Contour Enthusiasts Group Archives Forums General Troubleshooting How-To: Cleaning EGR passages in UIM (behind TB)

NOTE: This procedure is for a V6 Duratec. I'm not sure if the V4 Zetec is similar.

NOTE: Photos for this procedure are posted at http://community.webshots.com/album/48338095ulxYWh

Tools:

• 1/4" driver and sockets (to remove/install TB)(I believe that I used 7mm, 8mm, and 9mm sockets)
• Screwdriver (to loosen/tighten hose clamps)
• Gasket remover (to remove TB gasket)
• Stanley pick & hook tool set (to clean out small EGR passages)
• Gun cleaning brush (to clean out small EGR passages)(I bought a .243 caliber brush at Walmart)
• Mechanic's wire (to clean out large EGR passage)
• Vacuum cleaner (to vacuum carbon out of EGR passages so that it won't go into engine)
  

Supplies:

• Can of TB (throttle body) cleaner
• Rag (to stuff in UIM)(this protects the UIM from getting carbon inside)
• Roll of tissue paper
  

Parts:

• New TB gasket (Ford part #F5RZ-9E936-A)(Cost: $2.00-7.00)
  

Procedure:

• Remove TB (throttle body) from UIM (upper intake manifold). NOTE: Be careful when removing rubber hoses, since they might be aged and brittle.
• Remove TB gasket (if it didnâ??t come off with the TB). I used a gasket remover (looks sort of like a chisel). Once this is done, you will notice three passages at the bottom of the UIM opening (immediately behind the TB gasket).
• Stuff rag in UIM to protect it from any carbon chunks that might fall in.
• Clean out EGR passages. I used picks & a gun cleaning brush. I put down a large tissue paper underneath the passages to catch most of the debris.
• After the passages are sufficiently clean, you can spray TB cleaner on the passages. You might need to do this a few times. I wiped up most of the dirty TB cleaner with tissue paper.
• I then removed the rag out of the UIM and vacuumed out the UIM, the small EGR passages, and the large EGR passage.
• Put it all back together. NOTE: Remember to use a new TB gasket.
• If you have a P0401, then reset it.
  

Total Time: 1-2 hours. Most of it is spent cleaning the passage.

FYI: You might want to clean the back of the TB at this time, since it is already off.