Several Issues I Could Do With Advice On

[Josh775]

Hi all, my 1.8 TDCI 2004 has had a few EGR problems over the last few months which only occurs on motorway driving. P0401 insufficient flow. I have cleaned it out twice with EGR cleaner and even had a Terraclean and it keeps coming back. This is putting my car in limp mode which is also affecting my MPG. i keep clearing it with ObD2 but it keeps coming back

On this engine could I just stick a blanking plate on and what are the pros and cons? I wanted to take the Inlet manifold off to clean it all out but it looks a pain.

My second problem is I am losing coolant, but there is no visible signs of a leak. I had a new waterpump fitted 6 months ago. I have checked everywhere and can see no leaking but it's using at least 1 litre a week.

Any advice/Suggestions would be greatly appreciated as I am doing a 500 mile + round trip next week so would like to sort it for then.

Thanks,

Josh.

[MONDEO TXS 2.2]

Have you checked the inlet manifold for excessive carbon deposits ? Is the intercooler to E.G.R.V. hose intact & tightly connected at both ends ?

[mjt]

My second problem is I am losing coolant, but there is no visible signs of a leak. I had a new waterpump fitted 6 months ago. I have checked everywhere and can see no leaking but it's using at least 1 litre a week.

Have you considered a head gasket gailure? If the leak is into a cylinder maybe this could throw up a spurious error code.

[STEADS]

Have a look at the thermstat housing above the starter motor at the front common problem for leaking cost around 25/30 to fix and can be done in half an hour

[Josh775]

Have a look at the thermstat housing above the starter motor at the front common problem for leaking cost around 25/30 to fix and can be done in half an hour

Good suggestion, when I had a brief look earlier the Starter motor and alternator were wet so I guess you may be on the money here!!

Is it an easy fix? I have all the tools and have done alternator/starter changes before..

Have you checked the inlet manifold for excessive carbon deposits ? Is the intercooler to E.G.R.V. hose intact & tightly connected at both ends ?

Not checked this, I thought that cleaning the EGR twice and a terraclean would have done it but you could be right. Hoses are OK, no holes either

Have you considered a head gasket gailure? If the leak is into a cylinder maybe this could throw up a spurious error code.

Not something I have considered as it seems to be running fine and also the oil/coolant dont appear to be mixing but will check.

[Josh775]

P.S thanks for all the replies and help so far!

[Josh775]

Hello all.

I found the leak!

I'm 99% sure this is the Thermostat housing now.

[IINexusII]

for the EGR, blank it is the way, most users here have done it and there are only benefits. the only downside would be that the car would take a little longer to warm up because its no longer getting hot exhaust gases through the intake, but the car takes long to warm up anyway so you probably wont notice :)

the thermostat housing is the housing right in the middle of this picture: its from the MK2 but it should look similar.

[STEADS]

Yep that's your leak if I remember correctly only too.s rqd are a ten mil socket and a pipe wrench to get the clips off the hoses shouldn't take longer than half. Hour