2006 1.6 Tdci Zs Egr Delete.

[Garryboy1888]

I'm about to undertake this.

Just looking for the location of the EGR valve. on the ZS 1.6 tdci engine

Cheers

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[Garryboy1888]

Anyone?

I've seen Pdf guide for the 1.6 tdci but think it's for a focus. It's on the back of he block in the bulkhead in the guide.

Any help appreciated for the fiesta

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[bodgermart]

Hello Garry,

Just doing this on my Mk6 1.4, very similar to focus I think, a bit less room and removing the wipers and scuttle is not needed because the heater intake surround is still the same hinderance, you can just peel off the long rubber scuttle seal and that's it.

That gives you an extra inch of vis.

My egr came loose pretty easy when I undid the 2 bolts (all that was needed) and I put the plate in from my right hand side facing the engine, this is with the fuel filter removed for room to move.

I forced the bonnet open a bit further than the stay and that helped too.

I used a cut down ring spanner for the 2 bolts, don't know how else you could do it. I took plenty pictures because as you say the guide is for the Focus although they are a very similar deal. I hope to put it all in a guide as an extra to Lenny's excellent focus guide.

When finished you have to re-prime the fuel system to bleed the air, very simple on mine as there is a fuel bulb at the left of the air filter box you squeeze it about 15/20 times till you can see fuel without bubbles in the clear tube by the bulb. If you don't do this you will never get it started again (mine went first go).

It's a worthwhile mod imho although it isn't easy access wise, I hope this helps you decide.

[Garryboy1888]

Excellent mate. Thanks for the help.

I had a look and like you I couldn't see what advantage removing the scuttle would give as it's the same gap as the bulkhead.

Il get it done Asap and post up my findings.

Thanks again bodgermat

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[bodgermart]

Yes, from what I can see from the pictures you get a worthwhile gap of extra space by removing the scuttle on the Focus but no real benefit by removal on the Fiesta, still I did hoover out a few leaves and dead flies from around the air vent intake, but save yourself the trouble.

Also just to be clear, I didn't need to undo the egr cooler nut or the pressed on jointing clamp, just undid the 2 long mounting bolts (don't remove completely) and it pulled loose enough to be able to slide in the plate and hook it onto the top bolt then swing the plate down being careful to keep the top bolt hooked by the plate. When slotted on the bottom bolt go ahead and tighten up the two bolts evenly.

The original thin metal egr gasket stays on and the plate goes behind it so it ends up between the plate and the engine.

The fuel lines on mine were well worn where the airbox sits on top and nips them in a couple of places, where the marks were I took a 1/2 round file and took some plastic away from the airbox so as to hopefully give a bit of clearance for the fuel pipes.

The lower of the 2 bolts is an sob to reach and its by feel only, a pipe of some sort is right behind it, so no socket possible, ring spanner job, and I cut mine down with a dremmel so I could turn it.

[Garryboy1888]

I have some ratchet spanners. So they may be more useful for the bottom of the two bolts.

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[bodgermart]

Yes if you can get them on but if you slip off and round the bolt it's game over.

[Garryboy1888]

There a godsend for bolts with limited access to move a spanner. Il use a ring spanner to crack it and then the ratchet spanner to work it out.

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[S40Un]

On the DLD-416 engine, the egr can be accessed by leaning over the engine & using tiny hands :).

I removed the battery on mine just to make things easier.

Egr is located at the back of the block , behind the diesel filter.

Are you removing or just blanking ?

The egr has two 8mm bolts, if your blanking it only one bolt needs removing as the blank plates have a slot on one end .

[Garryboy1888]

Just blanking

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[S40Un]

Ok scrap what I said about removing both bolts on the egr , the blanking plates have a slot each end now.

So you just need to slacken egr off as the pic below & slot plate in !

Make sure it's the right way round though, it's obvious how it fits.

[Garryboy1888]

All seems pretty straight forward. Just glad I don't need to strip all that scuttle out of way.

