Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - mcl896b

Evening all, and apologies if this has been covered elsewhere before...

I've got a 56 plate Mk 3 Mondeo 2.2TDCi that has spent a year off the road, but has now been returned to running with a new clutch and various MoT requirements.

About two weeks ago my EML came on, accompanied by clouds of blue grey smoke and some juddering initially, but with no apparent loss in performance once I got going. I decided to bite the bullet and bought and OBD2 reader that connected to my phone. The OBD2 reader reported that the following codes came up:

P0404, P0405, P0406, P0409 - all of which pertain the the EGR valve. Having fitted a blanking plate, I decided to leave it out when I removed the offending valve and cleaned it. Tried to start the car, however the car refused to start. It would sound like the engine was catching and immediately die. Having had this problem before and knowing that these symptoms could be related to the EGR I re-fitted the blanking plate and except for some smoke on acceleration the car behaved fine, and performance was what I expected.

I decided to bite the bullet and buy a new EGR valve, and being a tight jock, I bought one from Amazon rather than shelling the £200 off that the local ford robber wanted. I fitted it today, and have had mixed success. The car starts and there is no notable smoke any more on acceleration, however on starting and while cold the dreaded glow plug light flashes and the car is in limp mode. Once the car heats up and the engine is turned of and restarted, all is well, no limp mode, no glow plug lights. I've attached my OBD2 reader to the car and while the glow plug light is flashing there is not noted trouble codes.

Being a man of extremely limited mechanical sympathy, I am now at a loss as to what might be wrong (barring a faulty EGR valve). Any steers from anyone as to what might be the problem would be much appreciated.

Al

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

If the egr valve was blanked off then it won't be the egr valve at fault was it more white or blue smoke? And what year of car is it?

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - Railroad.
Is the EGR valve clean and free of carbon deposits?
Does the EGR valve move to the fully open and fully closed positions when operated?
If the answer to both questions is yes then there's nothing wrong with it.

The EGR valve opens and closes. It does not perform any other magical function.

If the EGR valve is coked up with carbon then so will be the air intake downstream of it. This is more likely the reason for your fault codes than the valve itself.
Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phil_z70

This may help - www.obd-codes.com/p0409

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - elekie&a/c doctor

The problem with cheap happy shopper code readers is that they only provide basic generic information which is often incorrect or inadequate,especially when it comes to diesel engines.As suggested above,the egr valve opens and closes,but is the vacuum system that operates it working correctly??

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - mcl896b
As far as I can tell the new EGR valve is functioning as required.
I'm beginning to get the impression that the one reader I purchased is basic. With the glow plug light flashing it is showing no trouble codes so getting the idea that it doesn't show advisories, only full faults.
The weird thing is that once the engine is warm, everything appears normal.
Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - S40 Man

If you have a laptop Forscan code readers are very good. Can get off eBay etc. One end is OBD the other is USB. You get a CD with software also. It works well IMHO. Better than a generic reader anyway. elm327 approx £17

Re the egr can you drill a hole in the blank plate (e.g 10mm?) This lets some gas though but reduces flow rates. Someone did that on my old S40 with no apparent I'll effects.

James

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - mcl896b
The first EGR valve was in bad condition and was jammed open, hence the blank being the only way the engine would start. The blank has a hole in as my car is fitted with an electronic EGR valve. It's a 56 plate so 2007.
Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

Can you get live data on your eobd reader to check for cam/crank signal? Was your dual mass flywheel changed with the clutch?

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - mcl896b

The flywheel had to be changed, it was it disintegrating that led to the need to replace the clutch.

The reader does live data but not in any detail, it does note that the EGR system check is not complete. I am wondering if the issue with this EGR valve is the electrics, and if this is where the aftermarket company I bought it from has saved the money?

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

Good because a knackered dual mass can play havoc with the engine but ignoring the egr for the min you still had problems with the car with the egr blanked off so therefore it's not the egr at fault when it's blanked off the only issue you should have is the engine management light with the new egr fitted now what exactly are the symptoms is there a separate engine management light or only the glow plug light? Is the glow plugs relay stuck on ? This will cause some cars to go into limp mode

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - mcl896b
The engine management light is now not on, hasn't been on since the new EGR was fitted.
The glow plug light flashes and the car is clearly in limp mode. There's no smoke anymore either.
Once the car is warm, if I turn the ignition off and then on again the car starts and performs as normal.

By the time I blanked the EGR valve, the EGR was already jammed open, so was affecting performance anyway.

Edited by mcl896b on 02/06/2016 at 10:58

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

You probably need to look at the car on live data if there are no fault codes to try pin point anything did the car preform ok from cold with the egr blanked off? Try unplugging the air flow sensor see if it runs any better it's worth a punt for free at least do you have a scan tool that looks at live data?

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

check the map sensor too

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - phillip b

I would also blank off the egr valve again incase there is an electrical fault keeping the egr valve open when cold. Just clutching at straws really live data would be the way to go from here

Ford Mondeo Mk3 2.2TDCi - New EGR Valve fitted but glow plug light still lit - Annarosa Luko

Hello,
it seems that we have the same problems here. Can you tell me what had happened with your mondeo and what was the solution? Do you have any good advice what should be done in the same situation? EGR was removed twice already, but with the new EGR (an aftermarket one) it doesn't even starts. Codes come up mainly with the EGR, one was with MAF sensor... Sometimes it simply goes into limp mode.
Hope your problem was solved.

 

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