1982 240D Exhaust Gas Recirc. Line failure
 

A few weeks ago I posted a question concerning an exhaust leak and some clanking noises on my 1982 240D, which my daughter drives while at college. I had her take the car to Midas to have it inspected and send me a written estimate to have it repaired as I will not be getting the time to investigate this one myself.

She called and said the guy replaced a clamp that had rotted away on the exhaust pipe under the car, and that there was a hole in the "accordian-like" connection from the exhaust pipe to the intake manifold, which was the major problem. By the way the mechanic did the trouble shooting and replacement of the clamp at no charge.

So, it looks like I will be ordering a new EGR connector. Has anyone got any hints on doing this job efficiently and what parts are involved? My manuals do not show the connectors at all. I will be taking care of this over Thanksgiving, and I have no garage so the smoother it goes the better my hands and body will be.

Thanks in advance for the help, Jim

Its a very easy DIY job. Once you see the corrugated pipe, you'll understand. There are two clamps at each end connecting it to the two manifolds. I can't really remember, but I think you need a 12mm wrench. It might be a little messy if the pipe is full of soot.

SW,

Thanks for the help. I was wondering, since the corrugated pipe is what apparently has a hole in it, is that a replacement part by itself? I mean is the job just undo the clamp at each end and put a new one in its place, presumably new ones? Or is there more to it when you go to get parts? Thanks again for the information. Jim

You will be surprised when you find out how much that little piece of corrugate pipe cost. It is a straight forward replacement. If you can get the piece off without damaging it can be repaired by tig welding or soldering. You do not want to have to purchase a new one :) if you can get away with it.

engatwork,

I will check into repairing the item. Is it stainless steel or something more exotic? Thanks, Jim

I want to say that its brass or tin. I'm not sure. I have not seen many break. You might even try getting one off a junker if you are close to a junkyard.