I have small hands. They come in useful in these occasions.

Thanks for all the help lads

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[S40Un]

Ohh , one more thing don't disconnect the plug on the egr !

[Garryboy1888]

Noted

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[Garryboy1888]

All done. Took me 20mins.

Engine cover and airbox off. Unclipped and moved fuel filter. Loosend both EGR bolts using deep drive 8mm socket. My tiny hands came in useful here lol.

Had to remove the fuel filter locating bracket to let me drop the EGR blank in. Only 3 8mm bolts.

Tightened back up and replaced engine cover.

Job done.

Idles better and turbo seems to spool a bit quicker and more smoothly.

Great £2 modification.

Thanks for all the help guys [emoji106] [emoji106]

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[bodgermart]

Well done Garry,

Using sockets on them is an achievement!

Did you have any trip lights come up?

Are you having it remapped?

[Garryboy1888]

So far no check engine lights. Not going to bother with a remap. It's nippy enough for me and returns around 500 odd miles to a £42 tank of diesel.

Apart from slight engine vibration as revs drop to idle (Was there before EGR blank) then I pretty chuffed with the car.

Fitting new top mounts tomorrow as drivers one completely shafted

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[bodgermart]

Yes I was thinking you might have mountings gone. Was looking at mine shake about today and thought it was a bit much.

I'm thinking I may have blanked mine too late and the crap has already done other damage but should know by Tuesdays remap.

I'm hoping it will be smoother and more drivable, we'll see.

Your mileage is good.

[Garryboy1888]

I had a 2008 clio DCI that was written off last month when a women lost it on a bend and ploughed right into the side of me. It was a great we car. Engine was a lot quieter and more petrol like than the Fiestas but for having same bhp it had a lot less low down grunt.

I'm getting used the sound and feel of the ford engine and certainly enjoying the greater power delivery.

I wonder what a remapped one would go like.

Whos remapping yours and what figures you expecting to achieve

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[bodgermart]

Well to be honest, not really after more power, just want the thing sorted to run well. I wasn't convinced it was just an egr valve problem and that's after injector seals just being done. The garage that did the seals have been very good in the past but never mentioned seeing any other problems and it is quite an in depth strip down to do those seals.

I'm thinking the mappers might have some pointers if it 's still not sorted after they've done.

I said I was after reliability and mileage but the guy said I would get that as well as more performance, be back with the details on Tuesday.

[Garryboy1888]

I look forward to hearing how you get on mate.

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[bodgermart]

Today turned out a bit of a waste of time,

went to the tuners but the car went into 'safe mode' twice before I got there, cleared it both times and when I got there he said it was a pity I'd cleared it because there was no code to read and he wanted to do that so that the problem can be sorted before he goes any further (sounds logical) anyway I drove round and tried everything to get it to go into safe mode but no way, so now I'm trying again tomorrow, it usually goes going up a hill about 1/4 mile away, maybe once or twice after that and once it's warmed up then it seems to run ok but with an occasional splutter just to keep you worried!

What a pain, I've been reading up on diesel fiesta problems and it seems endless, all with a different slant on the causes.

Here are the usual suspects for misfires and fault lights (in order of most common);

1. Leaking injector seals.

2. EGR valve not working properly.

3. Mass Air Sensor faulty.

4. Split in Air Hose or Boost Hose.

5. ECU needs software update.

In addition to the above you can get fuelling problems with air getting into the injector feeds, the injectors themselves can go U/S also I've read a couple of threads saying their problems came from the acc. pedal sensor which is 'fly by wire', obviously cables are too unreliable and have now had the electronic solution along with everything else!

[Garryboy1888]

That's a pity mate. Hopefully you can replicate the fault and let them have a look at it and hope it points to the route of the problem.

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[bodgermart]

Thanks Garry,

I had just about enough of it yesterday!

[Garryboy1888]

Thanks Garry,

I had just about enough of it yesterday!

Any joy today mate

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