Mondeo EGR Valve - Info, Cleaning, Operation

[@moldeeside]

Huge thank you night owl, I was on the verge of getting rid of my 2005 Mondeo due to egr problems. So glad I found your channel, very kind of you to share your knowledge.

[@jonnyharris2724]

Just done this on my 2.0D x type. it literally is a piece of piss to do thanks to thanks to your video. Even without any lights on the dash or smoke it has made a huge difference to the way the car drives. I scrapped most of it out with a screwdriver then blasted it with wd40 and finished it off with wire wool. Thanks

[@jimpanzee9973]

Great video. Just some tips for anyone who cleans their EGR valve that I found helpful. Petrol is great for removing the oil/grease. For the bit with the valve that opens up I soaked it in petrol for 2/3 hours and the grease just washed away. Also you want clean out your inlet manifold as it's connected and fills up with oil/grease too. That's more of a pain to clean. I used a knife and spoon to scoop out the bigger deposits then I soaked it oven cleaner over night and washed it away. A jet wash would be great to use (such as one you can find at a car wash).

[@elbaronrouge]

Excellent video. Cleaned mine a couple of times, finally failed. Blanked off and I now get another 6 or 7 mpg fuel consumption. EML is on pall the time but I check the code once a week with F-super, no problems.

[@Hiccup77]

Excellent video friend, VERY well made. Although I will say, it's ok cleaning the EGR but 9 out 10 times if you have a stuck and gunked EGR, cleaning it wont really help, as it'll fail very soon after. This happened to me. Engine light on, so cleaned the EGR fully, better than new, and by the time I drove 40 miles to home the light came back on and the EGR was dead. By all means clean it, then fit a blanking plate, if the engine light comes on, remove it and drill a 10mm hold in the middle and re-fit, the light will go out after 4 start cycles and you'll be fine.

[@gardenstate78]

Hi this is exactly what happened to my Mondy. Would your advice also work for the ST or is there a big difference between the engines?

[@Hiccup77]

gardenstate78 The ST is a 2.2 155bhp engine. But blanking will be fine. most turbo engines have a egr valve and by blanking it you are not putting burnt oxygen and soot back into the engine.

[@Tambo74]

HiddenWarrior So basically the only real porpouse of these EGR Valves is to cut emissions.. but shortening the life of your engine in the process?

[@shanepatrick641]

@@Tambo74yup, pretty much!

[@NightOwlFactory]

Thanks for your kind words. I've been through same problems which got me to do some research and then share what I found out. Given symptoms you described EGR fault is very likely however there are other possibilities giving similar signs of a problem. I recommend checking EGR valve first because it's free and easily done by anybody.

[@NightOwlFactory]

Yes I did. It's a good practice to disconnect the battery before starting any kind of job on your car. And remember always disconnect negative wire first.

[@dziekiedziekuje4370]

Thank you for your advice,glow plugs have been changed and starting is much better, they also cleaned the EGR which they said was quite dirty. It is still a bit lumpy but I suspect that this may be due to the fact that it is only being used for short journeys so never really gets to operating temperature.Have given it a couple of runs and now consumption down to 8.2l/100km which is much better than it was.

[@gjj75]

Such a perfect video so beautifully explained, thank you so much for taking the time to make this

[@NightOwlFactory]

Thank you

[@philipbraiden9577]

Good, clear advice and step by step instructions. One of the best I have come across. Thanks!

[@55studabaker]

Im not a mechanic The beauty of a Mondy is its easy to get to. Did it first time about an half an hour with 30 mins cleaning. Drop the bottom pipe 1st then the top two bolts to give leeway for the inner side bolt. Gotta say yours looked clean, mine had about qtr inch hole left for breathing. The piston has to move so put a small pipe on it (2ft of cable outer with the wire pulled out) and suck to make the piston move. Think where the crap is coming from n clean that too. Follow it back!!

