Fitting an EGR blanking plate tomorrow

[Fallout]

I've received a blanking plate for my 2005 TDCI Mondeo 2.0 and am going to put it on tomorrow. I think I know where the EGR valve is! This is all due to horrible black smoke and bad performance problems until the car warms up. Could be a turbo issue, but since the blanking plate cost £3 it's worth a punt.

Does anyone have any advice for anything else to do while I'm in that area? I've read about taking the manifold off and giving it a good clean at the same time, but unsure if there are any gaskets under there I may need to replace or if there's anything else I need to consider. Any pearls of wisdom from the mechanically minded?

[cb1000rsteve]

I cleaned all my egr valve and manifold on my mondo earlier this year. It's all dead easy and is at the front of the engine on the left. Should ave a metal pipe in the side and a large rubber hose underneath the valve. If u take the manifold off. Be careful as there are a few small rubber gaskets in each inlet hole. They can be reused. The manifold will probably be full of coke! If you get a fault light on try drilling a small hole in blanking plate. This sometimes help trick the ecu into thinking its still working. If this doesn't fix problem next thing to check is the big rubber hose for splits. These can be invisible as the pipe expands under boost pressure. The next thing to check after this is the injectors which ain't cheap. Search google for mondeo diesel leak off test. Hope this helps

[Fallout]

Thanks mate. Good pointers. I doubt the pipe is split because it's fine once warm. It's probably due to all the short journeys I do taking the dog to the woods (less than 5 minutes). I reckon I'm filthing up the engine. Hopefully not a turbo issue, but will check the items you've said. Hopefully the plate will do the business though.

[BanannaMan]

Will it pass MOT with the egr valve removed?
Wouldn't here. Just saying.

[Wideboy]

I don't think it should fail as in theory it should be running cleaner I.e. smoke less. I think deisels are exempt from emission tests and its just a smoke test they have* might explain why some garares feel the need to sit there with the thte engine on the limiter. I don't even think the light being on would fail.

*I could be wrong

[Fallout]

I'll find out when I MOT it! It should only take a few minutes when I know where it's going, so I'll ask before it goes in what they think and whip it out if they think it'll be a problem.

[Wideboy]

Don't ask the garage your taking it to, they wouldn't notice if it was gone as they only check the car for being de-cat'd. If you make them aware then you might be creating problems for yourself.

Idiot!

[NTECUK]

I think deisels are exempt from emission tests and its just a smoke test they have*
*I could be wrong
Yep Your wrong
They have a smoke density test done by reving it to the limmiter.

[NTECUK]

I'll find out when I MOT it! It should only take a few minutes when I know where it's going, so I'll ask before it goes in what they think and whip it out if they think it'll be a problem.
Don't bother,we(Testers) don't care as long as it passes the emmision test.

[Wideboy]

and its just a smoke test they have

Yep Your wrong
They have a smoke density test done by reving it to the limmiter.

:confused:

[Fallout]

Well that was a waste of time. Made no difference apart from turning on a dashboard light, which I think is now an MOT failure in itself. When I started it up I heard some horrible noises I couldn't hear from inside though. Theres a metalic ting ting ting as you come off the throttle, but not there on idle. I can't localise it as I can't rev it and listen near the engine bay at the same time (without knowing where the throttle is under the engine).

All the symptoms now:
- Loads of smoke
- Car can't get over 2.5k rpm
- Metallic ting ting tinging noise when you come off the thottle

The other day when cold it left a nice trail of smoke behind it when I kept it at 2.5k rpm when driving cold. All symptoms are gone after a few minutes though.

Sound like a failing turbo to anyone? If so I may pop down the local garage and ask them for prices for a new one and if they'll fit a 2nd hand one if I go to a scrappy/ebay.

[NTECUK]

Disconnect the air flow meter harness..
It should then ignore it and run cleaner but not rev high as its on limp mode if its fulty
Get a reset tool . They are cheap enough even argos sell them now

[NTECUK]

Check the oil level.
Turbo that's goose will use lots.

[Fallout]

Had to top it up this morning. I think it's using a bit. Also bought an f-super off ebay. Hoping that will allow me to reset engine management lights as well as give me some pearls of wisdom.

