Talk Morgan Forums Morgan Sports Cars Classic Morgans (pre-CX) EGR valve issue ?

Hi

Strange one this one. I had the check engine light come on, 2 litre Duratec, and running the OB2 reader the error is P0403 which is the exhaust gas recirculation circuit. The car starts, idles and runs fine and you wouldn’t know anything was amiss, apart from the mil light, but there was a smell like burnt plastic. Having checked the car through thoroughly, including crawling underneath to see if a stray bit of plastic had attached itself to something hot, I can’t find any trace of where the smell came from. I understand that if the egr fails petrol can get into places it shouldn’t but does that smell like plastic?

Any advice on what to do about the egr, and whether the strange smell is connected or just a weird coincidence, would be much appreciated.

Andrew

I've pondered this for a while. The Plus 4 Duratec I'm familiar with doesn't have a take off for exhaust gas. From the manofold to the tailpipe its all contained. There are certainly EGR valves shown for the Duratec in Fords, and a gasket listed on one website, but if such a thing is fitted, and I can't recall having one on my Duratec, it would be in the inlet manifold side. So the error code might be related to readings from the O2 sensors?

Check that the wiring loom from the sensors is not brushing the exhaust. A burning plastic smell can't appear from nowhere, so something is getting hotter than it should, and triggering the light.

Good luck!

Cheers Dave

Mil lights on my previous Morgan’s, whether Zetec or GDI, have always been something to do with the 02 sensors and of no consequence so that was what I was expecting here but different error code this time, first one in 18 months with the car so about time really.

I will take your advice and have another route around.

Thanks for your help.

My 2011 plus 4 with 2L Duratec, exhibited a MIL light at 47009 miles in May 2023. I had not noticed any ill effects at all.
Not having a code reader, I took it to my trusted local non- morgan garage, anticipating it to be an O2 sensor.
But no, it was found to be a failing EGR valve. Apparently, the valve itself was ok but the solenoid that drives it had failed. Bit of a pig to get at apparently, but it was replaced with a new Ford part.
At that time, the valve itself was £128, labour £140, diagnostics £60, add on £65 for HM treasury and the total bill was £393.60,
It’s been fine ever since.

Ouch! Where is the valve located Doug?

Hi Doug

I am afraid that sounds like the problem, have had another look at the wiring loom and there’s nothing out of place. Have also had a look on you tube on replacing the EGR on a Duratec and it looks a nightmare so beyond my limited capability. Even found something online that said the smell can be like molten plastic.

Good news is I can now sound almost knowledgeable on the likely cause when I talk to the garage.

At the back of the engine, adjacent to the coil pack and a bit lower down. The bolts are even deeper and virtually not visible so you have to go by feel and use sockets with universal joints. It also has a coolant hose, just to complicate things. Even though my man had done plenty in the past, it’s still not his favourite task! I considered it money well spent as not sure my patience would have endured!

That would be for the EGR cooler Doug - sits between exhaust and EGR valve. Just had one replaced following recall on our nine year old Cooper D Mini.

Ahhh, I get it now. It must admit exhaust gases direct from the head, There's a link here which has a pencil drawing of the location, which is useful to know.

https://www.talkford.com/threads/egr-valve-on-duratec-he.74612/

In my limited experience the add to fuel egr cleaners are pretty naff. Whip it off give it a good clean with Mr Muscle and rinse clean with some acetone. If you dont fancy the clean egr's are available on ebay from a quite reasonable 60 quid.