Ford Mondeo Mk5 E.G.R. Valve Replacement Finally got the chance to show how to replace an e.g.r. valve as the engine was out of the vehicle making filming the operation much easier.
Thanks Alan. With the help of your videos, I was able to remove my EGR valve on opel Grandland X. maybe my advice will help someone: I used a liquid wrench to remove the vacuum tube and cooling tubes at the junction. I think another liquid will do, which makes it easier to unscrew. a few puffs and everything came off without any problems.
Allen I love the way u explained what u are doing u make these jobs easy to do and understand so us guts can save money by not going to the garage just great stuff to watch Phil in stoke
Brilliant video Alan 👍 you have a knack for making seemingly massive and daunting jobs actually small and easily manageable for us self taught mechanic's. KEEP UP THE GREAT WORK 👏👏👏👏
I’ve never left a comment on any Internet video, but I must say Allan as I own a Mondeo Taxi , your mustard , I have attempted many jobs, only because of the result of your videos,, note to everyone check the videos before you change the EGR valve and find the Thermostat housing is cracked 😂😂 Do a pressure test, keep it up Allan you crazy cat👋
Legend Alan - thanks so much for making that video. I was one of those pests asking you to video the process after your last EGR video. Really appreciate it, I'm pretty sure I'm going to have to tackle this sooner or later, makes it much easier having seen it done!
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Thanks for a very informative video. Followed it to remove my EGR valve. Thank you. I am in Australia and am bewildered that it costs 250 pound to get this part in Australia is over $1500AU that's about 750 pound. I feel extremely ripped off right now. Great car till something goes wrong. It get expensive. Real fast
@@alan4x i spoke to you when I 1st found out about the dreaded lynx wet belts. I did an engine swap to a lower chain engine. Took the old wet belt out and it was still a pain in ass then when it was on the crane!. Great watching your videos. The missis loves it {sarc!} The st with the same engine has only got 33k on it so should be OK they seem to be a reliable unit. Was gonna get it remapped stage 1 but i think I'll leave it alone.
@@alan4x I've finally got round to doing one in a Peugeot boxer 2.0. 2018 Luckily those little vacuum. Pipe came off easy. This video helped a lot. Thanks Alan
Thank you so mutch !!!!!! i come from Denmark and i just replaced that shitty Egr Cooler... it had broken at the exact same place as yours ... crappy design ! !thanks !!
Greetings from Germany .. Thank you for your videos they have helped me alot! I also changed the egr on my Kuga and now I am getting the P0170 Fuel trim bank 1 error code.. have you ever seen that code on a diesel ?
Hello. What do you personally think about the mechanical blocking of the egr valve? And if you agree with that, where is the best place to block the valve? On the pipe between the big and small part of the egr valve? Thank you.
Hi Alan. I've got a 2010 Mk4 with the 2.0 TDCI 163BHP which needs the EGR to come out and be cleaned, so my first question is can they be cleaned? 2nd question is it vertually the same way to take it out as the one in the vid? I can see the EGR pipe that bolts onto the same place as the one you show above but being a mk4 and I haven't done one of these before, i thought i was ask the expert!!
Hi alan. Wondering if you could help me. I have a well looked after 2015 2.0tdci auto mondeo with about 240k on the clock. Its developed a bit of a flutter in revs when at idol after warming up a bit and will generally stall out. This can be avoided by keeping the revs up a little. Had it in for diagnostics last week and all that poped up was a few seviceables. Had a full service done but the problem continues. My gut feel is its the egr. Is there a way of testing the egr? Or do you know of anything else that could be causing this. I know its difficult without seeing the car first hand but would appreciate your advice. TIA dan
Hello thanks for the videos! Do you know where is the intake air temperature sensor is in this motor? You disconnected the map sensor but I'm looking for the iat sensor for my ford kuga... Thanks
My mark 4 2.0 tdci has a different engine appearance than the mark 4s I see on videos. It has no metal pipe going over to the front from the egr. It has various other things on the inlet at the front. I'd like to know if you have late mark 4s on the fleet with a last model engine type. Mine is an auto as well. WR13BXW.
Great video, I've got a 2019 peugeot boxer 2.0 hdi. It's leaking around the plastic bit of the egr cooler...might give it a go myself, engine on these Boxers is really low down for some reason ..
Hi Allan, I replaced my EGR with this video, no more leaking now! THANKYOU, but the engine light is on and my active start won’t work now. I took the battery terminals off to try and reset the car but still not working, any suggestions?
Still not as bad as my Mk4 Mondeo, I had to take to inlet manifold off, incl removing all the HP fuel pipes to the injectors! Worth doing though, the EGR was fine but the manifold and head ports were 50% blocked with crud.
Was this on a 2.0l? I recall Alan saying that coking inlet wasn't really a problem with this motor? It was a common go faster bit of maintenance on the mk3.