[@johnmcquay82]

Excellent video. I'm not a mechanic and was hoping to find some clues for the problem I have. My Mondeo TDCi 130 sometimes judders when cruising and has a lot less power than I would expect; when the turbo has kicked in, the car throws awful black smoke out the back...I guess this is because the turbo pressure is lost through the valve and out the exhaust. I wouldn't have had a clue had it not been for your video.

[@josephglynn7196]

cleaned mine 3years ago couldnt believe how much soot was caked onto it, did you find when you started your car back up that it was very smokey for the first few minutes, i cleaned my manifold the same time, good video!!

[@chrislemm6356]

did mine today after watching this video, thanks

[@zgabeartzaiftodie8615]

Did you clean the inlet manifold?

[@dziekiedziekuje4370]

Thank you for your very prompt, logical information. As I don't know the history of this car I will get a set of glow plugs ordered up and ask my mechanic to fit them - nerve wracking for him :) As you say there does appear to be a rather nasty smell at the back of the car when starting. Will keep you posted.

[@terencejay8845]

I cleaned my EGR on a 2005 TDCI about 5,000 miles ago. Prior to that the hose was split, very common, and I replaced it with a silicone hose from eBay that means it won't split again. Now, at 100k, I'm getting the puff of smoke when accelerating on the motorway, so it may need cleaning again. One of the effects of around-town, low-rev driving maybe. Next thing will be to fit a new EGR valve, but they're not expensive. At least you can get at them.

[@dziekiedziekuje4370]

Well, the garage changed the glow plugs and cleaned the EGR which they said was dirty nad it certainly starts better now. Still running a bit lumpy but possibly just needs a good run as the run to work doesn't warm it up. Many thanks for your help

[@82Ingy]

Have just found a massive split on the pipe connected to egr valve. Changing it tomorrow so hopefully that cures the loss of power

[@paulharris4925]

Very good video, I had back smoke coming out of the exhaust on acceleration on my Mk3 Mondeo and watched the video then went straight out and cleaned my EGR. It was caked in black sooty/sticky goo.I also noticed the pipe attached at the bottom of the valve was split as well so Carried out a temporary repair with black insulation tape and after cleaning the valve refitted everything, went for a test drive and no moe black smoke. Wonder what a garage would have charged to diagnose and repair this fault !!! Thank you

[@zayk2981]

the split in pipe must be intercooler pipe , from fords about 40 50 quid , there are other company's out the doing silicone intercooler pipes at 30 odd quid and last a lifetime ! Iv learned this at an expense , been through three intercooler pipes so far , overall if split change it and as for egr , either soak in petrol over night or the best one is mr muscle oven cleaner, the best !!!!

[@cheaptramp]

Cheers for the vid, just did this on my car today and it's running great now!

[@BillSikes.]

thanks for this video bruv,it's the best one for egr cleaning,I'm gonna go and do mine now.. cheers

[@helpingsociety4447]

Thank you, Sir, for your expertise. Wonderful.

[@deonkruse3749]

thanks gave direction to possible reason for car going in limp mode - had no clue or idea where to start looking or scratch

[@NightOwlFactory]

I would suggest checking your glow plugs. If some of them are gone your engine is not warmed up properly when you start it which in turn leads to sub-optimal combustion (hence smoke) during first few minutes. Also the smoke has a really distinctive and unpleasant smell. In order to get to your glow plugs you're going to have to remove the egr valve anyway together with inlet manifold which is a nerve wrecking job cause you will have to bend fuel pipes. Good luck

[@iamkjb1]

Lacks details of access to EGR and tools required, e.g. what type of spanner will be required and what sizes. Most car maintenance vids on here lack these very important details.

[@iamkjb1]

***** With that kind of mentality, for heavens sake, please do not ever think about publishing a help article of any kind on any type of forum, sheesh what an amateur.

[@juliusblazek4876]

@@atraxr603 exactly

[@LeeLimerick]

Thank you! I'm gonna try this over the weekend. I'm losing power and seeing a lot of smoke. Hopefully this is the cure! I think also a pipe is split somewhere, because I can hear air escaping when the turbo kicks in. Feels like a misfire when cruising..

