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Member Since 30 Oct 2012
Offline Last Active Yesterday, 08:49 PM

#398171 Egr Blanking On Euro 4

Posted by FOCA on 16 August 2014 - 02:19 PM

There are many misconceptions about EGRs blanking plates etc -


#1 - you might think a working EGR valve would be best for your car/ engine, as this was how the car ws designed - WRONG:- even a brand new EGR valve in perfect condition contaminates the inlet (including the manifold, inlet ports etc) with carbon, causes hesitation, flat spots etc - a working EGR valve is BAD NEWS for your engine


#2 even if you clean out your inlet manifold (this requires taking it off and cleaning it with petrol and/or a high powered jetwash) every so often, if you are running an unblanked EGR it will eventually just fill up again - this can "choke" the engine - once you fit your solid plate and clean out your inlet manifold, the innlet manifold will stay clean - so no need to continually clean it out


#3 the whole concept of recirculating exhaust gasses (a waste product) and feeding them back into the inlet is a bad one, diesel engines run best on clean air, and diesel - not exhaust gases - its a bit like a human eating his/her waste - not good


#4 on modern deisels, the EGR valve opens only at part-throttle at lower revs - this is when you get the flat spot (aka hesitation or lag) when the enine ingests burnt exhaust gases instead of air (the burnt exhaust gases reduce or prevent combustion because they do not contain oxegen like air does)


#5 Any emmission control system that reduces MPG (even by a small amount) may have a worse long term effect on the enviroment due to the enviromental impact of having to produce more fuel - a diesel without a DPF or EGR is more efficient, energy and resources do not have to be used to produce the DPF/EGR, + when the DPF/EGR get filled up/ old or faulty, tey can have a worse effect on emmissions than not having one.


#6 - often, these things are political rather than technical, eg eurocrats/ politicians say "look what we are doing to help emmissions/ the enviroment" - even when they don't really work


#7 - when the car/ engine is new, the EGR valve may help emmisions, (but even then has a negative effect on MPG, performance efficiency, and that extra (even small amount of) fuel (multiplied by all the cars fitted with an operational EGR valve) can have a worse impact on the enviroment compared to not having an operational EGR valve - as the car gets older the inlet gets choked up, further reducing MPG, performance and efficiency, and increasing smoke output (or choking up the DPF, if one is fitted) this is even assuming the EGR does not fail, as if it does things can get much worse than that (with a leaky or permenantly stuck open EGR valve the car can produce a smoke screen james bond would be jealous of)


So the long term negative effect of fitting an EGR valve in the 1st place (or running without a blanked/ disabled or deleted valve) may be worse than running with a solid plate(etc), on the envioroment , as well as definately for reliability, elimination of flat spots hesitation and lag and preventing the inlet being contaminated


#8 after a solid plate is fitted there is no problem with moisture/ rust, draining water as the EGR valve is disabled anyway


#9 it is not nessesary to fit the solid blanking plate on the EGR cooler on a mk3 mondeo diesel, it can be fitted next to the EGR valve you can get solid plates that slot in (you don't even need to take the nuts off, just loosten them) - a solid plate is essential, ones with holes defeat the purpose of the plate, the EGR valve must be working properly to fit plates with holes, a solid plate can "fix" a faulty/ leaking EGR valve, by effectively disabling it - 2 solid plates can also be fitted (one next to the EGR valve, another next to the cooler) and the egr pipe removed


#10 the EGR valve has a design fault - it exists!


I am an engineer, I designed/ developed the first EGR delete kit for rear-mounted EGR Mondeos,about 9 years ago then improved the design, this has been copied and made into a commercial product, i have been an advocate for fitting solid plates and have advised and encouraged forum members to fit solid plates, and have helped to promote the resurgence of interest in the subject


I collect information on the subject and listen to feedback from members/ Ford owners that have fitted solid plates, i try to discourage misconseptions/ misinformation about the subject, especially from those that have never fitted a solid plate or understand the princepals etc


I suppose with the 9years of running without an EGR valve (i don't and wouldent have one on my car, i sold mine on ebay years ago!) + designing the delete system + following the subject for years + my technical knowledge = my involvement in advising/ discussing fitting them on the forum must make me an "expert"


I understand others have their opinions - and they are entitled to them, it is a subject i feel strongly about and don't mean to cause offence, of even to discourage members to express their opinions or to debate this, or other topics

#397609 My Son's Ordered A Fiesta St3

Posted by FOCA on 14 August 2014 - 08:41 PM

You'll have to convince your daughter to get a red ST, that would look awesome on the drive away with a blue and white one, lol.


