Member Since: 13 Dec 2015
Location: Highlands
Posts: 24
EGR exhaust pipe repair
So my EGR pipe has broken and I’m on restricted performance and smoke coming out of my engine bay.
My local LR 4x4 specialist garage tells me the only way to fix this is to take body off, it will take 2 men 5 days and the bill will £6000+.
Is there any other way around this?
Can I block off the EGR valves like you used to do in older models?3 x TD5s + 2 x D3s; now upgraded to a D4 after a 3 month flirt with a VW Toerag...
24th Mar 2024 4:33 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 21023
£6000? That's a bit excessive. Wasn't Hamish that quoted that much, was it?
It can be done body on, unless the bolts snap in the manifold. Then it becomes body off
The pipe can't be blanked, as it's the pipe directly off the exhaust manifold
Member Since: 13 Dec 2015
Location: Highlands
Posts: 24
I can probably get a video of it, say tomorrow, post it to you & you can have a look?
And if you think you can fix it then I can either get it to you, or you can do it next time you are up around Inverness3 x TD5s + 2 x D3s; now upgraded to a D4 after a 3 month flirt with a VW Toerag...
Last edited by tallhighlander on 24th Mar 2024 9:51 pm. Edited 1 time in total
24th Mar 2024 6:57 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 21023
Member Since: 13 Dec 2015
Location: Highlands
Posts: 24
EGR
Ok I’ve taken it off the road.
Can you give me a ballpark figure on your repair please3 x TD5s + 2 x D3s; now upgraded to a D4 after a 3 month flirt with a VW Toerag...
9th Apr 2024 8:04 am
Mike_Pax
Member Since: 11 Oct 2022
Location: North Yorks
Posts: 39
£6k ??? Thats absolutely extortionate. I had the body off mine recently at a reputable indi to replace the egr pipes. Had loads of other jobs done while it was off i.e. new prop, bearings, all brake inspected/pipes replaced, belts replaced etc etc and the total bill for it all was around £3k. I was talking to a guy who runs a fleet of disco 4's the other day who reckoned that if you know what you are doing and have the right gear (if they havent dont trust your car with them)....you can have the body off in a little over 2 hours
9th Apr 2024 10:41 am
J-and-N
Member Since: 27 May 2025
Location: Tyne and Wear
Posts: 1
LH EGR Removal
Exhaust blowing from LH side. Thought it may be the downpipe flexi . . . after removing that (wrestling match 1) it turned out to be the manifold to EGR Valve pipe :
Click image to enlarge
Wrestling match 2 confirmed you can get the pipe / cooler / valve assembly off the car with no special tools just a loss of knuckle skin.
Battery box removed and heat shields to enable wheel arch access / vision.
Black intercooler waterpipe bracket bolts both need to come out
Fortunately the manifold bolts didnt put up too much resistance / snap off.
Bend the aircon pipes aside a bit for final extraction.
Don't split the cooler from the valve on this type.
Click image to enlarge
27th May 2025 11:50 am
Norwegian wood
Member Since: 18 Oct 2013
Location: Sandefjord
Posts: 71
I did both sides in one long evening. I borrowed a induction heater and got out 3 of 4 bolts on the manifold side of the pipes.
You can cut of the pipes first with a metal saw.
It aint a easy job but its absolutly doable without lifting the chassis.De-tangoed, G4 Winch, G4 Raised airintake, G4 Sumpguard, V8 brakes, 3 flash, clock on dash. Done belts, brakes, parkbrake actuator, transfer ecu, wheelbearings, air dampers, suspension arms, alternator, cruisecontrol,steelpan autobox++
3rd Jun 2025 8:07 pm
Icarus
Member Since: 15 Jul 2023
Location: Essex
Posts: 162
£6000.00 sounds like they just don’t want (or can’t do) the work!
Agreed about approximately a 2 hour job to separate body from chassis.
That was backed up by a casual statement by the senior mechanic at my Indy.
So 2 hours off, around 2 hours or so back on, say 5 hours. Even at around £250 per hour, that’s only £1250.00 with 1 person doing it. Plus any parts and any other contingency, £2000 to £3000 max?I’m a Disco 4 believer. What a vehicle!
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