Contour Enthusiasts Group Archives Forums General Troubleshooting Anyone replaced EGR tube on 2.5L engine???

Has anyone replaced the tube/pipe that connects the exhaust manifold and the EGR valve on the 2.5L engine?

If so, how did you do it? Did you go from the top of the engine or below? If from above, how did you loosen the pipe from the exhaust manifold? If from below, did you jack the car up on one side or both?

How long did it take?

Also, did you replace it because it was clogged up?

I already know how to remove the pipe from the EGR valve (the top side), but don't have any experience on removing the pipe from the exhaust manifold (the bottom side).

Any and all help is appreciated.

Why are you suspecting the tube?

What usually plugs up is the passages in the upper manifold, right behind the throttle body.

-Lance

George
You're not still chasing that P 0420???

Paul

Originally posted by lkinley:

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Why are you suspecting the tube?

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I have an elusive P0401 (insufficient EGR flow). So far, I have replaced:

- EGR valve
- EVR (EGR vacuum regulator)
- DPFE (differential pressure feedback EGR).

I took apart the throttle body yesterday (see below), and have also checked most of the plastic/rubber vacuum hoses and they all seem fine.

I don't see much left. I'm trying to assess what to do next.

I ran Vehicle Explorer on the car yesterday. I started the engine, and then slowly raised the RPM to 3000 (while in Park), in increments of 500. The EGRVR reading went up to 90%, but the DPFE reading did not go above .8 volts.

This tells me that the EGR valve is being commanded open, but there is still no flow through the EGR tube. I can only think that there is either a leak somewhere (which I haven't found), or there is something impeding EGR flow.

Originally posted by lkinley:

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What usually plugs up is the passages in the upper manifold, right behind the throttle body.

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I took the TB (throttle body) off yesterday and looked behind it (into the UIM (upper intake manifold). I did not see much buildup and did not see any "EGR passage" that people talk about.

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. All of theses passages looked fine and were not clogged up.

I stuck my fingers into the UIM and felt around and could not find any "EGR passage". I even stuck a mechanics mirror into the UIM to see if I could find the elusive "EGR passage", to no avail.

Originally posted by F111D F:

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You're not still chasing that P0420??

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Actually, it's a P0401 (insufficient EGR flow), but I have been chasing it down for quite a while.

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. That can plug up, too. I seriously doubt the tube from the exhaust manifold would ever plug.

-Lance

With respect George & Lance the egr casting does go wher I discribed it,if you dont beleve me take off the EGR valve and push some wire down it and see where it comes out,sorry Lance but the EGR venturi has been known to block off...

Originally posted by Terry Haines:

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...the egr casting does go where I discribed it, if you dont beleve me take off the EGR valve and push some wire down it and see where it comes out

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Terry, I agree that the EGR valve is connected to the UIM. I also agree that the UIM has a passage where the EGR valve connects to it. But I could not see any part of this passage behind the TB. I was expecting to take the TB off and see a small passage (in the UIM) that went all the way to the EGR valve.

There have been a few posts that describe a passage behind the TB, and how it can be cleaned from behind the TB. All I'm saying is I didn't see any passage on the side of the TB that is closest to the EGR valve. All I saw was a passage on the bottom and two on the top, which don't have anything to do with the EGR system.

Anyway, I'm still trying to determine what is the next thing that I should do to fix the P0401 problem that I am having...

Before jacking up the car George, have you tried disconnecting the tube from the EGR valve and firing
up the motor and see if any flow eminates?
Paul
The manual says remove Idle air valve and raise up the vehicle (Lift would be easier) to remove
the lower egr nut on the tubes lower end.
Need to devise way to safety use black gun powder to clean the passages. Save all that tear down time!
Yes this EGR system for pollution control is a real pain

sorry ole habit from the 60's "call in air strike on my position"

I agree that you should be able to disconnect the upper end of the pipe and see if it is clear. You may need to remove the EGR valve.

There is a way of cleaning those passages withough taking everything apart. There is a cleaning tool that runs a cleaning solvent (it smells a little bit like diesel fuel, but not quite) through the passages. The EGR valve is removed for the proceedure, but nothing else needs to be removed. It really cleans things up very well. The one I am familiar with is made by MOC. I have seen it used on a variety of engines, but I have not observed it on a Duratec. It has worked well on everything else, so I'm sure that it would work on one of them too.

See my post here:

http://www.contour.org/ubbthreads/showflat.php?Cat=&Board=trouble&Number=1302&page=0&view=collapsed&sb=5&o=7&fpart=2&vc=1

My suggestion; do not remove tube, check from above first (EGR removed) and/or check exhaust pressure from hose above venturi (Caution: HOT) that goes to DPFE.