I didn't think it was going to be long the way you had been talking. Is he going to get a white engine cover?

The red white and blue was exactly what i was thinking - like the minis in the italian job :lol:

#396877 Up Coming Tax Changes

Posted by FOCA on 12 August 2014 - 09:24 PM

It's a similar story when selling cars to dealers at the moment.  When I sold my last car I asked them if it's easier for me to just leave it taxed and have them give me the cash to the value of what I would have reclaimed, but they said I needed to reclaim it and they would then retax it.


All I can think is it's a way for them to make a bit more money from it - unless you sell the car on the last day of the month and the next owner buys it the following day the DVLA get paid twice for the switchover month.  Once in your original money that can't be reclaimed and once for the new guy retaxing it!  I see no other reason for doing it.

There is another reason for doing it - 


If you buy a car,/ if it changes hands -  it must be MOTd, and insured  before you can tax it,  this must be done straight away


It may be to prevent forms of fraud, and to stop people running about in uninsured cars that had tax left over from the last owner

#396863 New To Mondeos

Posted by FOCA on 12 August 2014 - 09:07 PM

Nice one! - welcome to the club!

#396692 Engine Sounds Lumpy!!!

Posted by FOCA on 12 August 2014 - 11:00 AM

Was the soundproofing the underbonnet insulation? this can cut the engine noise down as well as help to keep the heat in the engine (can be important on a diesel)  you may also now be hearing the tappets or the noise of combustion ("diesel knock")


Often diesels run better on the stock airbox - especially if the induction kits draw warm/ hot air from  under the bonnet - + trying to make a diesel sound  "sporty" results in it sounding like a traktor, unfortunately

#396131 Help A Newbie With First Modifications ?

Posted by FOCA on 10 August 2014 - 03:47 PM

They tested a fake tuning box - this does not mean all tuning boxes are no use - i fitted a DTUK box to my mondeo diesel - it made a BIG difference and still has more bottom end grunt than my Superchips bluefin remap, (even after stage/ revision3)


Some tuning boxes are fakes (do nothing at all - like the one in the video) some are just resistors that fool the ECU that the engine is cold (IAT ones) - some connect to the fuel pressure rail sensor  and up the fuel pressure -


But others are serious alternatives to remaps (often with the price tag to match) with multi user-selectable maps, multiple channels (some with direct control over boost) and can produce as much power as a remap,


Comparing a £7 "ebay resistor special" (it looks like a chip!) tuning box to a £400 digital tuning box is like comparing a model T to a 2014 ST - there is no comparison   


I think for some, tuning boxes are an alternative to remaps, as they have some advantages

#396129 Modifications

Posted by FOCA on 10 August 2014 - 03:30 PM


If it's anything like the Focus sound system (I can see reasons why being a Ford, it would and reasons why it wouldn't be the same) then I know what you mean - one thing I wouldn't mind is a touch more bass, I like my rock/metal and I think a smidge more would be nice, so I'm looking into a cheap sub that I can easily take in and out of the boot when I need/want..

