How to: Remove & inspect EGR valve Ford Duratec HE (Mondeo, Focus, Mazda)

[@CraigsDIY]

Amazon links to relevant products are in the description.

[@craiggiles5285]

Thank you very much for the information, I have found a few of your videos very useful for the duratec he engine. I like to do my own maintenance so now I have a list of engine components to work my way through checking the condition of it all including the fun swirl flaps and pcv as a prevention rather than cure. My engine has only done 80000 ish miles on a 2010 MK2 focus and with these maintenance tips I'm confident it will do this mileage again and again as it's an excellent engine.

[@CraigsDIY]

A low mileage Mk2 Focus is a great car, look after it.

[@pdtech4524]

I did this job on my 2.0 duratec powered focus, awful access, lots of swearing and scuffed knuckles I managed to get a shallow 10mm socket on a small ratchet from underneath the hard to access rear bolt. To get better access remove airbox, throttle body and get to it from the side. Be aware you lose about 2lt of coolant as you have to remove the thicker hose going to the thermostat housing, as you remove it lift it up higher than the rad and wedge it somewhere, the smaller hose going to the EGR can be left on if you only want to inspect and clean, it is hard to get off and I did split the end getting mine off, luckily there is some slack so I had to cut some off past the split when refitting. The metal gasket needs to be replaced really as it has compression seals around the exhaust and coolant ports, once it is nipped up the compression seals flatten to seal. Use carb or EGR cleaner on the internal plunger/valve assembly, make sure it can move freely and doesn't stick, there will be a lot of oily carbon in there. I took mine off, removed the electronic solenoid part held on by 4 screws, and soaked the valve overnight in cleaner, dry it thoroughly and add a little lubricating oil to the valve, I also put copper grease on the fastening bolts. It might not be the actual valve that is stuck, it may be the electronic switch part that is faulty but you cannot get this part alone, I paid £59 for a complete new EGR prices vary wildly I got quoted anything from £120 to £175 so shop around. Symptoms- mine would run until warm then cut out, restarting would be problematic, I'd have to floor the throttle and crank it eventually it would fire up, run a bit then cut out. I had no engine light so no codes, to check I just unplugged my EGR valve and it ran fine with no cutting out. I guess my EGR was sticking open, the engine will not run like that, when I unplugged it the engine ran fine but my engine light came on! I ran it like that for months, without issue before I replaced it. EGR is purely to lower emissions it does not make the engine run better and has minimal affect on mpg! In my opinion you would be better without one, look at the filth behind the throttle body where the EGR port enters the inlet manifold!

[@CraigsDIY]

Thanks for all that. I agree with your last. Some cars in some regions don't even have them fitted, nor cats, so it is certainly possible to tune the car to run without.

[@m1ghtyboy]

on mine it absolutely fucked acceleration and mpg, but it did fail entirely.

[@pdtech4524]

@m1ghtyboy If I could figure a way of removing the EGR valve, Installing the blanking plate they make for the Duratec and having the engine run without throwing a code, I'd do it because it ran much better when the EGR was unplugged. The engine light comes on without the EGR plugged in, unless it just needs the top solenoid and electronics part plugged in, that might work?🤔

[@m1ghtyboy]

@ the car needs to be remapped otherwise it will try to use the nonexistent EGR to aid acceleration. Not a mechanic but I believe a remap will make it pull any air it needs from the intake instead of the exhaust, and of course stop it from throwing a code. If you’re in the UK this will likely lead to it failing its MOT due to emissions.

[@BugzKiller]

I got 2 new gaskets with my valve (Napa) brand. Make Sure you use the right one with the new valve because they are both different, different port holes, etc. Just match up the old one with the new. It took me approx. 3 hours to remove because of that right side bolt being hard to get at!! I also disconnected the throttle valve and air box for more room. And I bought some of those S shape box wrenches to install the right nut easier (I hope) going to do it today. Rather than cleaning it, Just replace it! In case you clean it only and it still might not run well. Mine was $81.00 at Napa. And I have a 2006 Focus ZX4 motor 2.0L. Of coarse I had to disconnect Both the radiator hose in front of the right bolt for more access, then you have to disconnect the small hose on the valve when replacing of coarse.