I have the x-type jaguar, with we know is 30% Mondeo and I'm constantly tinkering and cleaning the EGR , but is so much easier in the older Mondeos , its like the over complicated to stop the garden mechanic
Hi Alan . Could a stuck egr valve make the car shake when idling? I have seen your video about the bad flywheel but my mk5 being only 93 k miles I d say it s not that.
Alan, Please help. I’ve get an P1102 error in my Focus mk3.5 2.0TDCi DW10F engine. Maf sensor replaced, still the same. Map sensor replaced too, no changes. Replaced also egr valve (Ford regenerated one with 2 years warranty), wow, that hurts… And still no changes. What I’ve noticed - my car has a lower air flow and lower air pressure - for example, car with no problems maf shows 160g/s on 4th gear and pedal to the floor. Mine shows only 130g/s. And map from „healthy” car shows 2.4bar at the same conditions as above. Mine shows 2.27bar. Today I’ve checked all vacum pipes - all of them are ok, no vacum leaks. Any ideas? Inlet leak? Intercooler? I have no ideas…
How about blanking off kits for EGRs? I wonder how many are running about with those fitted? Mines a Mk4 and Im getting the yellow engine warning lamp on from time to time now and some times the Engine Malfunction with Limp mode happens as well. Im thinking its time for EGR. Its on 100K and about 2000 L of bio diesel has been through it to. Self made high quality bio.
Hello. I would like you to help me with a problem with Ford Kuga mk2 2017. I have a problem at about 140 160 km/h, it goes into limp mode and I think it is the problem with the egr. What do you say, could it be from the EGR? 
Great video Alan, again.:-) One question, are all egr valves prone to cracking and leaking or is there a difference from 2015 to 2016/2017 models? Did Ford improve material on egrs? Thanx and keep the good work.
Hello, I am from Polish, I have a car peuge 508RXH with DW10FC AHW. For some time there has been no idling work as I turn on the air conditioning until it is ok. OBD there is no error with the voltage to the sensors is ok.
Thank you Alan for all your videos. I want to ask you something. My 2016 MK5 2.0 diesel 180ops got the EGR valve replaced in 2020 at 80k miles. Today, four years later and odometer shows 160k miles I got the same error again P042E valve stuck open. Do you know if there’s any other solution to this EGR or I need to replace it again?
Hi. There are people who carry out diesel particulate filter deletes and they can remove the software for the egr valve so you won’t get any more electrical problems with it. Hope this helps
Hi Alan. After following this guide with a genuine Ford part I have P1102, and 2 codes relating to my dpf which were there before. Have you ever experienced it before? If there a plug I could have forgotten, or a pipe I haven’t connected back up properly? Also have heavy black smoke on acceleration which I didn’t have before
Hello, I have a ford galaxy 2016 2.0tdi I changed the EGR valve with a secondhand EGR but when I tried to do relearn on the scan tool it said failed. The problem I am having now all of a sudden is the auto gearbox is suddenly playing up. Would a faulty EGR affect the transmission drive?
I replaced the EGT on a skoda fabia mk1 this past weekend. It had 3 crush gaskets on each mating surface, Clearly that must be 3 times better than one.. LOL.
Thanks for a very helpful video Alan. I suspect my EGR cooler is leaking water into the exhaust gases as there is no obvious external leakage anywhere - only that the header tank level drops over 2 or 3 weeks of use). Is there any way to check this without tearing it off the engine (I have convinced myself I can smell coolant at the rear to the car when the engine is running)?
hi steve, if the egr is leaking it will run down the front of the engine and drip off the oil filter..you should see the water stains but those cars have a number of coolant leaks like the thermostat housing and water pump, also check the radiator where the end casings connect to the core..with a torch you can see through the cooling fan casing.
@@alan4x thanks Alan. I've had a serious look around with a torch and a borescope whilst the system is pressurised / engine running. No water pooling above the gearbox so not thermostat housing. Nice and dry below and around EGR valve so casing looks to be sound. Either end of the rad looks good. Generally the engine and surrounds are dry so I'm damned if I can find where the water is going. No oil / water contamination so head gasket looks okay. I'll keep on looking! Have you known of a leaking EGR cooling 'coil' matrix in your many reapirs of these?
no, never had the internal matrix from the egr leak, maybe replace your coolant expansion cap but i sure if it is leaking it will show itself at some point
@@route66weasel Have you found where your car's coolant is leaking from? I have the same problem, mixing water with oil, only water loss and pressure inside the coolant hoses.
