Ford Mondeo Mk5 (Abomination) E.G.R. Valve Replacement
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- Опубликовано: 10 фев 2025
- Ford Mondeo Mk5 E.G.R. Valve Replacement
Finally got the chance to show how to replace an e.g.r. valve as the engine was out of the vehicle making filming the operation much easier. 
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I’ve never left a comment on any Internet video, but I must say Allan as I own a Mondeo Taxi , your mustard , I have attempted many jobs, only because of the result of your videos,, note to everyone check the videos before you change the EGR valve and find the Thermostat housing is cracked 😂😂 Do a pressure test, keep it up Allan you crazy cat👋
Allen
I love the way u explained what u are doing u make these jobs easy to do and understand so us guts can save money by not going to the garage just great stuff to watch
Phil in stoke
cheers phil
Thank you! Excellent video. Just saved me £600 labour at the garage. The part from Ford was £360 inc VAT currently.
Nice work, have a good one john
Could watch your videos all day, beats the crap out of normal tv
Brilliant video Alan 👍 you have a knack for making seemingly massive and daunting jobs actually small and easily manageable for us self taught mechanic's.
KEEP UP THE GREAT WORK 👏👏👏👏
Thanks 👍fraser
And another great video and a great start to Friday with the beautiful Miss M
Nice one Alan - my coolant is dropping most days so I came to the expert to see how to change the valve. Cheers.
Nice one
Legend Alan - thanks so much for making that video. I was one of those pests asking you to video the process after your last EGR video. Really appreciate it, I'm pretty sure I'm going to have to tackle this sooner or later, makes it much easier having seen it done!
I guess im asking randomly but does any of you know of a way to get back into an instagram account..?
I stupidly lost my login password. I would love any tricks you can offer me!
@Tristan John Instablaster :)
@Waylon Peyton thanks so much for your reply. I found the site through google and im waiting for the hacking stuff atm.
I see it takes a while so I will reply here later when my account password hopefully is recovered.
@Waylon Peyton it worked and I now got access to my account again. I am so happy:D
Thank you so much, you saved my account :D
@Tristan John no problem xD
Morning Alan 😄 Love watching your fixing videos 👍🏻 Have a nice weekend and looking forward to seeing the next Mondingo Mk5 video Cheers Stevie 😎
Well i know its a few years down the line but this was very helpful and i managed to change mine in about 4 hours outside the house 😁
Unbelievble helpful Video, never worked on an Duratorq before and was able to remove the damn Thing in ~20mins.
Really appruciate it 🎉
Great video Alan. Loved the full explanations and camera work. Keep the videos coming.
Thanks for a very informative video. Followed it to remove my EGR valve. Thank you. I am in Australia and am bewildered that it costs 250 pound to get this part in Australia is over $1500AU that's about 750 pound. I feel extremely ripped off right now. Great car till something goes wrong. It get expensive. Real fast
Hey JIm- I just did mine - FOrd wanted 3k all up - ppfft. I only replaced the cooler side- $236- EGR valve was fine- just cleaned it
What faults were you getting @@PiliaeAl
This video has helped me out cheers for taking time out to do this
Love your work Alan. Fantastic informative vids and very entertaining. Here's to 100k subs!
cheers flyingelk
Very well filmed and narrated, was well worth the early rise out of bed.
I know that was recorded long time ago, but tomorrow I`m gonna do it with this video! Thanks a lot @Alan Howatt!
great vid helped me no end a big thanks hardly any vids on this Engine.
Awesome video. My Mondeo was rough to start the other day, then went into limp mode and said there was a transmission fault too. I wonder what could be wrong?
Thx did help with work on Peugeot boxer 2016+ dw10fud engine.
Definitely however that bottom 10mm screw was a pain. Was gonna take starter out but got it form bottom
Thanks Alan. With the help of your videos, I was able to remove my EGR valve on opel Grandland X. maybe my advice will help someone: I used a liquid wrench to remove the vacuum tube and cooling tubes at the junction. I think another liquid will do, which makes it easier to unscrew. a few puffs and everything came off without any problems.
Glad to see you're were careful with the wiring and connectors. :-)
Je vous remercie infiniment pour ce travail. Je galérais sur une C4 Spacetourer avec le 2.0 BlueHDi 163. J'avais une fuite d'eau sur l'EGR et je n'arrivais pas à la démonter. Merci beaucoup.
thank you! Simple instructions and helped save a fortune.
THKS FOR SHAREING WILL MAKE MYJOB HELL OF A LOT EASIER
No problem 👍
Saved me a bomb on my 2019 Citroen dispatch thank you!
