Fusion EGR Valve Issue

I'm experiencing a frustrating issue with my 2008 Ford Fusion, diesel engine. It's got 164188 km on the clock. The symptoms point towards a defective EGR valve: reduced engine power, check engine light, smoke during acceleration, rough engine running, increased fuel consumption, jerking while accelerating, and a hissing sound when I accelerate. I've checked vacuum lines, visually inspected the EGR valve (though not removed it yet), and monitored the EGR duty cycle with an OBD-II scanner. All signs point to a malfunctioning EGR valve. Has anyone else encountered something similar on their Fusion?

4 comment(s)

Sounds familiar! I had almost the exact same symptoms on my Opel Astra a few years back. Check engine light, rough idle, the whole shebang. Turned out it was the EGR valve, clogged solid with carbon deposits.

Thanks for the insight! I wouldn't expect so much carbon buildup, but I guess it's still possible. Did you manage to fix yours yourself, or did you end up taking it to a shop?

I tried cleaning it myself at first with some carb cleaner, but it was too far gone. Ended up taking it to a trusted workshop. They confirmed the EGR valve was faulty and replaced it. The mechanic mentioned the valve being jammed open, which was causing all sorts of problems with the air-fuel mixture. Honestly, I’d suggest letting a professional handle it. Saves a lot of time and potential headaches.

Appreciate the advice. I suspected as much, given the complexity and potential for further complications. I took it to my local mechanic, and they confirmed it was indeed the EGR valve. The final repair cost came to 355€. Runs like a new car now!

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