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Home > Technical > EGR fault - limp mode - and fix

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I Like Chips

Member Since: 25 Jun 2017
Location: Ascott Under Wychwood
Posts: 1578

2011 Freelander 2 SD4 HSE Auto Indus Silver

I have often thought about the inevitable time when I have to either pay a garage or do mine myself. It's access to the unit and maybe doing a clean up/replacement of the Turbo at the same time.

I have wondered if it's easier amongst other things to take the cam cover off for easier access after all it's only nuts, bolts and gaskets ha ha

27th Apr 2023 10:48 pm

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

2014 Freelander 2 SD4 SE Auto Firenze Red

I Like Chips wrote:
Not at all, I am sure the AP200 scanner has a reset EGR and a reset Throttle Body facility, I'll have a look tomorrow. Just wondering what is your mileage.

56K miles Jules

28th Apr 2023 7:44 am

I Like Chips

Member Since: 25 Jun 2017
Location: Ascott Under Wychwood
Posts: 1578

Sorry Jules I won't be able to use my AP 200 till Sunday. I was expecting you to say it's don 150,000 miles. Stuff happens but wondering why it's gone at so early a mileage. Have you had trouble with the O2 sensor

28th Apr 2023 11:29 am

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

This is the first time it has shown any engine related problem.

Except 4 years ago it went into "restricted performance " mode once for no obvious reason. It cleared by itself the same day when I restarted the engine. No fault codes found. Ive had no problems with it until now.
It seldom does short journeys, mainly 100+ mile trips each way. But often doesnt move for a few weeks at a time.

Been for drive this morning after clearing the all fault codes. Came back immediately with just one this time

P0405 Exhaust gas recirculation sensor A circuit low input Jules

28th Apr 2023 12:01 pm

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

Well, thats my jobs for the weekend sorted: Ordered EGR valve from Island4x4 yesterday, its arriving today. So better start the dismantling.
Weekend weather looks rather unsettled in the Midlands anyway. Jules

29th Apr 2023 9:03 am

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

Bit of a start/stop day - lots of interruptions.

But in the end managed to get the EGR cooler/valve assembly off. I couldn't see a way to separate the valve from the cooler with the cooler still in place.

Click image to enlarge

Its all about making enough room to get at the EGR and remove from above.
A 1/4" socket set in invaluable. For one of the EGR screw attachments I made a long straight allan key by cutting off the short end and driving it with the socket set.

This is the order I dismantled things.

Disconnected battery.
Carpet, so I could lie on top of engine.

1) Undertray - remove - in case you drop something and for access to the bottom connection of inlet manifold- turbo pipe.
2) Wipers - remove.
3) Plenum - remove.
4) Airbox cover and air pipe over engine - remove.
5) Engine cover & rubber insulation - remove
6) Secondary bulkhead & insulation - remove.
7) PCV pipe - remove
8 ) Bracket holding wiring loom - undo and move out of way - disconnect lots of plugs to maximise space - inc EGR valve connection & Turbo vane actuator connection
9) EGR bypass pipe to front of engine - remove.
10) EGR coolant hoses - inlet & outlet - remove - only a little coolant is lost.
11) Airpipe to turbo - remove - clamp accessed near turbo from underneath. Doing this allows access to the two bolts holding exhaust manifold to EGR inlet pipe.
12) Heated O2 sensor - remove - gives space to move the EGR
13) ECU & Support - remove - gives space for EGR.
14) Bracket on R side of engine - undo 2 bolts and move out of way - loom is attached to it.
15) EGR remove - the the most awkward bit - a mirror is invaluable to get at the 4 attachment points - all different !

Label all bolts/screws etc - easy to forget what goes where.

Cars with a VIN after AH999999 have a different EGR cooler (LR057662) which unlike the earlier cooler has a metal gasket for the exhaust manifold to EGR inlet which should be discarded (LR022515). I forgot to order this so I can't put it all back together until Wednesday probably.

The same EGR valve (LR000997) is used for all.

More pics to come. Jules

30th Apr 2023 11:30 am

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2086

2009 Freelander 2 TD4 SE Manual Rimini Red

The later cooler is an alloy casting by the looks of it, and it has a vacuum valve on the inlet, which the early cars don't get.
I'm wondering if this was to help reduce cooler failure, by shutting the cooler off from the exhaust gas when it's not needed.
It looks more work to remove than the thinner early stainless cooler.

I didn't strip anything like that much when I did mine, but mine is the early type.

I'm doing my HG again soon, so it'll be off again for that job. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

30th Apr 2023 3:36 pm

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

Yes- all the sticky out bits on the EGR make it awkward to get out around all the pipes and wires - very much trial and error - the workshop manual doesnt cover beyond 2012 and so makes it seem a bit easier than it was. Jules

30th Apr 2023 4:41 pm

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

Update - All fixed.

Split the EGR unit and replaced the EGR valve (it comes with a new gasket).

Install reassembled EGR unit (mine being the later version needed a metal gasket at the cooler inlet/exhaust manifold)

Click image to enlarge

Used a mirror to see the 4 attachments which are really hard to get at, especially the most LH side one - which is an allan head screw

Click image to enlarge

I cut the short arm off a long allan key and then used a small socket to turn it. Plus an extending magnet to pick up the bolts I dropped frequently. And that reminds me - DO NOT let muck or nuts etc fall inside the inlet or exhaust manifolds -best to cover with tape

Click image to enlarge

Heated O2 sensor has to be removed - no special socket needed, just a 16mm open spanner.

Click image to enlarge

This clip on the coolant hose required a large mole wrench to spring it open - I couldnt get the leverage needed with a small mole wrench. The other coolant hose comes off easily.

Click image to enlarge

When I started up the car the new valve made a ticking sound (not heard before) and the codes all popped back up with 2 miles of driving - with P0403 being the first to appear followed by "restricted performance" mode.

Luckily a friend of a friend kindly came over and performed an Air Path Calibration this afternoon and all is now fine.

Total cost £167, plus lots of swearing and tea. Jules

Last edited by jules on 6th May 2023 8:49 am. Edited 2 times in total

5th May 2023 11:02 pm

I Like Chips

Member Since: 25 Jun 2017
Location: Ascott Under Wychwood
Posts: 1578

Thanks for the write up, pig of a job

6th May 2023 6:15 am

Nodge68

Member Since: 15 Jul 2020
Location: Newquay
Posts: 2086

It's good to prove that an air path calibration could be needed after the EGR is replaced. I wonder how many fail again shortly after replacement, as this important calibration is seldom done. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

6th May 2023 8:07 am

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

Out of curiosity what is the going rate for replacing the EGR unit on a FL2 ? Jules

6th May 2023 11:02 am

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

FWIW This was the condition of my EGR unit - Ive seen worse

Jules

6th May 2023 10:20 pm

JonMs

Member Since: 25 May 2018
Location: Ilkley
Posts: 102

2011 Freelander 2 SD4 HSE Auto Santorini Black

Thank you for taking the time to photograph and write this up Jules. I've filed it away for future use!

7th May 2023 2:40 pm

jules

Member Since: 13 Dec 2007
Location: The Wilds of Warwickshire
Posts: 5254

my pleasure Jules

8th May 2023 9:37 am

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