Does this sound like EGR failure?

[Bailes1992]

Was chatting about the few niggles I have with my Mondeo with some guys from work today who are also well into their cars. One of the guys I reckon has hit the nail on the head saying it's EGR failure.

Symptoms...
If you hold the revs in neutral about 1400rpm the car will vibrate, it also vibrates (Only in neutral or with the clutch dipped) if the revs are dropping and passing through 1400rpm.

Sometimes when driving down the motorway and you adjust your foot abit the car has a little 'hiccup'.
The car also sometimes hiccups a few times after overun down a hill when you put your foot back on the accelerator?

This morning, I accelerated up the slip road and the car went in and out of limp mode every 5 seconds. I.e. 5 seconds in limp mode, 5 seconds out, 5 speconds in etc. No check engine lamp just the ESP light and "Engine malfunction" on the dashboard?
I pulled over, turned the car of and on and it was fine all the way to work and all the way home after.

The boys in work are conviced it's a sticky EGR.
Although it's going in for diagnostics under warrenty tommorow (Also to fix a dodgey coolant temp sensor) I would like to know what you lot think it might be?

[lozz]

They might be right mate, you never know,

not sure on the Mk4s, but the Mk3 was abit prone for EGR problems,
but normaly theyd throw sighns, Rough tick over, Diesel knock or throw loads of smoke out going up hill under strain,

Good luck with the Diagnostics, ihope its nowt too serius,

[jasper5]

Has the car had a new air and fuel filter?

[grasmere59]

Slightly different but my 09 Boxer van had an EGR failure but the symptoms were eml on,no limp mode,rough tickover,hesitation when pulling away and more diesel knock and smoke.I would have thought though the initial diagnostics at Halfords would have picked it up if it were egr related.My mate who has a garage had a mk3 Mondeo tdci in with slightly similar symptoms as yours and it turned out to be an electronic turbo actuator but it can't be bought seperately so it had to have a new turbo.

[Bailes1992]

Funny you mention diesel knock, I stopped at some trafic lights just now and it had a little diesel knock, gave it a little rev and it was fine.

I really don't think there is much wrong with the car, just bloody annoying.

Car has just had a full service, the engine pulls through the revs fine, no smoke either.

[lozz]

This might sound daft but ..
iwonder if youve picked some bad diesel upsome where?

ive had it happen once or twice, supermarket fuel mainly.. but it has caused loss of power, ok once topped up with fuel bought elsewhere,

[Bailes1992]

Only fill up at shell and this is the second time I've filled up...
Might be something to think about though!
I would love to start putting millers in the diesel but it has something called an Easy Fuel system. Essentially there is no cap on the fuel filler. It only opens when a diesel pump is pushed in.

[jasper5]

Only fill up at shell and this is the second time I've filled up...
Might be something to think about though!
I would love to start putting millers in the diesel but it has something called an Easy Fuel system. Essentially there is no cap on the fuel filler. It only opens when a diesel pump is pushed in.

You could always push the nozzle from a spare fuel can in it and pour the Millers down the tube.

[Bailes1992]

Only fill up at shell and this is the second time I've filled up...
Might be something to think about though!
I would love to start putting millers in the diesel but it has something called an Easy Fuel system. Essentially there is no cap on the fuel filler. It only opens when a diesel pump is pushed in.

You could always push the nozzle from a spare fuel can in it and pour the Millers down the tube.

It has to be perfectley sized or it won't open.
Apparentley there is a special funnel under the spare wheel to open it. I must have a look.

[jasper5]

That don't make any sense at all.

[Bailes1992]

There is lots of pins around the filler, when you push the pump in it pushed all the pins enough to open the filler.
It's a stupid idea really.

[jasper5]

It's a stupid idea really.

Yeah, that's what i meant

[Welly]

So it's not 'Easy Fuel' at all then

I'd be surprised if a dodgy EGR would cause rough running or 'hiccups' but who knows hope it gets fixed easily enough and don't be afraid to demand better service from the supplying dealer if you need to.

[sirwiggum]

My 406 had hesitation around 1200rpm that turned out to be a worn clutch pedal sensor.

Something to do with the system sensing if the clutch is in and burning lean.

My advice - get rid of that bloody FixOrRepairDaily.

[Bailes1992]

I went to drop it off this morning and the two mechanics there were barking at a stray dog
See what they come back with today now.