Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2908
Help Needed with EGRs
I have a leak of exhaust gasses around the left hand EGR, this has come after a leak from the EGR Cooler pipe, which was seeping a small amount of coolant down the left side of the engine, i know the stainless pipes connecting the EGR to the exhaust are very thin and i am assuming it has weakened and split.
Ironically this has happened after my D3 was taken off the road by a numpty in an artic and its the only car we have the dog can travel in easily.
I dont seem to find a removal guide for the D4 SDV6 EGRs - they are quite a bit different to the D3 and most stuff online says D3/D4 but is only really applicable to d3s and tdv6 D4s I guess.
Does anyone have a good removal guide or link to a video anywhere??
Must stop buying shiny toys....
25th Sep 2024 1:27 pm
darrind
Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2908
Anyone??Must stop buying shiny toys....
29th Sep 2024 2:17 pm
darrind
Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2908
Well that’s a job I don’t want to repeat in a hurry!
As suspected the egr pipe was split between the exhaust manifold and the EGR
Click image to enlarge
Click image to enlarge
Replaced the EGR whilst it was all out
Complete PITA but could have been worse as nothing snapped or stripped
Just got to fill up the coolant and put the battery back in tomorrow as I ran out of time to get it finished before a trip to see a bandMust stop buying shiny toys....
29th Sep 2024 10:53 pm
Marcrod
Member Since: 11 Feb 2024
Location: Cheltenham
Posts: 12
Good job😄. I’m just about to change both of these pipes on a 2013 D4 HSE. Any tips? I’m thinking removing the wheel and heat shielding and going in via the wheel arch. Maybe loosen the whole EGR and cooler by the 3 bolts to see if that gets better access to the bolts on the pipe. Is there a way to clean the egr without emptying the coolant all over me😂
2nd Oct 2024 1:27 pm
darrind
Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2908
I couldn’t see any way to get to the last bolt without having the unit at quite a contorted angle so just clamped off the 2 hoses and the only coolant leaked was what was in the EGR
There’s a few things that are handy to have available when you are doing it most important is 3 hands as some bits are a bloody pain such as the back heat shield bolt behind the egr exhaust pipe dropped it twice once on the way out and again on the way in when putting it back together Must stop buying shiny toys....
6th Oct 2024 4:23 pm
Marcrod
Member Since: 11 Feb 2024
Location: Cheltenham
Posts: 12
I agree. The back heat shield bolt was a pain. Mine was all going well. Battery out, Wheel off and both heat shields off. All three bolts on the EGR loosened. Then I thought I would attempt the (seemingly easy), EGR exhaust pipe to manifold. Bottom one was a pain to get to, but with an angle socket and an extension, it seemed to have a good grip on it. The bolt wouldn’t move, so thought I would try the easier top bolt. When I applied the breaking strain of a KitKat to it, I was left with half a bolt and a lot of swearing. Not really enough room to get a right angled drill in there, so it’s off to my local INDI for body off. Both pipes, maybe the cross over pipe, front to rear brake lines and possibly the rear upper arms. Annoying £1500-£2000 M8 bolt. Plus the truck sounds like a whining banshee (or a transit slipping fan belt) now. At least it’s only 20 mins to the INDI with some hot gases escaping. I couldn’t see how I would get the Torx bolt out on the EGR to the pipe without moving or removing the whole EGr either. Damn whoever over torqued those bolts.🤬🤬🤬🤬🤬
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