Great video! It’ll probably save a few people some ££££👍
If I had a mondeo, I’d go and change my egr valve right now thanks to this video!😂
bloody useful video. thanks mate
No problem 👍
Great work! Please post more often your work 👍
Dunno if you will see this but would be a great help if you could answer a question for me please Alan.. would a cracked EGR cooler possibly make the coolant turn black?
I’ve flushed my mk5 out about 30 times and put cleaning solutions through it but it’s still turned black. Had the car nearly a year now so been driving round in it fine no over heating etc. but just recently it over heated so I got the water pump changed and cambelt at the garage. When I collected the car there was a leak and he found there was a crack in the EGR cooler which is why my coolant kept disappearing without leaving any signs of a leak.
Definitely not a blown head gasket as there no water in the engine or white smoke etc.
Just trying to get to the bottom of the coolant turning black.
Would highly appreciate your reply.
Thanks
hi, i am not totally sure but if your egr is cracked it is normally the plastic housing which leaks coolant down the front of the engine...the core inside the egr which the exhaust gasses pass through is inside the plastic housing surrounded by coolant... i do not recall one of these cores ever leaking exhaust gasses into the coolant but it is possible and if that was the case it would turn the coolant black but would also put compression into the cooling system which would cause overheating....those egr valves are not very reliable and if yours has done over 80k miles its on borrowed time
@@alan4x Yeah I understand what you mean. Won’t know the true extent of the damage until I manage to get the part of the car. She’s done just over 124k miles.
If this wasn’t the cause do you have any idea what else could be causing it?
Thanks for getting back to me btw your vids have been a saviour with me owning a mk5 Mondeo lol.
@@michaellonergan1786 I have the same problem, the color of the coolant turned black, and some cooling water was lost, and the smell of exhaust gas with the coolant to unite the engine temperature. It is normal, and I want to find a solution. Did you find the solution to your problem?
@@mercedes-benzgroupamg hi mate, it turned out that there was a crack in the EGR cooler which is what cause the loss of coolant. I replaced this part and the coolant didn’t leak but was still turning black. I just traded the car in and brought a new one so not sure what was sending the coolant black in the end. Everyone i spoke too said suspected blown head gasket but I drove round in the car for nearly a year with this problem so god knows. Hope this helps
@@michaellonergan1786 Thank you.
Nice. Shall be coming back to watch this when the time comes to tackle one of these. 👍
Great video Alan. Thanks
Glad I've still got my simple EGR valved MK3 Mondeo without DPF.
Black smoke on a mk3 is the MAP sensor not the EGR :)
You are a good Mecanic mate
cheers fayjur
Thank you very much for this video.
I have used a number of your videos working on my car in Australia and they are a fantastic international resource.
You don't say anything about the carbon deposits in the throttle assembly or intake manifold which no doubt extend right up to the backs of the valves.
Do you ever bother to clean these and if so with what?
hi, never had to worry about the carbon deposits as it never built up enough to be a problem apart from a few which I would just scrape out with a screwdriver
Another brilliant video to watch.having a focus st tdci will be good to know if I ever do one of these!
cheers mr ritchie😁
@@alan4x i spoke to you when I 1st found out about the dreaded lynx wet belts. I did an engine swap to a lower chain engine. Took the old wet belt out and it was still a pain in ass then when it was on the crane!.
Great watching your videos. The missis loves it {sarc!} The st with the same engine has only got 33k on it so should be OK they seem to be a reliable unit. Was gonna get it remapped stage 1 but i think I'll leave it alone.
@@alan4x I've finally got round to doing one in a Peugeot boxer 2.0. 2018
Luckily those little vacuum. Pipe came off easy. This video helped a lot. Thanks Alan
Brilliant as ever the best on line
Pure insanity !! I'll just hold on to my daily driver 68 Dodge Charger, thankyou all the same.
Freaking hell! On my 2.0 tdci mk 2.5 focus this is easier :)) I've deleted the egr though because it was causing problems. Great video Alan!
Done the same on my 1.8
Have you got a link to the delete? I can't seem to find anything online plus I am in Australia.
TAHANKIOU ALAN
🙃
Thank you Alan for all your videos. I want to ask you something.
My 2016 MK5 2.0 diesel 180ops got the EGR valve replaced in 2020 at 80k miles. Today, four years later and odometer shows 160k miles I got the same error again P042E valve stuck open. Do you know if there’s any other solution to this EGR or I need to replace it again?
