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DO NOT on any account clean the egr tube with solvent when the tube is still connected to the exhaust manifold, the solvent will soak into the cat brick and cause a 'burn thru' when it ignites and give the same damage as dumping raw fuel,as in a mis-fire, onto the cat brick.The result will be the need for a new rear exhaust manifold..sorry but not a good idea.Take it off and do it correctly.

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Originally posted by lkinley:
There's a passage that runs from where the EGR valve and tube attach to the manifold over to the three passages behind the TB. It's along the top of the manifold and you can see it, it is a little raised part.


Lance, it seems that I misunderstood what you were saying. I was looking for a passage on the right side of the TB opening. When you said that the three passages ran along the "top of the manifold", I thought that you were talking about the area where the two black vacuum lines connect.

Originally posted by GeoPappas:
There were three small passages that enter behind the throttle body, but none of them were for the EGR system. There was a passage that came from the bottom of the UIM which seems to come from the evap hose. There were another two passages that came from the top of the UIM that seemed to come from the two black vacuum lines on top of the UIM.


Originally posted by Terry Haines:
The egr passage is 'cast in' to the manifold & exits behind the t/body via the three holes you mention.


Terry, I didn't understand what you were saying either, since I mentioned three other passages (one for the evap and two others for vacuum) than you. And when you said that they were "exits" for the EGR system, you really confused me, since the passages that I was talking about were inputs and not outputs.

Even though there was some confusion on my part, I would just like to thank everyone that helped.

Anyway, I finally figured out where these three EGR passages are. I wouldn't have found them if it weren't for the post at http://www.contour.org/ubbthreads/showflat.php?Cat=&Board=trouble&Number=1302&page=0&view=collapsed&sb=5&o=7&fpart=1

My passages were also totally blocked. You can view a picture of them at http://community.webshots.com/photo/37207779/47528989JLOiXi

It seems that I missed the passages, since I never removed the TB gasket.

I plan on cleaning out the passages next weekend.

Which brings me to my next question:

How can I clean out this passage?

Can I shove a steel clothes hanger into the passage to try and clean it, or is there something else that you recommend?


96 Contour SE Duratec V6 24-valve 2.5L ATX 108,000 mi. Replaced: crankshaft w/ DMD, EGR valve (clogged), EVR, DPFE, PCV valve, evap emissions hose & tube (cracked), window regulator (broken), LH & RH PCV tubes, UIM gasket (leak), ignition coil
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Originally posted by Terry Haines:
DO NOT on any account clean the egr tube with solvent when the tube is still connected to the exhaust manifold .. sorry but not a good idea ...


Agreed, but I can't see a post where someone suggested this; the gunpowder suggestion was just a joke, right?

GeoPappas:
Go back to this thread for excellent pic and cleaning info. Do not use metal object since it can scratch surfaces, plastic preffered.

http://www.contour.org/ubbthreads/showflat.php?Cat=&Board=trouble&Number=1302&page=0&view=collapsed&sb=5&o=7&fpart=2


98 Mystique LS v6 atx 163,000km 97 Contour LX v6 atx 163,000km
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I think you will find Big Jim's post on page one refers to a solvent type clean on the vehicle....

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There is a simple test to check EGR exhaust.
1. Start engine and run on idle.
2. Remove vacuum hose from egr valve.
3. Attach a peice of vaccum hose on to EGR valve.
4. Suck on it (or use a vacuum pump)to open EGR valve.
5. Engine should idle rough.(EGR valve should be closed
on idle or during acceleration).This will prove you are
getting exhaust gases into engine and that passages are
clear.
6. If you suck on the vacuum hose (or vacuum pump gauge
drops )and you can keep sucking air then EGR valve
diaphragm is caput.

The only sure way to test the EGR tube is to use a
manometer and for that you will need to know the specs
from Ford.i.e. what the pressure should be. Anybody know
what they are.You could stick a wire down it (after
removing the egr valve)and measure how far it goes
down. It looks like a [censored] to remove.
It will be measured in inches of water column. Too
technical for some. Also the diff pressure sensor
voltage could be checked.Again you would need to know
the specs.

7. If you have changed the diff pressure sensor I would
definately suspect a blockage somewhere.
Hope this helps

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