EGR Valve

[Greenstag]

Bit of a long shot really but you never know.

Has anybody ever replaced an EGR (Exhaust GasRecirculation) Valve ona MK3 Mondeo. I can see it but heaven knows how I'm going to get to it....Hope this doesn't break any rule cos it's not about Stags

Regards David

[Kevin Garrod]

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Never done it myself but there's some info here

http://fordwiki.co.uk/index.php/EGR_..._Clearout_TDCi

The mondeo owners forum is very helpful too.

[Greenstag]

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Thanks Kevin...not come across Fordwike before

[adieturner]

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Not done a Mondeo but did isolate a grumpy one on my lads' Golf. Runs better without and the MPG has also gone up. No emissions test as it's a diesel and no cost as the two bolts we used to block the pipes wern't even new!

[aerosilver]

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Ah, I've been down this well trodden road.....

Don't bother replacing it, just disconnect it and block up the vacuum tube, it's a useless piece of machinery that never works properly for longon the TDCi because it gets gummed up quickly with diesel muck. If you have a Euro 4with an electrical connection to the EGR valvethis mayresult in a light on the dash but you can ignore it. I have a Euro 3 (52 plate) so it's purely mechanical. I disconnected mine at around 90,000 miles after having loads of bother with it and have not had a problemsince (well not that problem anyway - currently 152,000 miles). It makes barely any difference to the emissions and still passes MOTs no problem. Runs smoother, pulls better.

There's loads of discussions on it here, andthere's a step by step guide onhow to do it as it's a VERY common problem.

http://www.fordmondeo.org/forum/showforum.php?fid/164/

The TDCi Mondeo is the worst car I've ever had but fortunately after nursing it through the last 3 years I'm finally chopping it in for an Octavia vRS TDI. Can't wait.....

Hope this helps,

Bob.

[Greenstag]

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Thanks for that Bob, that's really useful

I'd be interested to know how you blanked it off. Mine is Euro 3.

The most symplistic one I've read of on a forum was to slide a thin sheet of pre drilledmetal between the valve and the EGR pipe and clamp the 2 back together again. You mentioned the vacuum tube..think I've read of people sticking a small ball bearing in this. I suppose the only problem with this is if my valve is areadystuck open isolating the diaphram won't make much difference

Did isolating it cure your symptoms? Mine are a plume of smoke ie .unburnt diesel, when accelerating or under load and an occasionalsensation of surging power.

Regards

David

[chopperman]

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aerosilver wrote:

Ah, I've been down this well trodden road.....

Don't bother replacing it, just disconnect it and block up the vacuum tube, it's a useless piece of machinery that never works properly for longon the TDCi because it gets gummed up quickly with diesel muck. If you have a Euro 4with an electrical connection to the EGR valvethis mayresult in a light on the dash but you can ignore it. I have a Euro 3 (52 plate) so it's purely mechanical. I disconnected mine at around 90,000 miles after having loads of bother with it and have not had a problemsince (well not that problem anyway - currently 152,000 miles). It makes barely any difference to the emissions and still passes MOTs no problem. Runs smoother, pulls better.

There's loads of discussions on it here, andthere's a step by step guide onhow to do it as it's a VERY common problem.

http://www.fordmondeo.org/forum/showforum.php?fid/164/

The TDCi Mondeo is the worst car I've ever had but fortunately after nursing it through the last 3 years I'm finally chopping it in for an Octavia vRS TDI. Can't wait.....

Hope this helps,

Bob.

Strange, but the Mondeo TDCi is one of the best Euroboxes that I have had. It tows my caravan a treat and on a long run, without the caravan,I get 55 mpg even though I'm cruising (in Germany of course constable) at 85 mph. Mine has 130K miles.

Even after a 6 or 7 hour journey, I still feel reasonably refreshed. The only problem I do have is blue smoke on the first start of the day due to worn valve guide seals.

Keith

[Kevin Garrod]

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I've had my TDCi for nearly a year, it's done well over 100k now and I think it's great although SWMBO doesn't! and she drives it more than me. Much cheaper to run than the 2.5V6 we had before but not as smooth of course. It chucks out a fair bit of black smoke when you acceleratefairly hard, but apparently that's quite common:?

[aerosilver]

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I agree it's a great car to drive, very comfortable on long hauls, very economicalandpulls like a trainbut I've had a steady stream of mechanical problems, including alarming random engine cut outs which I reduced considerably by replacing the cam and crank position sensors, but it still does it occasionally so I can never trust it 100%. The Stag beats it for reliability!

David, what I did was take the EGR off (only a couple of pipes and bolts), thoroughly clean it with brake cleaner (not a pleasant job) and make sure the valve is fully closed again, then I did a belt and braces job by both pushing a ball bearing (favourite is one from a hamster drinking bottle) down the vacuum tube and crafting a blanking plate from a thin sheet of steel I had laying about and then just put it all back on.

Yes isolating it made a world of difference - as well as smoking it would misfire under slight load at 1800 - 2000 rpm - cured both.

Good luck, hope it solves it for you.

Bob.

[stustag]

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Kevin Garrod wrote:

I've had my TDCi for nearly a year, it's done well over 100k now and I think it's great although SWMBO doesn't! and she drives it more than me. Much cheaper to run than the 2.5V6 we had before but not as smooth of course. It chucks out a fair bit of black smoke when you acceleratefairly hard, but apparently that's quite common:?

Hi Kev

If it is chucking out loads of smoke your EGR is not working correctly. I had this problem on my 2.2 TDCI twice but on mine the glow plug light flashed on both occassions.

Power was gone with no more than 3000 rpm available!:shock:

My car has done 115K now and is on it's second EGR valve. Other than that 3 blubs (in the last 4K) and 16 tyres(don't have to pay for these).

42.3 MPG average over 115k no bad considering how hard I drive average speed over the 115K 48 MPH

Stuart

[Kevin Garrod]

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It goes alright so I'm not concerned.

I can get the mpg on the trip computer over 50 quite easily, but SWMBO has it around 45. To be honest I can't remember the last time I drove it, probably the F2 meet at Brands.

[Greenstag]

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Kevin Garrod wrote:

To be honest I can't remember the last time I drove it, probably the F2 meet at Brands.

Too many cars or short termmemory loss?

[Kevin Garrod]

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Neither!

I spend most of my time on 2 wheels

[Arbman Al]

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I have not gone round corners that fast yetBut working up to it:shock:

[Kevin Garrod]

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To be clear I'm talking about the last time I drove my Mondy was to Brands, not at Brands!!