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Problems with EGR Valve (Stuck!)

14675 Views 21 Replies 7 Participants Last post by  amc49
Good evening Focus Fanatics community.

I apologize if my thread seems to be mis-categorized or in the wrong place! [thankyou]

I have a 2002 Ford Focus zx3 Zetec that I'm trying to breathe some new life into. I've had it about a year (first Ford!), it's currently at 125k miles.

A couple weeks ago, I had a problem with stalling out when idling, as well as extremely rough idling. Codes spit up and pointed me toward the bank 1/sensor 1 o2 sensor. I decided to replace both in one go two weeks ago. I put about a hundred miles on without any problem at all. A slight sputter when idle, but nothing major. Two days after the new ones on, problems began again and even more intense than the last time. I had to pop my zx3 in neutral (it's auto) and rev at stop signs and red lights. Even scarier was the last ride home where the entire car shut off and stalled out mid-turn at an intersection, with all the lights blowing up on my dashboard (check battery, check engine) :)

At any rate, I decided to go all out after the 2 new o2 sensors and replace:
-DPFE sensor
-MAF sensor
-air filter
-EGR valve

I managed to pull off the air-box and all just fine. Also wiped down the throttle body with some cleaner while I was at it. I'm now at a point where I'd like to replace the old rusted EGR valve with a new one.

Having two problems with this:
1.) Can't get the top hose off

and

2.) Can't get the bottom unscrewed.

I'm just the average DIY-er who isn't all that mechnically inclined, trying to save a buck from shop prices (I'm a web-programmer by day, robotics hacker by night). I'd hate to keep tugging on the top hose, and keep trying to spin out the bottom. What's happening is when I'm unscrewing the bottom, the whole EGR valve is spinning with it. This is resulting in it pushing up against the side-mount (see video).

To speed up where I'm stuck, I posted a video on YouTube:

http://youtu.be/A-5ru_7opag

Thank you, and I apologize to any FF veterans I may have offended with my noob naievety :)

Kind regards,
Ryan
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· Registered
2004 Focus Wagon, Zetec DOHC, Auto
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1,722 Posts
It sits directly behind the engine, beneath the throttle on one end. This is where the elbow was cracked. I don't even know what this hose is or what it does. Anyone have any ideas? And could this be related to my idle problems?
It looks like you are describing the rear PCV hose. It is a common failure that occurs right where it connects to the intake. The hose runs from the intake below the throttle body over to a metal tube that goes under the ignition coil. When this hose splits open it can cause severe idle issues.
 

· Registered
2004 Focus Wagon, Zetec DOHC, Auto
Joined
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1,722 Posts
I'm confused, is this the same hose that everyone prescribes replacing ocassionally?

As in the hose here:
http://www.focusfanatics.com/forum/showthread.php?t=190218

And the valve here:
http://www.focushacks.com/mod/PCV_Valve_replacement_(Zetec_engine,_maybe_others)
The hose and PCV valve in those links is a very common failure item. I'm not sure you are showing the PCV hose in your photos. The rear PCV hose on the Zetec is 1/2" I.D. on the end that connects under the ignition coil and 5/8" on the end where it takes the 90 degree turn into the intake below the throttle body. The 90 degree turn is the failure point.
 

· Registered
2004 Focus Wagon, Zetec DOHC, Auto
Joined
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1,722 Posts
You found it...good job!

The P/N is here: http://www.focusfanatics.com/forum/showthread.php?t=28249&pp=15&page=13

The newer design has heat shield wrap around it. I don't know if the shield does any good because it does not cover the 90 degree bend and that is the failure point. Maybe if you install it, the shield could be pulled down to cover the bend.
 
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