I dont now if it is because the system is better or the acoustics are superior but the stock Mondeo system sounds quite good

#396109 Mondeo Tdci 130. Focus St Intercooler Upgrade

Posted by FOCA on 10 August 2014 - 01:41 PM

Its the old 2.5 - but its not an upgrade, my information is it will restrict the Mondeo, as the stock mk3 (Mondeo diesel) intercooler has 2-14" inlet and outlet , all the MK3 diesels have the same intercooler, from the 90PS di to the ST-TDCI - the ST-TDCI has 155PS and can produce 180+Hp and 400+ Nm with the stock intercooler  


Best to discuss your present and future modifications, how much you wish to spend, etc etc, like changing the intercooler is a waste of time - a remap or tuning box will make the biggest difference, followed by a back-box delete, decat, EGR blanking, resonator blanking, in that order (biggest to smallest improvement) 


Once you have done all that, an intercooler upgrade may be worthwhile (but not a stock Focus ST one)


It gets a bit complicated/ technical when you statt talking about pressure drop, internal volume, thermal inertia etc


edit - here is another post with more details - http://www.fordowner...-advice-needed/

#396088 Mountune Booked :)

Posted by FOCA on 10 August 2014 - 12:31 PM

So just been out to Gatwick and back with the mountune hose and defiantly the stock hose sounds better , you can really here the induction noise and hiss clearer with stock hose. I'm undecided on pickup / throttle response between stock and mountune hose . Is it worth 100 quid, doubt it now I've tested it a bit maybe get the 50 quid one from js

If the stock hose is louder it can be deceptive and give the illusion of more power, if you are timing the 0-60etcyourself  its difficult to get consistant results, and the differences (of the 2 hoses) small   


To truly test the difference between the stock hose and Mountune hose you need back-to-back testing on a dyno, which of course is what Montune have done


The map usually gives a much bigger performance increase to the hose, which may be quite small


I know some owners like a loud car or one that pops, bangs growls or hisses, for me, noise is an unfortunate side-effect of free-flowing induction, exhausts etc, and i try my best to keep the noise down to acceptable levels without compromising performance (the opposite of what some others seem to do on the forum)         

#395678 Advice?

Posted by FOCA on 08 August 2014 - 09:08 PM

Its not cheap but there is the pioneer "spare wheel" sub -




it fits inside the spare - you just relocate the jack/ bits (it has quite a beefy  sound (they say)


so you can keep your spoare wheel


you may be able to pick a decent one up at a good priice seconhand online 


or one of the slimline powered underseat subs ( you could put it in the boot) -



#395650 Help A Newbie With First Modifications ?

Posted by FOCA on 08 August 2014 - 08:12 PM

Hi guys

Would you be kind enough to give any help into what I should be upgrading on my car, I'm thinking about getting a remap done but not for a few months. I basically want the car to have better acceleration, I have a 63 plate Focus zetec sport 2.0 TDCI 160BHP powershift. Once it's out of first gear it really shifts it just seems a little sluggish off a standing spot.

I would have a guess and say a new exhaust and good air filter are a must but have no idea what make is best. (I would not be fitting these myself) Any good web sites ?

A remap or tuning box will make a big difference, exhaust will make a small difference, air filter will make little or no difference


simply sticking a tuning box on (without other mods) will increase the PS from 163 to 199, and the Nm from 340to 410 - DTUK -




its not cheap at about £300 but cannot be over-written like a map can and can be removed for services (dont know if its undetectable)  


Or you could go with a Superchips remap  


Its your choice whether you wish to void the warranty or not


Diesels can often be sluggish off the line, even powerful ones  (copmpared to petrol cars)- its a mixture of (realatively) narrow powerband, low rev-limit, low gearing, and the power may be restricted in the lower gears to protect the trans etc etc   

#395325 Blanking Off Egr Valve?

Posted by FOCA on 08 August 2014 - 03:47 AM

Hi Leonard,


I'm getting a new stainless steel pipe (from Turbo to EGR) fitted tomorrow and the EGR valve cleaned out. After that I will put a blanking plate in, the only way to go.

I have had the dreaded flashing glow plug and management light on (limp mode) recently (fault code P2263). I thought I would rather start with getting the pipe sorted first as it's broken, maybe a good starting point to my problems? I can even smell exhaust fumes in the car, which has been irritating me for a while now.

Cheers for your help.

No point in cleaning out the EGR valve or pipe, as nothing will flow in it anyway with the blanking plate fitted


Also, the pipe is not nessesary and does not do anything, once a solid plate is fitted, removing the pipe increases efficiency (you will need solid plates at each end, though).


