The Mitsubishi Pajero Owners Club®

Nudgie · Posted: Wed Jul 13, 2016 7:26 Post subject: Exhaust to EGR pipe broke off!!

Hi all,

I started noticing a nasty chattering sound coming from my car a few days when accelerating, and it was getting worse and worse. Opened the hood and noticed some smoke coming from the pipe leading into the EGR (or where it used to be). I moved the pipe to see how bad the leak was and it snapped off completely Shocked

Looks like it was hanging on by a thread

I know this happened because I didn't put the EGR back in place after installing the blocking plates to keep movement down, but it just wouldn't fit as I think the plates are too thick.

Anyway, I need some advice on what to do.. I was thinking of putting the EGR back in place over the plates and connecting the pipes using some hose and clamps, but I'm not sure on what temp the gas going into the EGR is at, so no idea what type of hose (if any) would be suitable.

I also thought of removing the pipe completely from the manifold but the bolts are hard to reach and most likely seized by the looks of them.

Any advice would be appreciated Neutral

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peteinchad · Posted: Wed Jul 13, 2016 7:44 Post subject:

The nuts that hold the pipe onto the exhaust manifold always look like that.

I removed mine to clean my EGR valve a couple of days ago - soaked them in PlusGas for a couple of hours and they loosened off OK. I used a short 1/4 inch drive ratchet so that I couldn't put too much force on the nuts that could possibly break the studs.

I doubt you will find any rubber hose that will take the temperature of the exhaust.

Maybe try some exhaust bandage - but it would look like a bodge, which it would be.

hutchy · Posted: Wed Jul 13, 2016 8:28 Post subject:

i thought when blanking the egr off you removed the pipe and the plates go in place of the pipe...i think thats what i did on my 2.8 many years ago,as for the nuts like Pete said a good soak with a good penetrating oil and use a box socket that is shaped like a nut,loosen the nut if it sticks wind it back on then off and repeat until the nut is fully removed Wink

peteinchad · Posted: Wed Jul 13, 2016 8:44 Post subject:

Nudgie · Posted: Wed Jul 13, 2016 8:54 Post subject:

Ah ok, the kit I got said to put everything back. I'll have a crack at removing it.

And regarding WD40.. now you tell me lol! I'll go buy something a little stronger tomorrow.

peteinchad · Posted: Wed Jul 13, 2016 10:08 Post subject:

PlusGas is very good - leave it to soak for a few hours though.

The blanking kit you have got is made of thick metal so you would find difficulty getting the EGR Valve and pipe back on. The thin 1 - 2 mm ones should let you get it back on.

Remember to plug the small rubber vacuum pipe that goes on the EGR Valve - my kit came with a bit of new rubber pipe with a plug already in it. If you didn't get the little pipe then use a small bolt or screw in the end of the existing pipe.

Nudgie · Posted: Wed Jul 13, 2016 10:30 Post subject:

Not sure we have PlusGas here but I'll have a look around.

I've had the kit installed for about 3-4 months with no issues until now.. I actually just put a screw in the vacuum pipe before it arrived and that resolved most of my problems.

At least I know I can remove that pipe to do it properly. Thanks again for the tips. Very Happy

peteinchad · Posted: Wed Jul 13, 2016 11:23 Post subject:

Nudgie · Posted: Fri Jul 15, 2016 3:50 Post subject:

So the bolt won yesterday, 3 hours and it didn't budge.. Gonna keep soaking and try again tomorrow Crying or Very sad

peteinchad · Posted: Fri Jul 15, 2016 6:04 Post subject:

Nudgie · Posted: Sat Jul 16, 2016 8:11 Post subject:

peteinchad · Posted: Sat Jul 16, 2016 8:53 Post subject:

Glad you got it sorted.