[@theguitarmanifesto]

Lee B. Geebeez did it help? My Mondeo is doing the same

[@LeeLimerick]

Rob The Meat Manifesto To be honest, I'm not really sure. I found a big split in the turbo pipe connected to the egr valve. Seeing as I had to take the valve off to replace the pipe, I gave it a good clean. Its a quick easy job, so no reason not to do it. I got power again and no smoke :)

[@55studabaker]

So many thanks best vid on youtube by far. So simple.

[@WalkWithWallace]

Useful VT, my coil light is flashing intermitting at the moment so will give this a go first. May save me a few quid.

[@cognitivedissonance4413]

Did it help? My coil light is flashing.

[@shanepatrick641]

Yeah, did it help at all?

[@WalkWithWallace]

@@shanepatrick641 it did for a few days, ran really smooth then back into limp home mode 😔

[@shanepatrick641]

@@WalkWithWallace did you ever figure out what the problem was?? I’ve got a new EGR valve I’m going to fit in the hopes it solves the limp mode. Thing is with mine, the engine management light hasn’t come on and only the glow plug light is flashing. (Limp mode)

[@WalkWithWallace]

​@@shanepatrick641​@shanepatrick641 mate, I sank over £400 into a diesel specialist and they couldn't sort it, to rub salt into the wound the car was still on the road a couple of years ago. I wish I had just put some V Power diesel in it and some injector cleaner and drove it about for a while. 😔

[@xnetcascais]

hi there, very cool video and easy to follow up. thank you. i have just one question about the 'old intercooler hose', it seems to be clean. i still dont know if my hose has a hole but mine is so dirty around it with greasy and messy sticky oil like it is in minute 02:24 inside of your egr. any comment or suggestion what might be the problem?

[@NightOwlFactory]

That's great. Always happy to help.

[@petedougan5682]

Great Video. Well presented. Easy to follow. Thanks

[@dziekiedziekuje4370]

Just as a follow up I have been trying to do some more km to get the engine warm but still a bit jerky/hesitant from time to time. Have cleaned MAF sensor with special spray from CRC and now seems fine!

[@akagorila]

if u have problemìs whit engine not heating ,u should try to change termostat of oil or termostat of water,i just changed bouth and now works's fine!(sry for bad english)

[@WireSniffer]

Thanks great video! , very informative and to the point! , just what we ordered. I drive mk3 petrol I don't even drive a TDCI, but it's always good to know. ;)

[@pedropolski1]

Phil its not egr!check your turbo actuator arm(must running very smooth). I had same problem flashing glow plug light and then car was going on limp mode.try that if not try repair your actuator!

[@shaunehook6520]

Thanks mate I will clean my egr valve with confidence or indeed replace it.....

[@southwestlondoncarp4313]

will you do a video of you cleaning the inlet manifold that would be a great help fantastic video by the way!

[@philfenna5211]

I did put quite a bit of pressure pretty much all my strength woth my thumb. I also didnt have a sensor on the side like yours does. I didnt fix my problem cleaning it and ive just replaced my camshaft positiion sensor so ill see how that goes but if not I might take the egr off and try to get that valve moving?

[@NightOwlFactory]

You could take the valve out and leave the suction hose (vacuum hose) attached. Stick a rag or something similar into exhaust pipe (in engine compartment) so you don't have to breathe the fumes in and don't get your hands burned and get somebody else to start the engine and rev it. At low revs (idle) the valve should stay closed at high it should open proportionally to revs.

[@steve_o379]

Saw a mk3 mondeo the other day with this problem it filled the road with black smoke. I've worked on a few using higher quality diesel reduces build up with no or very little need to put in redex.

[@shanepatrick641]

So should I fill up with Shell V Power???

[@steve_o379]

@@shanepatrick641 yes V power had additives in that reduce this and cleans your engine also regular oil changes will help this around 5-6k intervals also long journeys help 1-2 miles a day will clog it up as the car doesn’t get warm enough to get rid of soot and other things

[@OneTireFire]

"chances are if you're watching this video that your Mondeo has developed a fault" heck yeah :))) loads of them

[@cymru3693]

Just what I needed cheers!!

