Hello,

I've bought a Mondeo MK3 2006, not long ago. But I've experienced EGR failure(or components in the system).

I've been using a ELM327 with ForScan and read the following error codes:

P0404, P0409

I've tried reading the voltage values on the EGR sensor(3pin, with vacuum hose).

Here the idle value are 2.85v where I've read it should be about 0.5-1v when closed.

 

When disconnecting the sensor, the car runs just fine, but with the EML on.

When connected, the car runs rough and hesitates. Above 2000RPM it runs fine again

 

 

 

You need to clear the errors, then see which one(s) come back

Hello,

We have cleared the errors multiple times, and both seems to come back

Then, for starters, it's probably time to consider removing and cleaning the egr, plenty of tips on youtube and if you google 'Ford P0404' and 'Ford P0409'  there's also help there..... Good luck and let us know how it goes 👍

Thanks for the answer,

We have had the EGR completely disasembled and cleaned with EGR Cleaner(Soaked overnight and cleaned) nothing seemes to improve.

I've found a vacuum hose cracked near where it entered the solenoid and was able to  fix it with some rubber hose from Halfords. For starters, inspect the vac lines for splits. 

 

While doing all this take of the inlet manifold and clean out all the soot also use a nylon brush and vacuum cleaner and clean out all the inlet ports, makes a world of difference. It may struggle to start after the clean so make sure your battery is good. Only crank for 5 secs at a time then wait for 30 seconds and try again to avoid burning out the starter.