[johnboy1974]

3/ Remove the electrical connection to the egr solenoid. theres two lugs on the side...squeeze and pull away carefully.

4/ Remove the exhaust gas inlet manifold. Remove the two hex head screws with a 12mm spanner or socket. Retrieve the stainless steel gasket that lies behind this manifold.

 

[johnboy1974]

5/ Remove the egr assembly from the combustion chamber manifold. Use a 12mm spanner or socket, noting the location and position of a small bracket that is held on by one of the screws.

6/ Carefully remove the egr assembly by pulling upwards and away. Retrieve the steel gasket located under the egr unit.

 

[johnboy1974]

7/ Using Wynn's egr valve cleaner and cloth, thoroughly clean the access point to the combustion chamber and the exhaust gas inlet manifold chamber. Remove the hardened carbon. Elbow grease required here.
Use the straw on the can to get some of the fluid deep inside the chamber, so it works where you can't get the cloth.

 

[johnboy1974]

8/ Strip down the egr unit by removing the four phillips screws that attach the solenoid to the egr housing. Put a mark on the plastic solenoid unit and the aluminium housing so that they line up when reassembling.

9/ Thoroughly clean out the chambers of the egr housing unit. Fill the internal chambers of the unit with the Wynn's cleaner and leave for ten minutes. Use an old toothbrush to agitate the carbon build up. You may have to rinse and repeat a few times to get it cleaned thoroughly.
Push the spring loaded plunger upwards and clean it thoroughly as well, try to get the entire housing piece clean and carbon free. There are no electrics in here so be thorough with the cleaner fluid.
When I was done I used wd40 to lubricate the entire plunger mechanism by spraying it thoroughly whilst pushing it up and down. It should move easily without sticking. Give the entire housing a quick dry with a cloth or kitchen roll to remove excess oils and liquids.

That's it guys, just put it back together again by reversing what you've just done. it's a fairly easy job that should help to give you better acceleration response at low revs and hopfully better miles per gallon.

 

[johnboy1974]

When you start up your car you will get two error codes caused by dissconecting the battery. To clear these codes simply fully open and shut your two front windows.
The car might make some unusual noises and shudder for about 3 minutes. This is the Wynn's cleaner getting burned up and passing through the system.

 

[johnboy1974]

How dirty was it ?? how much carbon did you remove. Did same job on a 2 lt mondeo with 50 k on the clock and it was chocka with carbon and soot 3-4 mm all over ??

Cheers

Mark

Yeah mate sounds like it was similar to yours...quiet a bit of carbon and soot. Maybe do it every 30-40 thousand miles now.


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