Jump to content


Member Since 14 Jan 2011
Offline Last Active Jul 27 2015 08:01 PM

Posts I've Made

In Topic: Egr Valve

26 July 2015 - 05:32 PM

I though I would share my thoughts on removing the EGR from a mk4 Mondeo. Unfortunately due to stress levels I never took and photos.

The EGR is at the back of the engine on the top. 4 bolts are easy to see and remove, 2 of the bolts fix the EGR to the engine block and the other 2 bolt the EGR to the EGR cooler. There are 5 other bolts you need to remove as well. These are for the metal pipe that goes from the EGR to the inlet manifold, 2 at either end and 1 bolt that secures this metal pipe to the side of the engine.

The one bolt I couldn't find was underneath the EGR itself. You cant see it at all. I ended up going out to buy one of those dentist style mirrors which helped no end. This last bolt is an allen bolt that requires a 5mm allen key, the allen key needs cutting down somewhat in order to fit as space is very limited. Once this bolt is loosened (you dont need to remove it) the EGR can be removed by sliding it back towards the windscreen area. This whole precess took be about 2 hours plus to figure out and then about 10 minutes to put back together.

After all of this my EGR was nothing like I was expecting. My car has covered 80,000 miles and it was clean, a bit of soot but other wise there was nothing. My MK3 was caked at this mileage and to the point that you could scrape it out. It seems the MK4 runs muh cleaner.

I certainly wont bother removing it again unless it is to replace it. I was hoping this was the cause of my poor fuel economy but it now seems it's my MAF sensor but a full diagnostic on Tuesday will confirm this for sure.

I'm working for the next few days but if I get a few spare minutes I'll take some pictures that might help others out and save you time trying to figure out how it comes apart (Haynes manual was next to useless)

In Topic: Egr Valve

26 July 2015 - 05:22 PM

I have a 2.0 tdci mk4
I removed the egr from mine and it really wasn't worth it as its a pain to do. All it had a a small trace of soot. Nothing like I had on the old mk3.
If you do decide to undertake it then you will need to cut down a 5mm allen key. The bolt you'll need this for is underneath the egr and out of sight.
This is all assuming the 2.2 is of a similar layout to the 2.0

In Topic: Mk3 Tdci Replacement Dmf Help

11 July 2015 - 08:16 PM

It could be worth taking the car for a diagnostic update.
My engine had a very metallic clunking which I really thought was the DMF going. The sensor that needed the software update to re-calibrate it was actually the cause.
If you want to be doubly sure you can remove the starter motor and if it has metal filings on it it can be a sign the DMF is on its way out.
I've no longer got my MK3 but I sold it to someone I know and it's still going strong

In Topic: Mondeo Mk4 2.0 Tdci Egr Removal And Cleaning

15 March 2015 - 05:33 PM

Rocco was the Fiat branded EGR much cheaper than buying genuine Ford?


I did an ECU reset after I'd cleaned mine, it didn't make much difference really.


My next job is to remove the inlet manifold and clean it. First I need to order 4 new rubber O'ring seals. I did this same job on my Mrs 2009 Fiesta 1.4 TDCI and the inlet manifolds can be difficult to get back on as the seals are so tight, it does require some lube and lots of pressure.


I was so surprised at how clean my EGR was, the soot it had in it was only about the same as that found in the end of the exhaust. I'm wondering if it hasn't been working fully due to a possible faulty MAF sensor? I'll find out for sure on Tuesday.


Good luck doing your motor and if you need any help just yell.

In Topic: Sound Deadening Doors - Do I Need The Membrane Still?

06 February 2015 - 07:19 PM

There isn't much metal around the speakers so I don't think much would be gained.

I pretty much coated nearly all of the outer skin. It is tight to move in but it's more than possible.


Once I've done the rear doors I do plan on doing the rear wheel arches and undere the rear seat