[@riskytime]

Thank you. Well done. Wish more men would approach making their videos in this manner. Cheers

[@savirs17]

Thank you, I looked for it for about 10 minutes and couldnt find it until by chance after a 30 minute youtube search some how landed me on your video, although I have an Escape 08 the set up is identical, when you point it it out I felt like "duh" there it is, Im getting better at it.

[@mrcoolanddeadly2501]

Thanks Craig. The fumes are definitely coming from the front of the car and being sucked in through the air scoop at the rear of the engine bay. Its amazing how manufacturers add all sorts of safety gadgets on modern cars but they cant design them in such a way that fumes cant get inside the car from the engine bay. Very poor from a health and safety point of view. Thanks for your help on this. Much appreciated

[@incargeek]

My Volvo 1.8 is doing that too. I can smell fumes coming in through front open windows when I accelerate. I think its the EGR.

[@gregmonaghan]

Coolant does flow through the valve body from the hose to the block. If the gasket is not in good condition or the bolts not tightened properly there may be a coolant leak from the mating surface. Ask me how I know!

[@CraigsDIY]

That's a good point that I got wrong in the video, thanks. So the lower edges of the valve should be checked for coolant leaks, especially after the engine has been run up to temp.

[@michaelsanchez8519]

So If I keep the hose still clamped on the nipple and I removed the egr from the block, it will still leak coolant? Why did it not do that in the video? I drive a 2004 Mazda 3. By the looks of it, the egr valve on both vehicles are the same.

[@steiffcollector4185]

Thanks for the straight forward, "no bull" video here, found it very helpful.

[@keizomatsuzaki]

I did not torque bolts and exhaust gas leaked. What is the torque pounds/ft on these bolts. In your video, bolts were not torqued and no leaks. What a fantastic mechanic you are.

[@Oxygenefrl]

Well I managed to do it. But before touching the EGR, i unbolted the water outlet connector so I could slightly move up the coolant tube and reach the rear bolt

[@mickryan4677]

by the way your videos are fantastic, easy to follow, guys like me really appreciate down to earth stuff like this!!!!!cheers

[@johnburakowski61]

On my Transit connect I noticed a cheap assed plastic coupling in the radiator hose was weeping . I removed , cleaned and inspected it and found it was full of cracks and ready to fail at any moment . Unfortunately , the coupling only comes with the compete hose assembly . $150.00 U.S. from the dealer . $75.00 online . If you have fat fingers , good luck trying to get that lower bolt out of the egr valve . Could be a lesson in futility .

[@lou-e-gee1239]

Was about to give up because of the bolt behind the cooling tub being in the way could not get a grip on it. But if u did it with a 10 Mia meter n universal I guessing just need to be patient it can be done

[@latinoheat210]

Can't be done tried too

[@KonKrom]

Ok can you explain how closed egr can lead to knock and timing problems?

[@mattkeefe3850]

Good information, simple narration, and clear pictures makes for a good video.

[@latinoheat210]

The 2nd bolt on the backside of egr is impossible to remove

[@latinoheat210]

Agree I tried can't remove

[@roycai8895]

Yes I have been looking everywhere for this comment. I am currently banging my head against the wall. I hate 1/4 inch tool it flexes so much and breaks so easily. I am thinking maybe I'll just remote the top bit and work it up and down without cleaning the inside. Who the hell designed this, it's awful.

[@marko_._]

I think I lost almost 2 litres of coolant when i removed the EGR valve. It just dripped endlessly from the small hose for a long time and i couldn't remove the hose from EGR valve immediately (awful location and very easy to damage some cables etc). Anyway, some hours of wrestling and the job is properly done.

[@daniels6624]

That hose is connected to satans toilet I am sure. When it started oozing, I just stared at it in disbelief for about 2minutes haha. The special factory radiator fluid is hard to even know what it is. I thought that was an exhaust inlet port... I don't want to work on cars anymore.

[@JamJells]

Looks just like the one I have on my 2003 2.3L Ford Focus. Thank you!

