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Matt, Mechanical Engineer
Category: Ford
Satisfied Customers: 22759
Experience:  BEng hons Mech engineering, in auto industry 22 years
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How long/how many miles should an EGR valve last on a diesel

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How long/how many miles should an EGR valve last on a diesel Ford Mondeo 2006 (06 plate) 2.0L 135 BHP TIitanium X?

this very much depends on how the car has been driven

a lot of stop / start journeys will never get the exhaust really hot enough to burn off deposits and also if the car has been filled up with supermarket fuel on a regular basis then this tends not to burn as cleanly and makes more deposits than if say BP was used

so its possible for EGR to coke up in as little as 50 K miles when they should with the right conditions last 120Kmiles

however its always worthwhile trying to clean them out 1st as they can often be recovered
Customer: replied 3 years ago.

My car is driven very little around town. It goes 14 miles each way to work, across country, which takes about 25 minutes each way and is usually non-stop. Minimum distance to nearest local town is 15 miles, also about 25 minutes non-stop. Fuel used is Shell V-Power. First EGR replaced at 50000 miles. This one now claimed to be u/s 35K later (V annoying). Have to go to main Ford dealer as no other garages will touch Mondeo diesels (any idea why not?).

Hello Martin

OK thats unusual

and I'd suspect that the car may be overfuelling so could be due to a faulty water temp sensor. If this is the problem then the ECU will be leaving the car constantly ' on choke' and not reducing the fuelling as the engine warms - so unplug the sensor and clean the contacts on both sides with some switch / electrical cleaner (not WD40) and inspect the wiring for any signs of damage to the insulation especially where it runs over other components and through the bulkhead- if this doesn't help consider replacing the sensor as they're not expensive
Check for exhaust leaks before the O2 sensor as if this has been experiencing an exhaust leak then it will have been running very rich as the sensor will see the extra air pulled in as fresh / lean fuelling and be adding fuel to compensate.

this can lead to catalyst failure as the extra fuel can re-light inside and melt the catalyst

The best way to find an exhaust leak is to run the engine from cold and feel around the exhaust joints with your bare hands - you'll have about 30 seconds before it all gets too hot and you should feel any escaping gas blowing over your fingers
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