Hi. There are people who carry out diesel particulate filter deletes and they can remove the software for the egr valve so you won’t get any more electrical problems with it. Hope this helps
@@alan4xwonder if any of these guys are in Australia or if it is possible to buy and install the software yourself? Shame the car is too smart for a simple blanking plate to work any more.
don’t know but they have some fancy pieces of equipment which is quite a bit more than a laptop that they hook up to the car but if they do exist in Australia you can certainly get your egr valve deleted
Hello to Monica back mate!
So, if the little part at 9:02 did snap.
How screwed am I really? I was just hoping to replace the plastic housing that cracked.
I have a spray of coolant from
The engine towards the direction of the radiator. From the rough location of the egr valve.
Guessing this usual plastic housing is the issue.
Thank you very very mutch. God Bless you❤
Hi Alan. After following this guide with a genuine Ford part I have P1102, and 2 codes relating to my dpf which were there before. Have you ever experienced it before? If there a plug I could have forgotten, or a pipe I haven’t connected back up properly? Also have heavy black smoke on acceleration which I didn’t have before
I would definitely recheck all the vacuum pipes are fitted and the electrical connectors as it is easy to miss one
@@alan4x I’ll re-trace my steps. Thanks for the response!
Can you just replace the plastic cooler or do you have to replace the whole thing
Great video, I've got a 2019 peugeot boxer 2.0 hdi. It's leaking around the plastic bit of the egr cooler...might give it a go myself, engine on these Boxers is really low down for some reason ..
Sei molto spiritoso, bravo e puntiglioso ...grazie se vengo in Germania passo a trovarti con la mia vecchia mondeo td sw 200 cv. Ciao
😊🙃
Thanks for a very helpful video Alan. I suspect my EGR cooler is leaking water into the exhaust gases as there is no obvious external leakage anywhere - only that the header tank level drops over 2 or 3 weeks of use).
Is there any way to check this without tearing it off the engine (I have convinced myself I can smell coolant at the rear to the car when the engine is running)?
hi steve, if the egr is leaking it will run down the front of the engine and drip off the oil filter..you should see the water stains but those cars have a number of coolant leaks like the thermostat housing and water pump, also check the radiator where the end casings connect to the core..with a torch you can see through the cooling fan casing.
@@alan4x thanks Alan. I've had a serious look around with a torch and a borescope whilst the system is pressurised / engine running. No water pooling above the gearbox so not thermostat housing. Nice and dry below and around EGR valve so casing looks to be sound. Either end of the rad looks good. Generally the engine and surrounds are dry so I'm damned if I can find where the water is going. No oil / water contamination so head gasket looks okay.
I'll keep on looking!
Have you known of a leaking EGR cooling 'coil' matrix in your many reapirs of these?
no, never had the internal matrix from the egr leak, maybe replace your coolant expansion cap but i sure if it is leaking it will show itself at some point
@@alan4x thanks Alan. Yes, I'll give that a try and keep a close eye on the old gal.
@@route66weasel Have you found where your car's coolant is leaking from? I have the same problem, mixing water with oil, only water loss and pressure inside the coolant hoses.
Hello Alan, does the transmission box have a joint? The water leaks out there, can you help me with a video? Thank you very much and greetings.
Any benefits to carbon cleaning these parts and the intake valves on these engines?
Hi Allan, I replaced my EGR with this video, no more leaking now! THANKYOU, but the engine light is on and my active start won’t work now. I took the battery terminals off to try and reset the car but still not working, any suggestions?
Thank you so mutch !!!!!! i come from Denmark and i just replaced that shitty Egr Cooler... it had broken at the exact same place as yours ... crappy design ! !thanks !!
The EGR cooler casing is crap on the Insignia aswell, if you are losing coolant, there is a 95% chance it is cracked 👍
Hello thanks for the videos! Do you know where is the intake air temperature sensor is in this motor? You disconnected the map sensor but I'm looking for the iat sensor for my ford kuga... Thanks
Greetings from Germany .. Thank you for your videos they have helped me alot! I also changed the egr on my Kuga and now I am getting the P0170 Fuel trim bank 1 error code.. have you ever seen that code on a diesel ?
Hi, Alan do you have a video changing egr valve on Mondeo mk4 2 l disel 2012 ? Thank you
not yet
I have the x-type jaguar, with we know is 30% Mondeo and I'm constantly tinkering and cleaning the EGR , but is so much easier in the older Mondeos , its like the over complicated to stop the garden mechanic
Hi alan. Wondering if you could help me. I have a well looked after 2015 2.0tdci auto mondeo with about 240k on the clock. Its developed a bit of a flutter in revs when at idol after warming up a bit and will generally stall out. This can be avoided by keeping the revs up a little. Had it in for diagnostics last week and all that poped up was a few seviceables. Had a full service done but the problem continues. My gut feel is its the egr. Is there a way of testing the egr? Or do you know of anything else that could be causing this. I know its difficult without seeing the car first hand but would appreciate your advice. TIA dan
Thanks Alan. How long do you think it will take for cheaper after market components to be available? Just searched eBay and nothing as yet.
