Having fitted an EGR Bpyass Kit a few days ago, I decided to take my 2004 TD4 SE for a long run, after about 20 minutes out of the blue the exhaust started blowing.

I pulled over and spotted the problem instantly, the end of the EGR Pipe that I had fitted the blank onto had sheared off probably due to fatigue cause by the vibrations.

The kit I used did not have the EGR blank connected to it, the kit just had a small disk like a coin that slotted into the special Jubilee Clip.

I now have 2 problems, some melted wiring to replace but more annoyingly a sheared off EGR pipe to repair / replace etc.

I have taken the air filter off but can't see the end of the pipe, I have googled the pipe and know it connects directly to the exhaust manifold, my plan was to remove the pipe and make a blank to block it off at the manifold, a far neater job than before.

Does anyone have any suggestions on how to remove it, it looks like it might be accessible if I remove the base of the air filter, I have removed 3 nuts and a wire clamp but it is probably nor that simple.

There are several used pipes on eBay so I presume that it can be removed but of course that might have been with the engine on the floor etc.

I guess it would be the same problem if you wanted to replace the exhaust manifold or down pipe.

Many thanks, Karl.

Please post a picture to better describe what you are talking about ?
Did you remove the WHOLE egr assembly ?

A tad baffled as to what you describe.........................................................

Joe H, let me clarify.

I need to remove the ENTIRE EGR PIPE because the end has SNAPPED OFF.

Where it connects to the EXHAUST MANIFOLD is REALLY REALLY inaccessible.

You can only JUST slide your hand down the rear RHS of the engine to touch the 2 bolts, no chance to get a socket or spanner in there.

I am wondering if someone has removed theirs and can tell me how they did it.

My next thought was to put the car on a ramp and try and gain access to the bolts from underneath.

The only way to get to the turbo is from below. I suspect that is your only option in this case too.

Put truck on ramps so I could crawl underneath.

I can confirm there is no way on Earth you can remove the EGR Pipe from below, you can't even touch it let alone get any tools on the pipe.

I got a friend with access to an engineering shop to make me a 1 inch long tapered bung out of stainless steel.

I was able to pack it in the end of the broken pipe with a good slug of Fire Putty and the asbestos shielding from the pipe as wadding, like packing a lead ball into a musket, giving a series of good smacks with a long bar and a big hammer.

I left it for a couple of hours to set, then started the engine and left it ticking over for 10 minutes.

I then gave it another couple of hours to cure etc, then went for a drive for an hour.

I seems to have done the job and sealed the pipe.

I have checked the temperature at the end of the pipe with an IR thermometer and it is about 20 degrees cooler than a couple of inches along the pipe.

Job Done !

lol, well done but you'd better hope it holds - or else you'll be driving 1 day and it will shoot like a mini cannon ball through your bonnet.

Here are some photos to show you guys what I disaster I have had.

Seems ok still.

First photo is end of pipe that broke off on the motorway, so lucky it didn't get stuck on fan belt etc, when I pulled over it was just sat balanced on a pipe

As you can see the hot gases caused some damage but nothing functional fortunately.

3 months on and my fix is still holding.

Phew.

Rocky Ward said:

3 months on and my fix is still holding.

Phew.

Click to expand...

nice one

ur not lining ur sights up on ur next traffic warden with that are u, lol