[@moderatefkr6666]

Excellent vid. Thank you.

[@jasondonavich2758]

As this engine is very similar to the x type engine would the same be said for the x type turbo only kicking it at 2000 revs?

[@mattiemurphy223]

Excellent video Thank you

[@t5jerry]

EXCELLENT video !

[@jbmahmud1469]

hi, just start having flash glow plug light on dash once car warm start. it lost its 20% of power aswell while GP light flashing. i changed the fuel filter, cam position sensor and cleaned EGR valve. but still the same, do you advise blocking EGr will help. i also noticed white smoke first time you start the mondeo (mk3 tdci) from cold. ?? thanks

[@gibatron]

J B Mahmud I would guess your electronic turbo actuator is knackered.

[@ednureco]

Great vid Very helpfull and detailed

[@philfenna5211]

Hi finally got round to cleaning it! It was filthy got it clean after a lot of scrubbing. I put a bit of pressure on the actual valve and I couldnt push it back which I thought it would of. Do you think its seized or something?

[@NightOwlFactory]

No, I think it's fine. When I had mine out I was able to push it in with my thumb but I had to use much more than 'a bit of pressure'.

[@csinscorrections5934]

The part about the switch is wrong at the end is wrong its a sensors. It doesn't just measure open and shut either it measures position open, part open or closed. Also blanking plates don't work in anyway what so ever you might as well just leave it clogged up. Just take the time and fix the real problem witch is the the egr cooler. What people where thinking when they invented that thing is beyond me obviously condensation was going to develope inside one of something like that at cool down mix that with soot you get gunk. Only way around this is a silica block like what you get in them packets in electrical items to stop moisture (DO NOT PUT ONE OF THEM INSIDE THE COOLER IT WILL JUST BLOW THROUGH) you can get them in wire mesh bags that sit securely inside the cooler. Also think about recon injectors will cut down on unspent fuel that will create a lot of the soot in the first place them Volvo engines are notorious for that.

[@OldFloatingSeaman]

I have a pdf fro a complete strip down and clean, how do I post it on here which would compliment your excellent video. p.s. Always worth doing a Vacuum Test prior to removal.

[@shanepatrick641]

Do you have a link? 🔗

[@OldFloatingSeaman]

@@shanepatrick641 I have a workshop manual on a disk, so printed out what I needed.

[@shanepatrick641]

@@OldFloatingSeaman ahh, that’s what I need to do then!

[@skinhead1975]

Thanks very much, very helpful

[@danw1374]

Is it worth also flushing the engine using wynns engine flush to clear the carbon buildup?

[@gurdevsingh8534]

How did u get the egr valve clean ??so good

[@OldFloatingSeaman]

Carb cleaner and a scotch brit cleaning pad. Don'e tell the missus.

[@Triestini]

Superb video bravo (Jaguar X-Type)

[@mrchris123gmail]

really good video... thank you.

[@winchester12gauge76]

Great video!! Getting to the rear nut/bolt is tricky - any tips please?

[@winchester12gauge76]

+Anon James Ignore my question - I just watched to the end!!

[@dziekiedziekuje4370]

I have a 130PS Mondeo 2003and when I start it I get a big belch of blue smoke and then it 'coughs' until the engine is warm/hot - about 5 mins. Idle is also lumpy at this timeIs this likely to be an EGR problem or have you any other suggestions.Unfortunately recently the car has only been used around town as I have had problems walking so has not had a good run for a while. Fuel consumption showing 9+ l/100km Thank you

[@wilfadams7173]

Great video

[@jimpanzee9973]

Boom. Your a legend

[@mikecross]

Did u disconnect the battery before taking off wires?

[@josephflynn1382]

good vid man thanks!!!

[@marshylax12]

what did you use to clean the valve with? what products?

[@NightOwlFactory]

I used a random carb cleaner that I picked up from Halfords. The residue is sticky and horrible but with carb cleaner it's easy enough. Google it!

[@markraification]

Nice move going to try it my self thanx

[@Vanadeo]

I have either got this valve gunked up or a split in the hose as I can hear a hissing noise under acceleration, also surging between certain rev range.

