connected.

However, I am now left with a car that only runs in limp mode - the throttle doesn't seem to do anything and it stays at about 1200 rpm. The dashboard shows a 'check engine' light.

The split EGR blew hot exhaust gases onto the side of the engine and as you can see from the photo has melted some of the inlet manifold and wiring to the fuel rail pressure sensor. The manifold damage is cosmetic, but I will swap it for a replacement. To fix the wiring, it's been suggested to me that I replace the engine wiring harness. They're not too expensive on ebay. Has anyone done this before? I was wondering how easy it is.

Another option is to just replace the melted wiring. I assume that when I remove the inlet manifold, there would be a reasonable amount of room to get at the wiring and splice in (with solder) a replacement section of wiring and connector. This means less disturbance to the rest of the wiring harness.

I'd be interested to know what people think about this - is one option preferable over the other do you think?

Cheers,

Al[/QUOTE

Are the actual wires to the fuel rail pressure sensor in fact cut, burned or in anyway damaged?.
If they are not, as I cannot make it out from the photo, I would leave well alone, you can check the voltage using a multimeter I suppose, if the damage is predominantly to the shield I would use waterproof tape to insulate.

12th October 2021, 12:51	#2
grivas I really should get out more....... Rover 75 CDT Club Tourer Join Date: Nov 2006 Location: Milky Way Posts: 2,381 Thanks: 105 Thanked 513 Times in 382 Posts	[QUOTE=al_dente;2903334]Hi folks, I posted on another thread about some issues that have been caused by an EGR bypass that I recently installed (https://the75andztclub.co.uk/forum/s...&postcount=427). Photo... I have fixed the broken EGR pipe by removing it and fitting a blanking plate on the back of the engine where the EGR pipe was connected. However, I am now left with a car that only runs in limp mode - the throttle doesn't seem to do anything and it stays at about 1200 rpm. The dashboard shows a 'check engine' light. The split EGR blew hot exhaust gases onto the side of the engine and as you can see from the photo has melted some of the inlet manifold and wiring to the fuel rail pressure sensor. The manifold damage is cosmetic, but I will swap it for a replacement. To fix the wiring, it's been suggested to me that I replace the engine wiring harness. They're not too expensive on ebay. Has anyone done this before? I was wondering how easy it is. Another option is to just replace the melted wiring. I assume that when I remove the inlet manifold, there would be a reasonable amount of room to get at the wiring and splice in (with solder) a replacement section of wiring and connector. This means less disturbance to the rest of the wiring harness. I'd be interested to know what people think about this - is one option preferable over the other do you think? Cheers, Al[/QUOTE Are the actual wires to the fuel rail pressure sensor in fact cut, burned or in anyway damaged?. If they are not, as I cannot make it out from the photo, I would leave well alone, you can check the voltage using a multimeter I suppose, if the damage is predominantly to the shield I would use waterproof tape to insulate.