[@francescopalmieri74]

good morning friend thanks for your videos I have a big problem I have a Ford c max 2003 1.8 petrol 120 hp I would like to change the petrol filter the dealer says it doesn't port do you have more information?🙏🏻

[@Mr.M1STER]

The egr systems on engines are really horrible. Engines were intended to run with fresh air, fuel and in the case of petrols, spark also. None of the exhaust recirculation shit.

[@ContentForFriends]

You will go back to E2

[@KalleTuulos]

Thanks for this video! Is your ratchet wrench set a Kamasa Tools set from 80's, in green metal box?

[@CraigsDIY]

Nope

[@WASTEDST]

Right I have an issue the bolts on my egr are rounded I have the same mk3 Mondeo 2.0l duratec HE engine any ways I can clean the egr without removing it Really stuck for ideas at the moment

[@RockapeRockape]

Mate, you're doing a great job, I need to replace some burnt valves, could you please do a video about removing the cylinder head?

[@davidhendrickse2256]

Loved the vid. Second one I have seen and outstanding job sir.

[@jack765ful]

Why is there a coolant hose connected to the ERG valve? What on the valve needs cooling? And there's no coolant return hose?

[@Starfank]

The exhaust gases are too hot for that tiny valve so it needs cooling. Anyway exhaust gases are used to cool down the engine combustion chamber because they have very little oxygen, and practically inert in the process. The optimal temperature ensures NOx to be reduced before the cat

[@jack765ful]

@@Starfank Thank you. That makes sense. I do see besides the two holes for gas, there are 3 more holes between this valve and the return to engine block. Coolant return is probably one of those.

[@BruceLeeFannl]

Thanks for this video how to do it. But the tool you used did not fit by my mondeo I had to use another tool that was smaller so I could place it between the bolt and the hose.

[@catalinman6547]

If I replace the egr with a new one, do I have to calibrate or make an adjustment from the ecu or do I just replace?

[@CraigsDIY]

Just replace. If the old one was faulty or very clogged up you might want to reset the car's tune adaptions, just unplug the battery while you do the job.

[@susannes3135]

My car is in for rough idle low rpm vibration. They checked mounts and cleaned the throttle body and mass air flow. They are now "guessing" it might be the EGR. It will take them an hour to check it so they are recommending I just replace it. $425can tax in. Is this a logical reach and solution to a slight vibration? 🤔

[@jamewakk]

No video on how to delete it?

[@mynameiswoody4529]

I have Ford Focus 2007 model running on petrol and check engine lights have been a problem for a while now and it says EGR system flow fault, it might take more time and cost to order a new EGR and replace so I am planning on deleting or blocking the EGR but still unsure about it. do you recommend of using blocker plate for the solution?

[@CraigsDIY]

I don't have experience. It might cause inspection failure depending on where you are, also I understand might require ECU re-map to get the codes & lights off.

[@mynameiswoody4529]

​@@CraigsDIYThe inspection is not a concern for me, and if i don't get it remap the only downside is i will always get faulty engine light code is it

[@CraigsDIY]

No it can relate to tune too, the engine will not be getting the fuel/air mix it expects.

[@andrew1725h]

Just out of curiosity I'm doing this job tomorrow wondering how to check for air leaks

[@latinoheat210]

The second bolt on the backside is virtually impossible to undo...smh someone said try a 90° degree angle so ill try thet to take the backside bolt off.... smh

[@latinoheat210]

Did it work?

[@RetroBoy94]

So is that tiny hose connected to the EGR the coolant hose? Or do you mean the big hose running next to it?

[@CraigsDIY]

They're both coolant hoses, the small one cools the EGR valve.

[@garyturrell6299]

I'm changing my egr valve on my ford focus .IV for got how to put clamp back on egr valve.the clamp that holds the egr together

[@fulldeckjoker3372]

Where is EGR valve located on my 2012 ford fusion sport

[@BruceLeeFannl]

Good video I know where the erg is now. But can you spray it with some cleaner? And must you spray it where it is attached on the engine? And if so what cleaner spray I can use?

[@daniels6624]

Yes it must be "cleaned" where it is connected into the engine. It made more sense to clean these when they were removable.