[@sllca]

get a new pipe off ebay for under £20 with life time guarantee . Ford asking over £100 pound

[@sukamanut8921]

good video but if your going to clean the egr valve you may aswell clean all the air intake pipes aswell??

[@svensekmirko]

Does that apply for mondeo mk4 as well?!?

[@kristijannikolic6502]

when i am in fifth gear,the engine just wont go when i am presing accelerations,its just like i am keeping the same speed,its that the reason? asap pls

[@shanepatrick641]

Limp mode possibly?

[@MobileRecordingsRo]

Hello ! I have a Ford Focus II Turnier 1.6 90HP. My car ejects white thin smoke when it's cold, after a while the smoke stops. But if I let the engine to cool down (3-4 hours) the smoke reappears. Could be the EGR in my case ?

[@ely_mine]

normal for a diesel, dunt worry

[@matisms]

can you tell me exactly what tools i need?

[@ashfar1368]

very helpfull thank you

[@dougthemughewett3143]

Hi its that the same as x type jaguar engine

[@philfenna5211]

Great video! My mondeo 2.0 TDCI 53 plate 130 cuts out randomly when driving without any warning chugging etc. The car looses power (engine cuts off) and the glow plug lights start flashing. it starts perfectly on the restart. I've read on a couple of forums that cleaning the EGR valve might help. It doesnt look to hard to do after watching this :-) ! But do you think that a dirty EGR could be the cause of the car cutting out completely?

[@NightOwlFactory]

It's certainly possible, mainly because the CPU can't 'see' the valve actuating as it can't move due to crap build up inside. The CPU thinks there is a problem so puts the engine in a limp mode to prevent further damage (at least I would like to think that this is the reasoning behind it).

[@philfenna5211]

NightOwlFactory Thanks! I'll give it a go this Saturday :-D The car drives perfectly, pulls really well etc. at all speeds. Makes me think its not to do with the injectors or pump (wishful thinking maybe...) but more an electronics issue or sensor..

[@stuartbennion]

@@philfenna5211 was it the egr valve? As my mondeo does the exact same thing How did you get on Thanks

[@philfenna5211]

@@stuartbennion wasn't the egr valve as the problem continued. I ended up replacing the camshaft sensor which was one bolt on the engine very easily accesable and 20 pound to buy. When I compared the old camshaft sensor with the new, the edges were rounded as oppose to flat. Might be worth taking it out to check before ordering

[@stuartbennion]

@@philfenna5211 thank you, ive just looked at my egr and the previous owner has blanked it off so they must of had issues with it aswell. Thanks for the advice i will look at the other part you mentioned Really appreciate it Thanks

[@baviaanshit]

How is the EGR on the new 2.0Tdci with 163hp? Is it reliable?

[@johnmathias9892]

I rounded of one of the 10mm nuts holding the EGR to the rigid pipe so off it goes to the garage. I hope they've seen this video!

[@gamba15dollars59]

like it so much good video very helpful thumbs up!!! is it possible if you can do one abt pulley and alternator on mondeo thank you

[@Idalove16]

is it easy to take out the EGR on a money Mk3 2005 petrol 1.8 16v 110HP engine? i got issues with my car also, doesn't always start the first second.. and runs poor sometimes and spends a lot of gasoline.. hope this can fix my issue. is it a lot of job to remove the EGR and clean it?

[@steve_o379]

There's a new system out called terra clean where a garage hooks it up to your engine and it cleans the fuel system and reduces emissions right upto the tail pipe. Have a look on KZbin:)

[@Idalove16]

Steve o thnx Steve, i will check it out :)

[@TheBurer]

Mine is 43.000 Miles. Do you think it needs cleaning? Thanks

[@NightOwlFactory]

I'm pretty sure it does. I check mine every 6-8 months and there is always plenty of soot inside.

