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Discussion Starter #1
I have a lil bit of stumbling and I was wondering if it would hurt anything to try it out? or it would hurt performance at all? or it will make things worse.....i was going to try the golf tee trick and just plug it up and leave it at that...(focushacks)
 

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EGR removal will only help the engine, both reliability and performance (smooth operation). I did a complete removal of everything EGR: no sensor and a block off plate to cover the actual valve port; and no CEL, even after three years of driving. The golf tee trick will work too, but does not look as clean.
 

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Discussion Starter #3
lol ok, maybe i'll paint my golf tee black or something.......do I need to do anything else after I put the golf tee in?
 

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[FJ] Special Ed.
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... that is a crude method to get rid of the EGR, but it does work... why dont you just chip it... FocusSport has a program to eliminate the EGR system altogether, I think that would be better than golf-tee`n it.
 

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ya take ur chip to ray and have that egr lite turned off... otherwise ur gunna throw a cel all day long... but if u can live with that then do it... plus i know in pa if that lite is on u wont pass emmisions...

jason
 

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well i might do the egr thing to beings that my cel is dead i think its been 3 weeks with race header and still no cel
 

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Discussion Starter #7
I'm not sure if my cell light is one because of the egr, i'm only doing this because of the stumbling I seem to come across and the stalling that happens twice a day unless the AC is on....I was only going to try to cut off the egr to see if the stumbling goes away and to see if it helps anything out......
 

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Discussion Starter #8
well I went and unplugged the hose going into the egr and plugged it up w/a golf tee lol.......but from that 2 minute job I noticed better idling and no stalling sitting still....not yet at least.....I drove around for like 15 minutes stop and go and it didn't want to shut off at all. is that all there is to it lol? other then my check light coming on? next time I goto mcnews i'll get the egr disabled, but this seems to do the trick for now
 

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Two questions/comments

well I went and unplugged the hose going into the egr and plugged it up w/a golf tee lol.......but from that 2 minute job I noticed better idling and no stalling sitting still....not yet at least.....I drove around for like 15 minutes stop and go and it didn't want to shut off at all. is that all there is to it lol? other then my check light coming on? next time I go to mcnews i'll get the egr disabled, but this seems to do the trick for now


It is simply amazing what a cheap little golf tee will do for the driveability of a Zetec .
Here I was all set to spend several hundred dollars on a 'chip' but because of an appontment
misunderstanding, I accidently stumbled on that tidbit of information, and I too cannot
believe how much better my almost new 2000 Zetec now runs.


Now, how do I get to "Mcnews"?


 

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Re: Two questions/comments

Now, how do I get to "Mcnews"?

Well, let's see...drive east for about three days.


Ray @ McNews rocks, but even he'd tell you it's nuts to drive that far...just go to FocusSport!
 

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Re: Two questions/comments

What hose do you plug up? Do any of you have Pics?
 

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Re: Two questions/comments

What hose do you plug up? Do any of you have Pics?

Tech Notes:
This fix WILL cause your Check Engine Light (CEL) to come on, and this hack is certainly considered messing with your emissions control system. In reality you won't get in any trouble for doing it, and the CEL is annoying but it can be disabled as well (take out your instrument cluster and remove the light bulb for it) Use the IndiGlo Gauge or Indiglo odometer hack to help you in getting that far if you want.
Procedure:

1) Locate the EGR (Exhaust Gas Recirc) Valve. It will be a Circular metal object near the throttle body behind the large air intake tube coming out of the airbox. It will have a Black rubber tube coming out of the top of it, and may resemble a UFO


2) Yank that sucker off! (The Black Rubber tube, that is. Pull The tube off the top of the EGR Valve. To keep this hack from depressurizing all the rest of the things that require vacuum, shove the golf tee into the hose and if you want, clamp it down with a small hose clamp or nylon zip ties.
3) Test it out. See if it works. It may take only a few seconds for your Check engine light to come on. Mine took a few days though.

Why it works?! For some reason, the PCM on a lot of Foci seems to like to modulate the opening and closing of the EGR for emissions purposes. For most people, it is more noticeable in mid range RPM's on level ground, at a constant speed, like going 45 in 3rd gear. The "fluttering" seems to stop when the throttle is wide open (flooring the gas pedal) and that's because the PCM shuts down the Emissions controls under high load, in a similar fashion to how the Air Conditioner compressor shuts down as well.
What this hack does is makes it physically impossible for the system to open the EGR Valve, even if it's trying. It will eventually sense that the EGR is not opening when it commands it to do so, and after repeated errors are recorded, it will be flagged as a "fault" and that's when you get the Check Engine Light.

To clear the CEL, simply unhook the Negative battery Terminal for about half an hour. To completely un-do this mod, reset the CEL as stated above, and place the EGR Vaccuum hose back on the EGR.
If the stumbling stops after doing this, then you likely need a new DPFE sensor, or a chip that disables the EGR system entirely
 

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Re: Two questions/comments

Well, let's see...drive east for about three days.


Ray @ McNews rocks, but even he'd tell you it's nuts to drive that far...just go to FocusSport!


That makes sense but I've tried, and they do not want my business,
so I must find someone that does want it. Know what I mean?

 

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No Pictures, but . .

What hose do you plug up? Do any of you have Pics?


All the modifications you list for your car and you're having a problem with this?

It's so simple. I located that approximately three inch diameter shinny round shaped metal cylinder (pot)
just off the end of the valve cover which has a single black hose running right out of the middle of it.
Remove said black hose and insert a golf tee or other suitable plug into the end of that hose.
A short bolt of the correct diameter and length will do fine.
The idea here is to plug the hose that is using vacuum to open the EGR.

You will be amazed at the differences just doing this simple modification will do for the driveablility of your Zetec.

 

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Re: No Pictures, but . .

off topic, but does anybody know where I can get an egr block off plate???
 

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EGR block-off plate

off topic, but does anybody know where I can get an egr block off plate???


Don't know where you can get one, but it shouldn't be too hard to make one yourself.


 

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[FJ] Special Ed.
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Re: EGR block-off plate

you can always fab one yourself. you could make it out of a really old piece of toast, or the blades of a fan, the door from a computer scanner, or hell even some keys on your keyboard glued together.
 
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