Inlet manifold swap

[igotalake]

Anyone replaced the old style manifold on a 2.4 tddi with a new style 2003 -on mannifold?

need a good idea on how to connect old egr to new manifold as diameter is different

or using the new style egr (quite cheap to buy), how to mount the two sensors which are mounted in the old egr but not in the new one.

TIA

[igotalake]

I've done a mod to my intake to allow the new-style plastic inlet manifold be used with the old EGR. Motor is 2.4 125hp D0FA

https://imgur.com/a/D4MoAVV

the two bolts that come with the manifold have collared "washers" that need to be cut down.

https://imgur.com/jrF0v5u

The first photos of the adaptor show it to be a longer length than the final product fitted to the van as i cut it shorter in the end to make it interfere less with the coolant pipe underneath.

https://imgur.com/a/wz3OLJZ
https://imgur.com/a/ci15RAR

Blank off EGR and voilà !

Got a lot more power than before with the leaky manifold.

[kwuk23]

This helped me a lot. I also had a cracked manifold. Tried to fix it with JB weld, but it didn't hold. Ordered a new type manifold and my neighbour helped me with the mod. Indeed a lot more power and no more hissing and black smoke.

Thanks @igotalake for the pictures!

[Bukko2000]

Hi there , got same problem , need to fit the newer manifold ,down here in NZ. Do you need to make any electrical mods ? .. thanks , Vic

[igotalake]

No you can plug back in the sensors in the egr unit, just blank off the egr exhaust connection and exhaust pipe from manifold.

My advice after a issue that came up a few months ago: Be careful to secure the exhaust egr pipe or even remove it from where it has a join back in the engine bay. (it's a bugger to get to there though). If not, and the metal pipe from the exhaust moves around too much it may come adrift and you'll have a loud exhaust leak and no turbo and, as in my case, no brake servo after a short distance once the plastic vacuum pipe has melted through from the hot exhaust gasses leaking onto it.