P38 Inlet Manifolds

Hi all, looking for some advice.
I have a 98 2.5 Diesel, which is currently having a replacement engine fitted. I bought it a month or so ago after previously owning a 4.6 a few years ago. I bought it in Derby and made my way happily back to sunny Scotland, until it started smoking heavily dropping in power, before emptying its oil all over the M6 and showing the engine disabled message..

Got it recovered home where it sat for a week while I was on holiday. After using my EKA and getting it running again, the investigation by myself and mechanic began, the problem was a cracked head. Decided to replace the engine rather than messing about with heads. After a bit of research and some prices I decided to buy an engine from a 325 or 525tds. Looked in all the usual places but ended up going with a supplier through 24/7 spares £321.60 (using the reg number drom a 98 525tds). The engine arrived at the garage, but a 2.5 petrol. After a week of arguing with them, they accepted it was their mistake and gave me a refund.

In my haste to find another equally priced I engine, I stupidly bought one with a plastic inlet manifold (mine is alloy), despite already knowing they couldnt be swapped, due to the bolt orientation. I am having difficulty sourcing a second hand P38 plastic inlet manifold, but have found two. They are both fitted with egr valves, while mine isnt (appears that all plastic ones are). So my main two questions are, are all P38 plastic manifolds fitted with egr valves and if so can I use one and just leave the valve unplugged, do they stay open or closed when unplugged (dont think I would have anywhere to plug it in anyway). I can also buy the EGR blanking kit, although this would have to wait until next month, once the car is back on the road and I have cash again.

Sorry for the rather long winded post, but I wanted you all to appreciate that I have already bought 2 engines now and have been without the car for a month. I really dont want to hear that my newest engine is no good either and I will have to shell out for a 3rd.

I forgot how much I loved owning a P38.

Thanks in advance.
Barry

Yes all the plastic ones have egr valves.

Why buy a kit, just stick a blanking disc, a modern steel two pence piece works well, in it.

With the new MOT regulations that are threatened I'd make look as if the EGR valve is hooked up properly. Keep the pipework and wiring and just make the other ends look as if they're joined into a loom somewhere.

So im all good to go ahead and buy the inlet manifold and just block off the EGR using a 2pence piece. Anything else I will have to buy/use to make the plastic manifold/EGR work in my car?

Thanks
Barry

Well I hope it will be ok as I have just bought a plastic manifold and EGR blanking kit. I was hoping to get a concrete answer from a knowledgeable member, but I couldnt afford to wait any longer with ordering the parts, as they wouldnt have been dispatched until Monday if I did.

With the way my luck has gone with it so far, I wont be at all suprised if someone comes along just shortly and tells me it wont work.

On a different note, are there any Scottish (central belt) members with a faultmate tool, as the battery was allowed to go flat and the dash gave me the key code lockout message before the engine was removed.I tried to enter the EKA but to no avail (although I suspect the battery still had insufficient charge). I am just thinking about once the engine is back in and its ready to fire, if the EKA still fails. Could this even be solved using faultmate, or is it a becm out job and send it away

I emailed Callrova through his website, and got this very much appreciated, honest response

Hi Barry, Unlocking costs £75 + postage.
I'll be kind now, Unlocking a becm does jack **** except to allow it be to programmed to another vehicle.
When the keycode lockout appears it's because some binary data in the logics has corrupted, & this takes a few other operating codes out with it.
All these codes have to be replaced in the right order at the right addresses. Our trade price for addressing this problem with a becm reset & service & testing is usaully £200 + postage.
But fingers crossed, the EKA code procedure will work & get you out of trouble.
Regards,
Richard.

Any advice/information/assistance would be very much appreciated.

Thanks
Barry

Sorry mate, I had to go to work.

You should be all right with the manifold but if you're going to fit the blanking kit rather than just blanking the EGR then hang on to the EGR valve assembly until these new MOT regs shake themselves out. It seems to be that under the new regs the engine must be as it was built so no power boxes and no EGR blanking but they haven't come in yet so no-one truly knows what is going to be a fail.

You didn't say what the engine came out of and how much of it you're using. I only ask because of other threads about the differences in the electrics between LR and BMW injector pumps.

It came out a 97 325tds. I need to swap inlet manifold, exhaust manifold/turbo, sump, oil pump, pulleys and the infamous FIP top. Thats what I can remember off the top of my head.

Barry

BAZ 2780 said:

It came out a 97 325tds. I need to swap inlet manifold, exhaust manifold/turbo, sump, oil pump, pulleys and the infamous FIP top. Thats what I can remember off the top of my head.

Barry

Click to expand...

You have definitely got a fighting chance. Go for it. Sorry I'm not closer.

Anyone got any more info for me.
I cant bear to drive my good ladies meriva anymore. Although getting in and turning the key, knowing its going to start, is almost pleasant.

These rumours about new MOT regulations are just that at the moment. It has been suggested that a check will be made that the engine has not been modified, but no suggestion as to how far an inspector will have to go, indeed many modern engines have covers, will the inspector have to remove this to have a closer look at an engine? Said engine may even have the EGR kit inaccessible or covered by other components. Will the MOT testers manual have pictures of every engine and what to look for? Would the law essentially say it's not permissable to modify an engine in any way? My Lotus had an injector fail, they're unavailable now, and a different set that fits required the injection map to be modified - I now have a plug in box connected to the ECU to allow my laptop to modify the map - would this be illegal? I'd have to scrap the car otherwise. Time will tell I guess. Oh yeah, just remembered, I've already broken the law, the Lotus's insurance has just run out, it's in my garage (so parked off road) and I haven't submitted the tax disc and declared SORN - oh no, I'll get fined, arrested, put in jail........another stupid law that only effects the honest motorist.

Anyway, in your case Baz, you legitamately could have a non functional EGR valve as your vehicle wasn't originally manufactured with one. How would you prove this if the tester failed it for it being non-functional or appearing removed? Stupid proposed laws. Rant rant rant.

To be honest with you gentlemen, I couldnt really care less about possible proposed changes to M.O.T's and the laws surrounding them at the moment.

Can anyone actually answer the questions I have asked about using the plastic manifold with EGR blanking kit fitted. Will it work and is there anything else I need to fit/buy.

Are there any members in central Sotland with a faultmate tool and if so do you think it will work if my EKA fails for my keycode lockout message?

Thanks
Barry

Hopefully you will know the answer yourself by now and you are happily driving around again, but if not yes just blank the EGR off, i've had a couple in over the last few weeks with 5 Series, plastic manifolds/EGRs fitted. If your still needing your car resynced or BECM unlocked give me a shout, i do have a faultmate.

It should work fine, you wasted your cash on the blanking kit, two pence piece works just as well. All in all it would have been easier to swap the head if the rest of the engine was OK.