I have a 53 plate Mondeo 2.0 petrol. I am looking for the EGR valve. I know most people think its on th right hand side of the engine, near the coils. But how could that be. The EGR valve needs exhaust, yet there is no exhaust on the side of the engine. So does anyone actually know where the EGR valve on a 2 litre Duratec is?

Its definatly on the right side of cyl head as you look under bonnet. That's where the exhaust gases enter cyl head . very rarely have issues with duratec he egr valves.

seems to me exhaust gas probably shouldn't be in the cylinder head and the EGR should probably run from the exhaust.... The only pipe that goes onto that "so called" egr valve is a small coolant pipe

That egr valve is ported internally from exhaust manifold through cyl head then ported in to intake manifold, Japanese way of doing it quite often. (It is a Mazda designed engine) others are externally piped

how can one test the egr valve to see if its good or bad?

If you have running issues and suspect egr valve, diy way to check is blank the ports off with a piece of metal plate and check it runs OK.if it does then egr jamming open.

i am guessing i would need to block off the small coolant pipe running to it too. So what exactly does one do with the wire connector that goes to it? surely that would be a cause for the engine light to come on if not connected.

Keep coolant pipes on and connector, unbolt and slide metal blanking plate between egr valve and head. If your unsure what to do then best leave it for garage to do. What's the problem with engine?

where do i start with the problems.

1) it has a water leak which seems to be intermittent. Its not the thermostat as i replaced that last week and have checked it. Its not the water pump as i have visually checked that too. It doesn't leak when i want it to :(

2) it has a very rough idle when warm, the rpm gauge yoyo's from 1000 rpm down to about 400rpm (to the point of stalling), its not the air idle control valve as i have had that off and cleaned it thoroughly, but it wasn't that dirty.

3) the engine management light has just come on, and i don't know why.

4) the engine is quite clicky (sounds like tappets), sounds kinda like a diesel. As far as i can tell its only doing that on cylinder 4 (one nearest gearbox)

Not saying for definate but what your describing sounds like your swirl plates chattering, or broken, or simply a cacuum pipe split on the controler. Swirl plates inside intake manifold.

what is the function of these "swirl plates"?

They increase the intake air swirl which helps combustion burn at low speeds, improving economy and emmisions

just seen a video of these swirl plates, i think u nailed the sound exactly. Can the swirl plates be just removed? I see when you unplug the small pipe in the front of the manifold, the sound stops, can this just be blocked off or something? Are the swirl plates active (i.e. sit on a shaft and all move together) or passive (just sit there and open and close independently).

would this also sort out my rough idle ya reckon?

There on a shaft and move together, if you block pipe the swirl plates will stay shut and you needbthem to open when accelerating more and high revs. Poor idle could be due to rod bearings broken up allowing excess air in manifold, or could still be something else, the manifold needs to come off to see whats happening or not to swirl plates, have known someone who removed plates , rods etc and blanked off the rod holes. Wether it was sucessfull long term I dont know.

Doesn't seem to be the swirl plate problem. I have had the car running and making the clicky noise and u plugged the vacuum tube between cylinders 2 and 3 and it doesn't quieten down.

well it seems the water leak was coming from the reservoir. When it got hot, there was a tiny hole in it what would shoot a very fine jet of water out from the underside of the reservoir and leak down the engine mount to the floor. now taken care of. I had a diagnostic computer on the car yesterday also, and the check engine light is on because of the egr valve. so It looks like I will have to go buy a new egr valve and fit it next weekend.

Quick question, would a faulty egr valve cause a rough or low idle when hot?