Hello Alan. Can only the cooler part of the EGR valve be replaced? I would appreciate an answer. There is a hairline crack somewhere.
Hi Alan . Could a stuck egr valve make the car shake when idling? I have seen your video about the bad flywheel but my mk5 being only 93 k miles I d say it s not that.
Hello, I am from Polish, I have a car peuge 508RXH with DW10FC AHW. For some time there has been no idling work as I turn on the air conditioning until it is ok. OBD there is no error with the voltage to the sensors is ok.
Hello. What do you personally think about the mechanical blocking of the egr valve? And if you agree with that, where is the best place to block the valve? On the pipe between the big and small part of the egr valve? Thank you.
I wish. From what I understand a blanking plate not only throws an error code which would be tolerable but may throw the car into limp home mode.
Great explanation, thank you!
Thank you. It helped me.
Hi,can i replace just a cooler or whole thing ?
Alan, Please help. I’ve get an P1102 error in my Focus mk3.5 2.0TDCi DW10F engine. Maf sensor replaced, still the same. Map sensor replaced too, no changes. Replaced also egr valve (Ford regenerated one with 2 years warranty), wow, that hurts… And still no changes. What I’ve noticed - my car has a lower air flow and lower air pressure - for example, car with no problems maf shows 160g/s on 4th gear and pedal to the floor. Mine shows only 130g/s. And map from „healthy” car shows 2.4bar at the same conditions as above. Mine shows 2.27bar. Today I’ve checked all vacum pipes - all of them are ok, no vacum leaks. Any ideas? Inlet leak? Intercooler? I have no ideas…
Hi Alan. I've got a 2010 Mk4 with the 2.0 TDCI 163BHP which needs the EGR to come out and be cleaned, so my first question is can they be cleaned? 2nd question is it vertually the same way to take it out as the one in the vid? I can see the EGR pipe that bolts onto the same place as the one you show above but being a mk4 and I haven't done one of these before, i thought i was ask the expert!!
How about blanking off kits for EGRs? I wonder how many are running about with those fitted? Mines a Mk4 and Im getting the yellow engine warning lamp on from time to time now and some times the Engine Malfunction with Limp mode happens as well. Im thinking its time for EGR. Its on 100K and about 2000 L of bio diesel has been through it to. Self made high quality bio.
I miss you
hi alan, what causes it to crack? you never said
My mark 4 2.0 tdci has a different engine appearance than the mark 4s I see on videos. It has no metal pipe going over to the front from the egr. It has various other things on the inlet at the front. I'd like to know if you have late mark 4s on the fleet with a last model engine type. Mine is an auto as well. WR13BXW.
Hi alan. I have a focus st3 2.0 tdci with 57k. I do have the following codes p0490 p042e and p0401. Is my egr needs replacing?so early 57k? thanks
With coolant loss being the main issue with this particular egr can those black covers be replaced on their own? Thanks!
Hello Monica :-) Great video Alan :-)
So my car has the same egr been mapped out, and now it’s leeking, is there a way to bypass it?
that valve pushes into the cylinder head so would be very difficult to bypass it as coolant comes through the head ..through the valve and into the oil cooler
@@alan4x thanks mate, it’s a shit design. Common failure 😞😂
Hi Alan
Just wondering if you can sort out a small problem for me.
I got a Mk5 mondeo six months ago (16 plate) which has a start/stop feature but has only worked for four days
And that is only after the garage charged the battery overnight,they keep telling me that i am not doing a sufficient amount of mileage to charge the battery and therefore the start/stop would not work, so i drove from Glasgow to Edinburgh and surprize surprize this had no effect on the start/stop system.
I am starting to wander if the garage, ( I don't want to mention any names or point any fingers uncle Arnold ) are just telling me anything to get rid of me
I have a 12 reg focus with stop start and have this issues as well
It is correct that the battery charge state determins if the stop start works or not
Also among quite a few other factors as well are considered for stop start to work
Like cabin temp , if aircon is on, or DPF regen is due on diesel cars.
You may have a weak battery if it's old or just doing short journeys and using the radio with engine off
You can reset battery monitoring to see if this helps you will need to google this as not sure if its same
Button press on the mondeo as the focus.
on mine it didn't work until my battery failed and got a new one
But over time just doing short journeys it stopped working, after a few trips on the motorway it works again
Had the same on my 11 plate Mondeo. Original battery. it was absolutely fine however the start stop stopped working basically due to the battery 'quality' fading, I put up with it for years. Had the clutch done a few months back (battery out job) and got them to drop a new battery in. Start stop works fine now.