I've made the mistake with my bike of buying bits I didn't need because the fault was elsewhere. I'd rather not spend £350 on a reconditioned turbo and the fault be somewhere else so going to put the ground work in to diagnose correctly. Thanks for your help. Currently browsing Ford forums too.

[yorkie_chris]

I don't think it should fail as in theory it should be running cleaner I.e. smoke less. I think deisels are exempt from emission tests and its just a smoke test they have* might explain why some garares feel the need to sit there with the thte engine on the limiter. I don't even think the light being on would fail.

*I could be wrong

Yep Your wrong
They have a smoke density test done by reving it to the limmiter.

I thought it was done with brief bursts of full throttle?

I.E try and see how much smoke it will put out under load.

On the bosch M series governors like on mine that's the full load screw that would make the biggest difference to say smoking when plodding uphill and the torque capsule spring tension that starts to back off the juice as the revs increase and the volumetric efficiency drops.

Not much point trying to rev it to death as they'll all smoke when running at the limiter for no reason.

(bear in mind this is a proper chuggy diesel none of this electronic bollox...)



Black smoke sounds like too much fuel or not enough air. Air filter nice and clean? Fuel filter ok?
Turbo seal letting a bit through when cold might give that but I doubt it as thinner hot oil would leak more I reckon.

The other possibility which you won't like is a leaking injector.

[NTECUK]

Common rail diesel is more electronic control .
You do have a pump but it only part of the story .
Re your Mot.
You can watch one. Its all done by measuring smoke.
We have a pc based system . You can on some only do one accel and it will "fast pass".
The more dirty ones can go on for 6 cycles .

[yorkie_chris]

Common rail diesel is more electronic control .
You do have a pump but it only part of the story .
Re your Mot.

Yes I know, and on those mondeos with that common fail bollox on them the high pressure pump breaks down and all the bits of glitter damage the seats of the injectors. :(

I seen smoke test. What I'm saying is it's the part of the run when the revs are going up that is of interest not just holding your boot to the floor.

[NTECUK]

Yep. That's the dirty bit.

[cb1000rsteve]

Egr blanking ain't an Mot fail. My zafira 08 runs no egr and no particle filter either. Both items r a waste of time

[NTECUK]

There not there to make your car run better .Only to reduce the emissions of soot (DPF) & Nox (EGR ).

[yorkie_chris]

Reduces NOx (not tested at MOT...) at expense of engine wear, lower volumetric efficiency hence economy... smoke (is MOT tested) and gunking everything up with sh*te.


My merc never had EGR from new, it has nearly 200k, I had inlet fannymold off and there was no soot or crap in there... had turbo bits off a newish astra other day and it looks like the powervalves on a 350LC!

[Joe Marcon]

My bro had his egr blanked off and dpf and cat removed . Will still pass an mot . Its just a test that doesnt pick these missing .
It will need engine managed light remapping off when egr is blanked off

[NTECUK]

It will need engine managed light remapping off when egr is blanked off
On some vechles

[Wideboy]

I thought decatting a diesel was a fail?

[NTECUK]

If you fit a decat pipe it's the same size as the main part of the system.
If you knock its guts out who s to know.

[Wideboy]

ah i see

[cb1000rsteve]

NTECUK
The bloody Vauxhall DPF is only there to make them money. especially at £1000 (dealer price) to supply and fit a new un.
Mines had it removed then re mapped and had them turned off in the ecu. She runs brilliantly now especially with the extra 25bhp (143bhp) and that aint the max. It could be mapped up to 165bhp but thats pushing it in my eyes.

You could always try a fuel additive to help reduce smoke. I really good one is Millers diesel power eco max. Pour it in before you fill up and it helps keep the injectors clean and reduce smoke. this worked on my old vectra. Supposedly gives it a bit more umph but i doubt that.

[Thunderace]

I've made the mistake with my bike of buying bits I didn't need because the fault was elsewhere. I'd rather not spend £350 on a reconditioned turbo and the fault be somewhere else so going to put the ground work in to diagnose correctly. Thanks for your help. Currently browsing Ford forums too.

Good boy Simon "pats on head" Nice to see your learning, start simple!;)

[Joe Marcon]

No smoke no poke :)

[Thunderace]

That's what she said!;)