The bit you need to clean out is the inlet manifold, the air the engine breathes with goes through this, the EGR valve often fills this with carbon, choking it


If you have a Euro3, you can fit a solid plate with no EML, with a Euro4 Mondeo, unfortunately the EML may come on, this can be reset with a code reader, -  you can have front EGR Euro3 and Euro4, there are several configurations

#394402 Egr Blanking Plate

Posted by FOCA on 05 August 2014 - 05:45 PM

after remap and dpf removal,
1st gear becomes a bit of a chore and not used for very much duration,
Almost but never would :lol: start off in 2nd gear all the time.
Overall though i dont floor it until 3rd gear and upwards because the increase in torque going flat out in 1st and 2nd could put strain on the cogs i reckon but no facts to back that up just my theory im putting out there y'all.

Agreed, the (Mondeo 2.2) ST-TDCI is restricted in 1st and 2nd to protect the trans/ DMF, the gearbox (on any car) acts as a "torque multiplier" so more torque is "seen" at the wheels in the lower gears than in the higher gears


Often modifications that increase power/ torque have to be coupled with more modifications that strengthen the car (like stronger clutches, transmission etc) like an SMF, heavy-duty clutch (carbon/ kevlar, etc) - ic can become expensive   

#394158 Lost Horses???

Posted by FOCA on 04 August 2014 - 10:11 PM

The warmer weather can reduce power by increasing the inlet temp + reducing the efficiency of the intercooler, but - 


Your EGR valve chucks muck into the engines inlet and the manifold, etc gets blocked/ choked  up, choking the engine/ reducing power/ torque -  the CAT can get coked/ blocked up too, as well as the VNT mech/ turbine housing/ wheel/ blades


You  never mentioned replacing the air filter - this is important (as well as the fuel filter)


As well as the EGR valve contaminating the inlet, with carbon/ gunge it also lets burnt gasses into the inlet (instead of clean, unburnt air, containing oxegen this is normally at part-throttle at lower revs, this is lible to be your flat spot  


Cleaning the inlet manifold out (by taking it off and cleaning it properly with petrol and/ or a high pressure jetwash) and fitting a solid EGR blanking plate will "fix" the EGR - it will no longer continue to be contaminated (will not need to be cleaned out again), and the flatspot should dissapear, throttle response should improve, lag from low revs reduced, performance and economy should improve (even a little)


As the engine gets older the crud builds up and more muck may be injected into the inlet - cleaning it out and fitting the solid plate will stop this


As well as the muck that comes out of the EGR valve, the crancase breather injects oily residue/ droplets/ burnt gases into the inlet, usually into the airbox or in front of the turbo compressor, all the boost hoses, right into the engine tend to get coated, it builds up over time and older, worn engines tend to inject more oily droplets (due to the bores/ valve guides/ seals wearing, or a build up of pressure, - the oily drops mix with the carbon from the EGR in the inlet manifold, forming an oily gunge, the intercooler also acts as a condenser, where the oil cools and builds up,


The answer is to clean the inside of the intercooler out, and fit a crancase breather catchtank - (one with the same diameter as the breather hoses - hard to find



So to repeat -


New air/ oil filters


Clean out inlet manifold and intercooler


Fit solid EGR blanking plate


Fit crankase breather catchtank


Keeping the weight down in the car, making sure there is plenty air in the tyres and checking the brakes are not dragging


A code reader is a worthwhile investment, and a Haynes manual


Finally, to get the power back (and more!) a remap (including bluefin) can make a big difference       

#393291 Declaring Insurance Mods

Posted by FOCA on 03 August 2014 - 03:22 AM

Can someone tell me how scuff plates and painting brake calipers are classed as modifications.OK I understand adding performance parts etc affecting the insurance but not the above.Before long you will not be allowed to polish your car as a nice well kept car is more attractive for a thief.When i picked my new car up it wasnt as shiny as it is now,is this classed as a non factory mod. :lol:

Agreed - its all getting a bit silly


If you dont just consider your car as simply a  method of getting from a to b and you care enough  about your car to personalize it  you are more liable to take pride in your car/ look after if and take more of an interest in your driving skill - why be penalised?