Tell Monica cheer up!!!
Amazing video. Thnks
I replaced the EGT on a skoda fabia mk1 this past weekend. It had 3 crush gaskets on each mating surface, Clearly that must be 3 times better than one.. LOL.
🤣
@@alan4x Well at least it confirmed the previous owners claim that the ERG valve hade been changed.
Still not as bad as my Mk4 Mondeo, I had to take to inlet manifold off, incl removing all the HP fuel pipes to the injectors! Worth doing though, the EGR was fine but the manifold and head ports were 50% blocked with crud.
Was this on a 2.0l? I recall Alan saying that coking inlet wasn't really a problem with this motor? It was a common go faster bit of maintenance on the mk3.
@@gs425where did Alan say that? The mark 5 in this video looks pretty coked up and I would have thought the car would run a lot nicer with it clean or at least make more power
@julesmoto9022 sorry it was back when they were running mk4s so a few years ago now.
Need help keep
Getting P1102 and I've tried 2 maf sensors
Hello, I have a ford galaxy 2016 2.0tdi I changed the EGR valve with a secondhand EGR but when I tried to do relearn on the scan tool it said failed. The problem I am having now all of a sudden is the auto gearbox is suddenly playing up. Would a faulty EGR affect the transmission drive?
its possible, you would need to check for any ecu codes first
Did you change the egr valve or repair it? what was wrong with it?
Must be same engine as in citroen jumper/relay/boxer/ducato 2.0hdi,its a pig to do when in the van ive just done one,i advise when youve removed the metal u pipe block the hole up on the engine so no bolts fall into engine cos that could be a nightmare
Thank you🎉
Great video Alan, again.:-) One question, are all egr valves prone to cracking and leaking or is there a difference from 2015 to 2016/2017 models? Did Ford improve material on egrs? Thanx and keep the good work.
There are no Ford recalls due to EGR issues, they have their head in the sand :(
Why improve something that makes them money
Can you delete the EGR on these with a blanking plate?
i would say no plus as coolant runs through it they normally fail due to a cracked casing so i think your stuck with this one
Someone needs to try it and see if it throws the car into limp home mode. That and perhaps a catch can would eliminate all that terrible carbon build up
Hey alan, do you know if you can add an egr blank plate to mk 5 mondeo 2 ltr.
I suspect the lack of answer on this question is related to the fact that it is illegal for him although I would have hoped another random viewer might have answered the question by now
Hi Alan would you be able to change mine to do far from you ??
Have you done a MK4 egr?
P2000 code, no oil level raise but rough idle and now while speeding as well feeling a little rough, Just had mine replaced, lets hope it helps but what a terrible thing on these cars
Great tutorial Alan, did the thermostat housing to cure the leak over the gearbox, towed the caravan to Skye and checked the coolant level and it was down so kept checking on the way home and did a pressure test when got back to work and egr was taking a dump so they were leaking in tandem so did this last night so hopefully that's the end of it, still can't get a DMF from LUK and the 2nd hand one off a low mileage car is beginning to rattle once that's done we're good for another 100K.
Have you had any issues with the door mirror switches on the driver's door as ours fold when you press mirror select to adjust the glass aim really annoying when you want to reverse the caravan.
hi i have s max 2016 is 136000 on the clock you recomend replace egr valve before traveling thru europe?
if its not been replaced since new then simply...yes
Well done great video 😀😀
Where I can find your garage please ?
Hi Alan.
please give me some good news
ive got 08 1.8tdci Mondeo , its stood for 5 weeks and the battery went flat . cant jump start it the imoberliser on i put jump leads on the battery and there arent any codes when i checked. i have ignition but no starter. can i do some magic to sort it.ROB.
the battery lead on the positive terminal has a fuse link in it i think, and check you have a good earth leads and power down to the starter motor and starter solenoid when you turn the key to crank
Hi Alan im hoping you can help me, my ford mondeo mk5 Auto diesel 2015 starts to over rev when the gears change as its an auto and i have to take my foot off the accelerator and then wait for revs to go down and then i can drive but it does this on all gears, could this be an EGR problem? Help!!
It could be. Happened to me same situation as you described and there were 2 DTcs at same time: one P0490 in PCM and U0401 in TCM. It went to limp mode. In vehicles with Powershift the ECU limits engine power also thru transmision.
Hi did you ever resolve the issue please
I have mine that's loosing exhaust gasses that end-up in the cars interieur.