So after 7 years and 56K miles of almost trouble free motoring the FL2 went into "reduced Performance" mode coming down the M6 tonight. I guess it had to happen at some time.
Engine sounds fine, just nothing beyond approx half throttle.

Torque Pro Scanner shows:
P0403 Exhaust gas recirculation valve position control malfunction
P0405 Exhaust gas recirculation sensor A circuit low input
P0409 Exhaust gas recirculation sensor A circuit

I'm guessing it means the EGR valve is gummed up and probably the EGR needs replacing.

Ive not replaced an EGR before so any advice would be gratefully received.

Is there anything worth trying first before replacing the EGR unit?

Also any advice on sourcing a new unit before I start searching the internet ?

Looking at the pics here
https://www.freel2.com/forum/topic38223.html?highlight=egr
and perusing the JLR workshop manual it doesn't look difficult - just a bit awkward. Jules

Last edited by jules on 30th Apr 2023 10:56 am. Edited 1 time in total

It's a ball ache of a job if you don't remove the false bulkhead first. Even then space is tight and bolts are tricky to get at.
It's not a job that can be done in ½ an hour. 3 or 4 hours is more realistic time for the 1st time. I did mine last autumn, which took me over 2 hours, and I've had the EGR off 3 times in the last 2 years. 2009 Rimini Red SE TD4. Soon to be sold.
Hyundai Ionic 5 Ultimate on order.
Gone. 2006 Tonga Green i6 HSE.

Just to make things more awkward there appears to be two versions of the EGR unit.
My car has the later version (after AH999999).
The JLR manual only covers the early type.

Is the later version vastly different to replace ? - hard to tell from the exploded diagrams but it looks similar. Jules

Nodge68 wrote:

It's a ball ache of a job if you don't remove the false bulkhead first. Even then space is tight and bolts are tricky to get at.
It's not a job that can be done in ½ an hour. 3 or 4 hours is more realistic time for the 1st time. I did mine last autumn, which took me over 2 hours, and I've had the EGR off 3 times in the last 2 years.

It seems the two versions of EGR unit have the same EGR valve and gasket (LR000997 and LR000998 respectively).
But the coolers are different; LR001002 vs LR057662 (after AH999999). Jules

BTW prices of parts are way up - cooler LR057662 is about £450 on ebay ! and the Pierburg valves are over £200 now Jules

Probably a waste of time but have you tried at least the EGR reset. I am looking forward to a full report on the job for when I have to do mine

Another question.

Does a new EGR valve need some sort of calibration or can it just be plugged in ?

JLR manual makes no mention of any calibration so Im hoping no calibration is required. Jules

It might be worthwhile doing a throttle body recalibration as that can have a knock on effect throwing up EGR codes amongst others.

Here https://www.freel2.com/forum/topic31325.html

Hi Jules
Hi have a post 'egr removal and replace turbo with pictures ' however I don't know how to send you the link.
I had to remove the egr to remove the turbo so gave it a good clean while it was out. Nothing wrong with the valve but the cooler took a bit of cleaning.
Good luck 🤞 Now at the point when I learn something new something old is lost out the other side !
Now retired so it doesn't matter anymore.
Freelander now gone.

thanks - i'll investigate that tomorrow - I know the battery is not great as the car flags low battery now and again. Car always starts OK but I put it on the charger if the car is not used for a week or so. Jules

gasman wrote:

Hi Jules
Hi have a post 'egr removal and replace turbo with pictures ' however I don't know how to send you the link.
I had to remove the egr to remove the turbo so gave it a good clean while it was out. Nothing wrong with the valve but the cooler took a bit of cleaning.
Good luck 🤞

You managed to find it quicker than me.  Now at the point when I learn something new something old is lost out the other side !
Now retired so it doesn't matter anymore.
Freelander now gone.

I Like Chips wrote:

Probably a waste of time but have you tried at least the EGR reset. I am looking forward to a full report on the job for when I have to do mine

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.