Egr valve - missing bolts

Hi all

I just went under the bonnet to check everything was ok with my air filter after a long journey ( which was fine) and also to check my egr hose for gunk buildup. Found loads of gunk in the egr hose so decided to take it out to clean. When I got down to the egr valve I noticed that one of the bolts securing it has sheared off and two oter have been tightened up cross threaded. I've only had this freelander for 8 months and never looked at the egr until now. I got the valve off, cleaned it and replaced it with the three remaining bolts. The one good bolt is really tight and the two previously cross threaded bolts haengone bak in asthey where as I'm away from home and can't replace the seated nuts in the plastic. My worry isthat the seal isn't 100%. Are there any issues if tis seal isn't complete and may let in a small amour of air? Does this part of the sstem rely on pressure?

Sorry for any typos, I'm away visiting family before Xmas and only have the phone to browse on. Any advice would be greatly appreciated as I won't be home for another 2 weeks.

Cheers
john

If you haven't noticed any problems in the 8 months it should be ok for now. If the seal isn't perfect it will leak a bit of boost pressure but you would see some oil seepage as a telltale sign that this is the case.

You may have to change the manifold if you can't clean up the threads with a tap.

Thanks Chaser.

Just took it out for a quick run and it seems to be running ok. no hesitations and running smoothly. There was a hell of a lot of gunk in the EGR, only a tiny tunnel running through it. I don't suppose you know the exact name of the manifold I would have to replace, I might just order the part instead of trying to tap new threads. Its a 52 plate TD4.

Cheers
John

Your simply looking for a Td4 inlet manifold. Don't rush into anything if it's running ok. Keep an eye open for a second hand one. This one on ebay at the moment comes with an egr valve and is a bit too pricey!

FREELANDER TD4 INLET MANIFOLD on eBay (end time 24-Dec-09 18:59:50 GMT)

Cheers Chaser.

Taking it for a 60 mile round trip in the morning so should be able to see if we are good to go. Will defo buy a new inlet manifold, but will keep an eye out for a cheap used one.

John

Why don't you consider trying to drill out & tap the holes to the next nearest size up (possibly an imperial size even) if you're determined to replace the manifold. It might save you the cost of another & if it doesn't work then you've lost nothing as you were replacing anyway.

I agree it's worth a try. Only problem might be if for some reason it's unsuccessful the cars off the road until a replacement comes along.

I need the car onte road for the next 2 weeks bit I might drill them out. From what I can see the holes run right through the inlet manifold so I could drill tem all out and run bolts trough the holes with nuts on the other end. I can see they run right through at the top, are they the same underneath does anyone know?

I'm tempted to buy a blanking kit off eBay and fitting that in place either on this manifold drilled out or on a new one while I'm at it. Quick job turned into a nightmare, now to track down the ham fisted previous owner.

John

Jodsclass said:

I need the car onte road for the next 2 weeks bit I might drill them out. From what I can see the holes run right through the inlet manifold so I could drill tem all out and run bolts trough the holes with nuts on the other end. I can see they run right through at the top, are they the same underneath does anyone know?

I'm tempted to buy a blanking kit off eBay and fitting that in place either on this manifold drilled out or on a new one while I'm at it. Quick job turned into a nightmare, now to track down the ham fisted previous owner.

John

Click to expand...

I found the bypass to be a good modification & it stops crappy exhaust gases from blocking things up. Pointless trying to find previous owners as they might have innocently used a ****ty garage without knowing it. Best to concentrate on sorting things.

one of the top bolt holes is a blind hole. how lucky are you? is that the one that the thread is ok?

Chaser said:

one of the top bolt holes is a blind hole. how lucky are you? is that the one that the thread is ok?

Click to expand...

the top back hole is the one with good threads. Is that the blind hole?

Took it on a 100 mile trip today and it seemed vastly improved compared to what it was pre taking the egr off with tHe faulty bolts. Two bolts fully tigthened and two missing ( in opposite corners diagonally) and no sign of oil seepage or air blowing so it may actually be sealing on two bolts. I may get away with it for the time being until I can get home to my garage and tools.

John

Yep, top hole nearest the exhaust connection, lucky bastid, buy yourself a lottery ticket this week

It does sound like it's sealing ok. you just need to watch that engine vibration doesn't eventually cause something to fracture.