[@HRHKingJamesIXofScotland]

thanks

[@zayk2981]

mondeo mk 3 , egr gets glogged turbo stops working , actuator messed up , many problems lol but trust me all solvable and preventable ! 2 litre tdci lol when it starts rattling , dual mass flywheel time , open heart surgery in engine omg , remedy is no1 drill hole I into side of turbo , thread the whole , mr muscle oven cleaner , McDonald's straw attached , stick in hole , spray , cleans the Finns of the turbo etc , job done money saved , in the hole stick a bolt and two washers and close , no2 actuator , open box , re solder loose connections on circuit , look carefully around the whole circuit , u will see 1 or 2 loose unattached connections , re solder , job done , no 3 intercooler pipe split , replace with silicone one , no 4 egr.fucking valve , take off soak in petrol over night or use mr muscle oven cleaner , lol lol all problems solved for pennies lol by the way all videos relating to these problems are all on KZbin !

[@jtothew4201]

I take it the dual mass flywheel problem isn't preventable?

[@Loundsify]

I've been getting very low mpg on my Jaguar X type which has the same engine. About 37mpg while the car is rated 50mpg. It's not had a service in 18 months so could be a clogged filter, but I have a feeling the EGR has never been cleaned. I've been told it could be blocked injectors and that using some adatives should help clear it up

[@julianrucho]

Qué es y cómo funciona ese Egr

[@meritonberisha3871]

Wha will blocking that area off with the plate do? Performance wise?

[@NightOwlFactory]

You will see no difference whatsoever. The engine will be taking in only clean air instead of mixture of air and exhaust fumes.

[@meritonberisha3871]

wont that affect my MPG?

[@NightOwlFactory]

In theory it's possible however based on my experience there's no difference.

[@meritonberisha3871]

oh okay tanks, do you have a link to that plate thing?

[@Hiccup77]

EGR or Exhaust Gas Recirculation transmits a certain amount of burnt gasses back into the engine. This chokes the engine as there is very little to NO oxygen left in the gas. It also clogs up the inlet manifold with soot. By blanking totally you are not putting the gasses back into the engine, thus it'll breathe better and run better. looking at a few more BHP and torque plus better throttle response. You MUST block the entry, Zorst IN to egr NOT egr to manifold!!!!

[@WHATTHEFUXYY]

hes good at explaining things but needs to work on his clarity ..good job tho buddy

[@nev2487]

Good c

[@monikakoziol4628]

I had i problem with black smoke on my x type 2.0d,so I clean egr valve but nothing happens,i try everything then I change injectors(my was 00504Z most expencive one)since than run like a dream no needed to blank egr valve and don`t do it!remember big company like ford spend millions on different test.if they put egr valve don`t change it!

[@NightOwlFactory]

The main reason EGR exists it to satisfy environmental regulations and bring cost of road tax down (as it's based on emission). The only other useful thing about EGR is that it helps warming an engine in first few minutes after start.

[@bulltraderpt]

NightOwlFactory Hi Night Owl, I've just come from the garage and they had to replace a fuel pressure regulator. Now although the car runs it's still down and power and they said the next step is to put in a blanking plate. I'm not particularly mechanical but I may try this as from what you say, it doesn't look that difficult. Ours is a diesel mondeo MK3, the injectors were replaced with new ones (not recon) so I know it's not an injector fault.

[@nickward9839]

👍👌

[@MikaHakkinen83]

One troubled VW fan has seen the vid.

[@Jordan_-iu8bn]

заглушил и нет проблем! чек только выбить может из за низкого давления на егр. снял клему чек пропал!)))

[@alanmiell6754]

Ufos

[@shaunpmarshall]

One of the worse cars around

[@shanepatrick641]

Why is that? Why is it the worst car??

[@shaunpmarshall]

@shanepatrick641 ...dual mass clutch that packs up and costs a fortune to replace and known for injector problems...also the serpentine belt is a pain in the ass to replace ...lovely to drive when running well though

[@shanepatrick641]

@@shaunpmarshall like most diesels? Run like charm when working, and go horribly wrong when they break, turning into never ending nightmares. I haven’t had luck with diesels, I’m sticking to petrol for now, unless you know a reliable diesel engine?