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Old 12-05-2013, 05:53 AM   #1
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Join Date: Dec 2013
Fan#: 126802
Location: NoVA, VA
What I Drive: 2002 Gold Focus SE

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EGR to intake manifold broke

Hey everyone. I recently got a new-to-me focus SE to use as a daily and to also help my wife learn how to drive a manual trans. After getting the car, I found out about the common valve seat failures in 100k+ 2.0 SOHC and decided to remedy the problem before it could arise.

In the process of getting the EGR off the intake manifold, the 2 bolts that hold it in were rusted off completely. I figured I'd try to drill and tap it, however I've broken 1 drill bit and cracked another. FYI, the car is back together, starts, but runs very rough. No CEL and can't pull codes from a scanner, but I'm getting DTC123, and DTC041 from the cluster.

I'm wondering if anyone here has had this problem and tried a different method to get the EGR back on. I'm wondering if there is a dowel pin large enough to fit in the EGR hole and I can clamp the rest down with chicken wire.

Any help would be appreciated.

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