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Old 24-07-12, 01:52 PM   #1
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Default Boxer EGR

Hi, can anyone help, I have a 2007 boxer 2.2, with very low mileage 21k. The problem I have is the EML is on all the time and the garage diagnosed it as the EGR requires replacing or cleaning. The van starts first time and runs well, albeit not so smooth on tick over. I have noticed a slight drop in power, but nothing dramatic and it is doing over 40 mpg on a run. Can I damage the engine or turbo as it is? Can anyone tell me where and how easy/difficult it is to remove the EGR and can I clean it with Carb cleaning spray? Thanks for reading and any help would be much appreciated
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Old 15-08-12, 09:26 PM   #2
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Trust me when I say the egr needs replacement. It will also need programming and a software upgrade
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Last edited by MadV; 15-08-12 at 09:41 PM.
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Old 15-08-12, 09:50 PM   #3
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Trust me when I say the egr needs replacement. It will also need programming and a software upgrade
Hi, thanks for the reply, I had almost given up on this one. Will it do any damage as it is, as I`ve been told not to worry about it? I am surprised it needs replacing after only 21000 miles or is this a common fault, which has been implied by other people who have the Puma engine?
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Old 15-08-12, 11:38 PM   #4
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Hi, thanks for the reply, I had almost given up on this one. Will it do any damage as it is, as I`ve been told not to worry about it? I am surprised it needs replacing after only 21000 miles or is this a common fault, which has been implied by other people who have the Puma engine?
as mad v says..
get it done and done propper asap .. it will eventually break down !!!!!
wount cause danage i dont think but never the less its starting with power loss.
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Old 16-08-12, 12:20 AM   #5
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get an oil catch can fitted to the rocker breather, a lot of oil disperses up this pipe and into the air intake to be burnt off. after 50000 miles there could be 10mm of treacle like gunge blocking the air intake and egr pipes and valve.
prevention is always better than cure!
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Old 16-08-12, 09:03 AM   #6
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get an oil catch can fitted to the rocker breather, a lot of oil disperses up this pipe and into the air intake to be burnt off. after 50000 miles there could be 10mm of treacle like gunge blocking the air intake and egr pipes and valve.
prevention is always better than cure!
I will look at getting it sorted soon, is it a difficult job, as I`m not that familiar with this engine and where`s the best place to get the EGR, have seen on ebay for around 110?
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Old 26-09-12, 09:01 PM   #7
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Hi,

I take it the engine is of Ford Duratorq originality if its a Boxer 3
Ya dont want to run too long with egr knackered as i have fitted plenty and they stick in any position and can cause some serious probs. The back pressure can cause the seals on the turbo to go or even the compressor wheel to shatter and bang goes the engine ooppps sorry lol

But one way to tell if egr is at least not sticking, is when you turn the engine off you should hear it open and close 3 or 4 times.

They are a pain to change and the bolts that hold the egr pipe on will no doubt shear off and ya will need to re tap them.
But ya can pick up a new egr valve off ebay for 120 and fit for nothing if ya know how as dealers want 190 for egr alone


But another thing is the main loom from the engine to the ecu and fuse box rubs through on the body and causes malfunctions to the egr and other things and needs checking once new egr is fitted as if loom is cause it will only happen again.

Jon
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Old 27-09-12, 08:33 AM   #8
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Hi,

I take it the engine is of Ford Duratorq originality if its a Boxer 3
Ya dont want to run too long with egr knackered as i have fitted plenty and they stick in any position and can cause some serious probs. The back pressure can cause the seals on the turbo to go or even the compressor wheel to shatter and bang goes the engine ooppps sorry lol

But one way to tell if egr is at least not sticking, is when you turn the engine off you should hear it open and close 3 or 4 times.

They are a pain to change and the bolts that hold the egr pipe on will no doubt shear off and ya will need to re tap them.
But ya can pick up a new egr valve off ebay for 120 and fit for nothing if ya know how as dealers want 190 for egr alone


But another thing is the main loom from the engine to the ecu and fuse box rubs through on the body and causes malfunctions to the egr and other things and needs checking once new egr is fitted as if loom is cause it will only happen again.

Jon
Hi Thanks for the info, sounds like you have had a lot of experience with these before. The engine is marked as a Puma, so I assume it`s the same as the Transit. I have had the EGR out recently and as you say, it`s an awkward job, plenty of cursing. When I got it out, the port was fairly clogged with carbon, so I cleaned it with electrical contact cleaner and cotton buds, as I didn`t know how sensitive these things are, put it back on and started it up, it ran a lot better, so I had to take it for MOT and they reset the codes, which cleared the EML, but within a couple of days the light was back on, so now I`m looking at changing it, when I get the chance. In your experience are the valves on ebay a good buy, as the price from a motor factors is close on 200 and how often have you had to replace these, as mine has only done 21k? Thanks again!
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Old 27-09-12, 09:35 AM   #9
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Can you not just remap it out?


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Old 27-09-12, 08:27 PM   #10
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Yep its a popular Engine in early Mk 3 mondeo`s, transits ,LDV vans, Jag`s and land Rover being the popular choice.

To be honest not worth cleaning as once they go they are shot.

The original part number is 1618 R5 but has been superseeded a couple of times. The ones on ebay are fine as most are OEM spec.
There is one now on ebay item number 221006206561. Its only 103 from Cannock.

I fitted 1st one to mine at 195000 miles but then i spent most time on motorway. They will clog up quicker if its on short journeys all the time

But like i said fit new one and check wiring after without fail and most common place to rub through is under the N/S headlight where the loom is tight against the body between UCU`s and fusebox

Jon
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