Hi Alan Just wondering if you can sort out a small problem for me. I got a Mk5 mondeo six months ago (16 plate) which has a start/stop feature but has only worked for four days And that is only after the garage charged the battery overnight,they keep telling me that i am not doing a sufficient amount of mileage to charge the battery and therefore the start/stop would not work, so i drove from Glasgow to Edinburgh and surprize surprize this had no effect on the start/stop system. I am starting to wander if the garage, ( I don't want to mention any names or point any fingers uncle Arnold ) are just telling me anything to get rid of me
I have a 12 reg focus with stop start and have this issues as well It is correct that the battery charge state determins if the stop start works or not Also among quite a few other factors as well are considered for stop start to work Like cabin temp , if aircon is on, or DPF regen is due on diesel cars. You may have a weak battery if it's old or just doing short journeys and using the radio with engine off You can reset battery monitoring to see if this helps you will need to google this as not sure if its same Button press on the mondeo as the focus. on mine it didn't work until my battery failed and got a new one But over time just doing short journeys it stopped working, after a few trips on the motorway it works again
Had the same on my 11 plate Mondeo. Original battery. it was absolutely fine however the start stop stopped working basically due to the battery 'quality' fading, I put up with it for years. Had the clutch done a few months back (battery out job) and got them to drop a new battery in. Start stop works fine now.
Hi Alan. please give me some good news ive got 08 1.8tdci Mondeo , its stood for 5 weeks and the battery went flat . cant jump start it the imoberliser on i put jump leads on the battery and there arent any codes when i checked. i have ignition but no starter. can i do some magic to sort it.ROB.
the battery lead on the positive terminal has a fuse link in it i think, and check you have a good earth leads and power down to the starter motor and starter solenoid when you turn the key to crank
Dunno if you will see this but would be a great help if you could answer a question for me please Alan.. would a cracked EGR cooler possibly make the coolant turn black? I’ve flushed my mk5 out about 30 times and put cleaning solutions through it but it’s still turned black. Had the car nearly a year now so been driving round in it fine no over heating etc. but just recently it over heated so I got the water pump changed and cambelt at the garage. When I collected the car there was a leak and he found there was a crack in the EGR cooler which is why my coolant kept disappearing without leaving any signs of a leak. Definitely not a blown head gasket as there no water in the engine or white smoke etc. Just trying to get to the bottom of the coolant turning black. Would highly appreciate your reply. Thanks
hi, i am not totally sure but if your egr is cracked it is normally the plastic housing which leaks coolant down the front of the engine...the core inside the egr which the exhaust gasses pass through is inside the plastic housing surrounded by coolant... i do not recall one of these cores ever leaking exhaust gasses into the coolant but it is possible and if that was the case it would turn the coolant black but would also put compression into the cooling system which would cause overheating....those egr valves are not very reliable and if yours has done over 80k miles its on borrowed time
@@alan4x Yeah I understand what you mean. Won’t know the true extent of the damage until I manage to get the part of the car. She’s done just over 124k miles. If this wasn’t the cause do you have any idea what else could be causing it? Thanks for getting back to me btw your vids have been a saviour with me owning a mk5 Mondeo lol.
@@michaellonergan1786 I have the same problem, the color of the coolant turned black, and some cooling water was lost, and the smell of exhaust gas with the coolant to unite the engine temperature. It is normal, and I want to find a solution. Did you find the solution to your problem?
@@mercedes-benzgroupamg hi mate, it turned out that there was a crack in the EGR cooler which is what cause the loss of coolant. I replaced this part and the coolant didn’t leak but was still turning black. I just traded the car in and brought a new one so not sure what was sending the coolant black in the end. Everyone i spoke too said suspected blown head gasket but I drove round in the car for nearly a year with this problem so god knows. Hope this helps
Vehicle details of age milage and any other relevant information would be great.... As to give an Idea of when such issues could occur or could a 3 year old 60k car suffer from the problems you come across
alan , have you ever had a 2.0 diesel , the psa engine make a ticking sound from the drivers wheel area when hot ? mine has one now and im shitting it thinking one of my rockers is about to spew parts all over my cams
Hello, I am from Poland, I have a Peugeot 508RXH with DW10FC AHW. For some time there has been no idle work as I turn on the air conditioning until it is ok. OBD there is no error with the voltage to the sensors is ok. Sorry for the errors, the translator explains that.
Hi Alan im hoping you can help me, my ford mondeo mk5 Auto diesel 2015 starts to over rev when the gears change as its an auto and i have to take my foot off the accelerator and then wait for revs to go down and then i can drive but it does this on all gears, could this be an EGR problem? Help!!
It could be. Happened to me same situation as you described and there were 2 DTcs at same time: one P0490 in PCM and U0401 in TCM. It went to limp mode. In vehicles with Powershift the ECU limits engine power also thru transmision.
Hi Alan I have a Mondeo 1.8 tdci 2009 it is really slow revving up and cuts out seems to run better hot . Only fault code Invalid Data Received From Vehicle Dynamics Control Module I had earlier on my Delphi diagnostic laptop Any ideas what could be wrong.The engine management light doesn't come on ?
Wish you lived near me Alan as i am tearing my hair out even ford cant give me a straight answer to my problem. although to be fair they did not charge me for a diagnostic check.
P2000 code, no oil level raise but rough idle and now while speeding as well feeling a little rough, Just had mine replaced, lets hope it helps but what a terrible thing on these cars