[@latinoheat210]

How would you clean it ?

[@harveyhyke8165]

MY CAR IS 1/8LX PETROL WHEN I LEAVE THE CAR FOR AN HOUR THE FUEL FINDS IT HARD TO BE PUMPED THROUGH THE ENGINE BUT IF I KEEP IT ON HALF FULL I DONT GET THE PROBLEM. WHEN I DO I FIND OUT THAT IF I PUT A GALLON IN OUT OF MY CAN IT WILL START ANY IDEA. IVE CHANGED FILTER THAT WAS BLACK WITH MUCK BUT STILL THE SAME ANY IDEA

[@billmacdonald5906]

Hi Craig, I'm confused wondered if you would know, I'm sure you will, I have a mark 3 mondeo petrol, recently on start up the engine flies to over 3000 revs, the throttle cable is not stuck, can't check for vacume leaks, replaced the throttle position sensor, cleaned out idle air control valve, not looked a egr vale yet, any suggestions?

[@CraigsDIY]

IACV or its electronics could still be faulty. Check throttle butterfly valve closing properly. Have to suspect vacuum leak. You would want to check OBD diag for air/fuel and related info to find clues.

[@billmacdonald5906]

@@CraigsDIY Thanks Craig, I disconnected the IACV and started the engine, it went straight back to normal idle. I have ordered a new one. Thanks for your help, and great videos by the way.

[@CraigsDIY]

@@billmacdonald5906 I saw your other post. So did the replacement IACV not fix it? If disconnecting the electrical plug solves the high idle and a new valve is no different, that must mean an electrical problem. Have you checked codes?

[@billmacdonald5906]

Hi Craig, thanks for your reply I think as you suggested I have a vacume leak, I can hear it sort of around the coil pack area, can't seem to locate it.

[@mookie0271]

nice video , explained very calmly

[@safranhamad]

nice job!! is it the same thing to do with ford focus 1.8 tdci ? thank you

[@CraigsDIY]

It's different but the principle is the same.

[@pawelw6579]

I'm going to to this tomorrow

[@vanstreun]

Thank you for all your helpful videos on this Mondeo. I have a 2003 Mondeo with this same duratec engine. I have a question you might be able to answer, sometimes when the engine is warm it won't start without giving it a little gas. I also noticed that the throttle percentage never goes bellow 18% and it doesn't go above 80,4%, is this normal? Engine seems to run just fine though, but I never owned a Ford, so I can't really compare. Obd once gave a p0400 fault code but that never returned after deleting. Could this all be related to the egr?

[@CraigsDIY]

I don't think it's likely to be the EGR, they can be finicky and I wouldn't worry if the code doesn't return, but anything is possible if it is clogged up or failing. I understand the codes are more common on manuals. Have a look at my other videos for the one on checking the TPS, and compare my voltage low/high to yours. There is also the old thing with Duratecs where if you kill them after a short trip there can be exhaust gases left trapped in the intake manifold which give trouble starting next time. You can 'fix' this by opening the throttle as you turn off the engine, or just accept it will take a few more cranks to start again, but it's basically normal and not a mechanical fault.

[@vanstreun]

Craig's DIY Car thank you so much, now I'm a bit more reassured that all is normal. It indeed starts normally after I give it some gas when shutting down. Now after the thermostat, and broken springs on to fix the central locking on the passenger side door. You're videos are super helpful! Thanks again for replying.

[@michaelrobson9331]

Craig's DIY Car Really good video this,my Mondeo 1.8 is pinking under load / heavy throttle and my chief suspect was this or the knock sensor. Do you have any vids for a knock sensor swap? It's a 2002 model.

[@kalujny]

I keep thinking of removing EGR module altogether from my engine (I have the same as yours). I have bought a egr stub part (they are used on old Duratec/L blocks on mondeos). Apart from ECU problems, I cant seem to figure out what to do about the coolant line, if I just throw away the EGR. Where does it go, and is there anything else that depends on this line for cooling etc? Do I just plug it and forget about it?

[@RATON012345]

It is also the valve is clean?

[@martinkrestan6250]

Please, I need to clean egr on the monde and I do not understand you because I can not speak English. Do I have to drain water with coolers?

