2002 Focus SE EGR Questions - Input Requested - Focus Fanatics
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace

Go Back   Focus Fanatics > Ford Focus Tech Discussions > General Technical Chat

General Technical Chat This section is for technical discussions relating to general maintenance, electrical issues, engine trouble, and recalls.

Search This Forum | Image Search | Advanced Search    
Ford Focus Tire & Wheels FocusFanatics Merchandise

Thread Tools Display Modes
Old 05-31-2007, 01:34 PM   #1
Focus Rookie
Join Date: May 2007
Fan#: 47609
Location: Edmonton
What I Drive: 2002 Red SE Sedan

Posts: 2
FF Reputation: 1 Enggboy Good Standing Member
Buy-Sell-Trade Rating: (0)
Question 2002 Focus SE EGR Questions - Input Requested

Hello All, I am looking for a little advice from some people with a lot more Focus experience than I.

I have a 2002 Focus SE (8 valve SPI engine, auto tranny) with about 93k kms (57.5k miles) on it.

The EGR tube has separated from the flange that bolts it to the exhaust manifold. I called Ford and the EGR is not covered under the emissions system warranty (apparently this warranty ONLY applies to the cat), so I am on the hook for the cost of repair.

I have no trouble doing the work myself, it is a simple job, but the part I need costs $200 (Canadian) from Ford and is not available from NAPA, etc. I have called a few wreckers and none have one either.

My question is: What would happen if I just plugged the EGR off? Would I get a code thrown, or would there be driveability problems?

To do this I am thinking I could find some scrap metal and make a blanking plate to block off the exhaust manifold hole, and then plug the intake to the EGR valve to prevent unfiltered engine compartment air from entering the system. I would leave the valve hooked up, just block the flow of gas from the manifold and block the intake to the EGR valve.

This 'patch' would only be temporary, as I am currently trying to save money for my wedding this fall, and once that is over I would get the right part and put it back to OE specs.

Any thoughts you may have on the pro's and cons would be much appreciated.

P.S. There is no emission testing in my area, so I don't have to worry about that.

Thanks in advance,


Enggboy is offline  
    Reply With Quote
Sponsored Links
Old 05-31-2007, 03:16 PM   #2
What bump stop?
tiresmoker's Avatar
Join Date: Mar 2005
Fan#: 20426
Location: Youngstown, Oh, Afghanistan
What I Drive: '00 ZX3 Turbo, '06 ST Turbo

Posts: 1,947
FF Reputation: 24 tiresmoker Great Standing Member
Buy-Sell-Trade Rating: (1)
there shouldn't be any driveability issues. All the EGR is there for is emissions anyway. EGR = Exhaust Gas Recirculation.

You'll bropibly get a CEL, something along the lies of insufficent EGR flow, but it won't make the car drive like crap.

Is there a bung on the header that the EGR tube screws into? Not too familiar with the SPI but on the Zetec there is a bung on the cat the tube screws to. If that is still there try and find a bolt that will thread into the hole instead of welding a plate on the header.
ST Crew #19
2006 ST Turbo: JUNE 07 ROTM 2007 Ride of the Year
2000 ZX3: superturbochargedpartscar
2005 Shinka RX-8: too many mods....
Originally Posted by 03OrangeSVT
It was like concentrated death on chicken
tiresmoker is offline  
    Reply With Quote
Old 05-31-2007, 03:34 PM   #3
Focus Fanatic
Join Date: Sep 2005
Fan#: 27586
Location: Aberdeen, MD
What I Drive: '04 Mazdaspeed Mx-5, '72 M35A2

Posts: 4,602
FF Reputation: 27 arrestmespi Great Standing Member
Buy-Sell-Trade Rating: (8)
make a block off plate for the header using some flat iron, and cut the pipe leading to the intake, and put a small breather plug filter on the end. YOu may get a cel, and you can just get a tune and have the egr system tuned out anyway. pm mike b16sir1991 and he may be able to hook you up with the part. also you could take the plate and tube off and weld the tube to the plate back on
arrestmespi is offline  
    Reply With Quote
Old 05-31-2007, 04:05 PM   #4
Focus Rookie
Join Date: May 2007
Fan#: 47609
Location: Edmonton
What I Drive: 2002 Red SE Sedan

Posts: 2
FF Reputation: 1 Enggboy Good Standing Member
Buy-Sell-Trade Rating: (0)
Thank you for the ideas.

On the SPI the EGR take off point is a bolted flange right off of the side of the manifold where the tube extends anbout 1.5~2 inches then takes a 90 and heads straight back (under the distributor cap) to the EGR valve, where it connects to the valve with a threaded connection. I plan to just take the old flange and use it as a template to make a new blanking plate without the hole in it.

I may end up getting the things weleded back together anyway, but I think I know the reason it failed in the first place. Now that the pipe is disconected from the flange, it actually has a gap of about 1/8"~1/4" that it has pulled away from the flange plate. My guess is that something wasn't properly aligned or a length wasn't quite right when it got put together and the repeated heating/cooling cycles have just fatigued the joint and one day she snapped clean. My fiancee was driving it at the time and said that it went from 100% normal to "sounding like a really loud sportbike" within 10 miles.

Thanks again, keep it coming.

Enggboy is offline  
    Reply With Quote

Bookmarks & Social Networks
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Engine Light zummracer General Technical Chat 18 12-10-2013 09:08 PM
Ford debuts Focus Coupe-Cabriolet Kneel Ford Focus & General Car Chat 50 10-02-2011 07:04 PM
mix of focus questions focused on the focus Ford Focus & General Car Chat 0 11-23-2004 05:16 PM
A Few Focus Stuff...Questions Happenedtoyou General Technical Chat 9 08-09-2004 01:38 PM

All times are GMT -5. The time now is 03:06 AM.

Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Terms of Use : Privacy Policy : Advertise Information

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Acura TLX or Fiesta ST. You can find all Ford Focus and Focus ST related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area.