[@CraigsDIY]

You don't need to, but you'll probably spill a bit of coolant in disconnecting the hose. If you lose a lot just top up after.

[@SannyDavid7]

Is this a gasoline engine?

[@harwoods11]

Hi Great videos btw. Clear and easy to follow. Can I blank off this valve but leave it wired in?

[@Brian-Bedania]

I'm also keen to know the answer

[@johansvensson9586]

Will a bad EGR result in a "check engine light" of some sort?

[@CraigsDIY]

It can set codes but could be quite bad without doing so.

[@daniels6624]

I believe a "check engine light" could result in the actualization in people's minds that the egr is bad. How about that?

[@mickryan4677]

Hi Craig, I've a 2007 ford focus 1.8 petrol with the duratec engine, how do i know its a duratec HE, in all my details it shows its a focus style flexifuel 125ps model or does it make any difference, also are the 1.8 and 2.0 litre engine manifolds interchangeable cheers

[@CraigsDIY]

I'm not sure it's styled a Duratec HE, possibly different, but all these engines are based on the Mazda L. This article suggests you have a variant called a Duratec FFV: en.wikipedia.org/wiki/Mazda_L_engine ~ I don't know more about it sorry. It's obvious that the intake manifolds are again all the same base design, but there are varying attachments between years and models so you would need to visually check to be sure.

[@chaancehirawani5606]

hi there my car ford mondeo 2002 vtec needing to know where my EGR is located as it is not where yours is in this video

[@CraigsDIY]

If you have a Honda you're on the wrong video. If you mean Duratec and you mean the 2.0 HE, then it is where shown. I think however some locales with lower emissions standards didn't get them. In this case you will see a blanking plate where it should be. Where is your car from?

[@jorarr5174]

Does coolant go true there

[@CraigsDIY]

Sure does

[@BruceLeeFannl]

Question can you remove on top of the erg the four screws and than clean it ???

[@daniels6624]

I did that... and no. It has the ports for the exhaust only on the side facing in towards the engine. I did find that the top (with the sensor and motor in it) are easier to swap for a new one if they are the problem. Also if you take the top off you can manually depress the valve on the bottom piece to see if it is gummed up or not.

[@BugzKiller]

@@daniels6624 Daniel did you do that taking the top off with the four screws and try to clean it? It's harder than hell to reach those bolts. I have to do this the next day or two!

[@latinoheat210]

​@@BugzKillerI couldn't take the bolts out either ...they don't have have a tool or the room to do it ...smh

[@brendanstack7833]

Why the need to diconect the battery termination ?

[@scorpionwins6378]

Always a good precaution to take when unplugging any electrical connections from the engine. The reserve charge in the circuit can sometimes damage the electrical system.

[@ZakKol69]

do you have any experience with an egr blank kit?

[@CraigsDIY]

No experience sorry.

[@Andy77337]

I used to have a focus 1.8 duratec the egr valve was sticking open intermittently making it drive like a pig, so I ordered the blanking kit off a company in Poland through eBay, when it arrived I un bolted it like Craig done in is video removed the original gasket, then carefully slid it in between the head and egr valve with the gaskets they sent one on each side then done the bolts up lost I bit of coolant that I replaced the next day, anyway it worked a treat, drove nice and smooth, only thing was lost about 1 mpg average the mpg not good on the 1.8 used to average about 34 before then went down to 33, also after 2 weeks exactly the mill light came on but did not effect the running of the vehicle got 2.0 version now much better even better on fuel can average over 40 mpg on a run (and also has disc brakes on the back:))

[@vanessayoga7522]

Andrew Thomson The EGR block off plate ? It works ? Any noticeable power or efficiency ?

[@steiffcollector4185]

Craig, I am a total novice, and can't afford to pay someone to fit my new egr valve on my MK3 Mondeo 2.0 Petrol (2003). So have tried doing it myself, but I cannot for the life of me get at the lower right hand bolt! I am wondering if the extension bar that I have is too fat for the job? The one you are using here in your great video appears to be quite a bit thinner, am I just being daft or does this sound plausible? I have a standard set by Draper, what would be the correct name of the part I need please? I could do it if it were not for this one bolt! Many thanks. Mark.

[@CraigsDIY]

Yes it's tight. You'll notice I'm using 1/4" socket parts (at the bolt anyway), including the universal joint. Anything bigger probably won't work. If you look at 2:38 you can see the tools clearly.

[@andrewkehoe9116]

HELLO. IS THIS THE SAME AS A FORD FIESTA ST 150

[@CraigsDIY]

I think so.

[@barrymichaels2663]

It is yes

[@kiwitrains]

Very useful thanks

[@ersinvanhulten8802]

Hi craig My question is i replaced my egr for a new one after i did the job i set off the faultcode.. when i go for a ride the fault code pops up...so i read the obd end i see its the egr valve over end over again it will popd up back

[@15coals39]

I'm having the same issue

[@vicentetorres279]

Spray soapy water over the engine to make sure it's not a leak on your gasket or a vacuum line.

[@Andy77337]

That could be a broken wire, it could be stopping the egr opening, causing the ecu to throw a fault code

[@YourPointOfViewPodcast]

I'm having the same issue did anybody ever resolve the issue I need some advice

[@dangerousdave74]

When replacing the EGR with a new one, which way does the new EGR gasket go on as one side has a slightly raised lip on it.

[@jvst20051]

Whrs the iac valve in this engine

[@CraigsDIY]

Under the throttle body.

[@jvst20051]

@@CraigsDIY thanks

[@th0ut]

thank you! that was very helpful

[@aguywholifts4024]

Hi if you undo the four screws on top of the egr valve will that give you access to the inside so i could squirt some egr valve cleaner inside ?

[@CraigsDIY]

It will give you access to the solenoid or springs inside. What gets coked up are the ports and valve on the EGR ducting, which is why you remove it as shown.

[@berrymucuckiner4890]

Hummm… similar but much different on the American model… battery and airbox are reversed

[@mrcoolanddeadly2501]

Hi Craig. Could a faulty or blocked EGR valve cause fumes to leak in to the engine bay? The reason I ask is that fumes are getting sucked inside the cabin of my petrol Mazda 2 and causing me to become dizzy. 2 separate mechanics have checked car and said there's no problem but I have been monitoring the issue closely for an extended period and there are definitely fumes getting inside cabin. I have had this problem on several other cars and no one can ever find the cause(or even acknowledge that there's a problem in the first place) any ideas, suggestions?

[@CraigsDIY]

Are there fumes from the engine bay though, when you open the bonnet. Otherwise it could be fumes being pulled in through a failed seal e.g. the boot. If engine bay then exhaust leak somewhere, any/all parts of exhaust system including the EGR gasket are possibilities I guess.

[@jamewakk]

That motor doesn't look like the one I have

[@NZfabrock]

You shouldnt have reused the gasket on the EGR valve, poor practice and can cause futher problems.

[@daniels6624]

lol. You did it in a 6min video... project took me 11hours. 'Course, I had to flush the radiator, buy new r fluid and MAF cleaner while they were taken apart..., and pull a salvaged sensor. Let me just say that I don't like EGR valves anymore. Taking the radiator hose off doesn't help all that much, because the socket for the hose still blocks the bolts pretty completely. I used a "box" wrench with a 90 degree bend in it (available at harber freight) to get them broke loose- only after I removed all of the wiring including the ECU wiring. NOT WORTH IT!!! Throw the car away and buy a scooter.

[@latinoheat210]

So did you sell or throw the car away?

[@latinoheat210]

So you were able to get the back bolt with a offset wrench? Or s type ?

[@paulinesmith5077]

Oceana

[@sylhet1978]

Fuck youtube too much ads..try ti watch important stuff..keep popping one othe one ads

[@thelonelyhunter942]

So can you please watch my link to see the egr voltage ? Its 1.50 volt and dont change. And can you watch the lambda numbers please the sensors above of its doing his job well ? kzbin.infozmRqyQB-Rx4?si=P31WWpu7SPtxQ6xk

[@giovannibotta6628]

Il

[@tanyokrollo6641]

Hi