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how do you clean the egr ports?

 

Was reading this thread and it was suggested that the EGR ports could be blocked. How exactly does one go about checking this and cleaning the ports out?

Thanks in advance.

Tim

 

Wow what a old thread. You apply vacuum to the EGR valve with the engine idling. If it stalls out, the ports are open and everything is good. If it starts misfiring, all the ports except one or two are clogged. The upper intake manifold has to come off to clean the ports out. Blow compressed air through each port to get all the carbon out.

 

Yeah and it seemed like it took me 4 years to just read through it as well ...
I am currently working on a 2001 with a 4.2 ... re occuring P0303 .... I don't think I am dealing with and air / fuel issue though ... I believe this to be ignition related ... I have checked the plug and the wire .... I have no spark coming out of the #3 tower of the coil ... I don't want to condemn the coil just yet as I know it gets it's signal from another source telling it to fire .... Just not sure where to go from here and how to do it ..... I'm not trying to hijack the thread so I believe I have already posted a new thread stating same info .... Any help would be greatly appreciated ....
Thanks,
The Doberdewd ...

 

So how would you go about applying vacuum to the EGR. Sounds like this could be my problem

 

I am a Master Tech. and I do alot of repairs on Ford trucks. The test above is correct. After you have done the test and the results come back that the EGR system is cloged you will need to get a Plenum Gasket Felpro # MS95981 And about 4-5 large cans of Carb kleener. Now for the repair prosess >>> Drain the cooling system, remove the airfilter ram system, disconect all electrical wires that go to the plenum, remove the throttle cable & remove the bracket, Disconect all the vacume lines > Make a note as to where the all go < Remove the coilpack from the top of the Plenum, Now it's time to unbolt the Plenum their should be 13 bolts that hold it to the intake. Look around the Plenum and see if their are and brackets attached to it and unbolt them. Remove the Plenum and set aside after turning it upside down and looking inside the ports you should have alot of buildup in the two center ports. >>>> The whole inside of the plenum will need to be cleaned get all the junk out of it <<<< Now look at the ports in the intake manifold they also have alot of build up they to must be cleaned. Their are little butterfly valves in 6 of the ports that need to cleaned to so make sure you clean them to. >>>> I find that GUMOUT Carb Kleaner works the best <<<< Now that u have the Plenum kleened ant the intake kleened u can put it all back togeather. >>>>> Before you try to start it up <<<<< PULL ALL THE SPARKPLUGS OUT AND CRANK THE ENGINE OVER >>>> PUT RAGS OVER THE PLUG HOLES AND THAN CRANK IT OVER THE KLEENER WILL COME OUT AND WILL BURN YOU. Now Kleen the plugs and set the gap 52-56 and put them back in the engine. >>>> YOU WILL NEED TO CHANGE THE ENGINE OIL <<<< Now that you have done all of this its time to start the engine up ........... HOLD YOUR THE PEDDLE TO THE FLOOR AND CRANK IT OVER TILL IT STARTS >>>>>> It will blow out all the rest of the kleener keep the throttle revening it up and down till it runs smooth. Now take it out on the road and run it on the road for about 20-30 miles. CODE P0303 is now fixed

 

Well, how's that for a first post on FTE!?

Thanks! and glad to have you join in.

 

Hmmm... all I do is take the upper intake off and blow out each of the ports with compressed air. Sometimes I have to take a pick and dislodge some of the crud. Seems to work well for me.

 

I have an '02 F150 5.4 with 230K on it.

It's been intermittently misfiring over the past week or so.

New COP @ cyl 3 this week. Problem solved!!!
...for about 2 days.

Checked codes last night...getting the following:

PO303 cyl 3 misfire (this is the one that was just replaced 4 days ago)
PO136 O2 sensor error code
PO141 O2 sensor error code

• Would an O2 sensor issue cause an intermittent misfire at one specific cylinder?
• Is it likely that the new COP is defective?
• Has anyone else experienced anything similar?

Any help is greatly appreciated.

Also, I should note that I reset codes last night and got SES light this morning with these three codes again.

 

08/03/2010 UPDATE:

• Swapped COPs and plugs from cyl #3 and another cylinder...still get PO303 error code, thus ruling out bad COP and/or bad plug.
• Checked compression @ cyl #3 and got 165psi max with 164psi sustained. Compression good, thus ruling out a ring failure or valve stuck open. (Although it could possibly be an exhaust valve stuck closed. However, I find this to be unlikely given the fact that this problem is seemingly intermittent.)
• checked O2 sensors, found bank 1/sensor 2 was disconnected. reconnected, error codes PO136 and PO141 now cleared.

I am puzzled...

C'mon all you Ford Master Techs out there, please help me out.

Thanks!!!

 

The code P0303 is a misfire in a cylinder pos. #3 Your EGR system is clogging. Do This Find the EGR Valve and pull the vacum hose off and put a hand vacume pump on it Engine running apply vacume to it and if the engine starts stumbling it is cloged up if the engine stalls its ok. If the system is clogged you will need to do a system kleening. See my last post of how to do it.

 

NJ he said he has a 5.4, clogged EGR won't cause a misfire on v8s. Black you should really start a new thread in the correct section. But while I'm here you either have a bad fuel injector or a broken wire in the COP connector. Being that you said the problem was intermittent I doubt its the injector. Wiggle the connector while the engine is running to try to duplicate a bad connection.

 

Thanks to everyone who posted up. My E150 4.2L v6 (2000) threw a code at 51k (misfire #6) and I did some checking. Before I started replacing anything I discovered the EGR problems. Pulled the EGR vacumn line and put vacumn on it, the motor stumbled. Yesterday I pulled the plenum (thanks particularly to Dusty) and cleaned the manifold ports. #6 was clean, as expected, the others fouled. I was able to pick out the junk with a dental pick and then blew the ports clean. Lots of carb cleaner on the plenum and put it all back together. The code cleared and the stumble is gone. And I did not spend a month trying other things.

Also discovered a couple of hoses deteriorating and replaced them.

I did not drain the cooling system, just plugged the two small hoses when I pulled them.

 

1999 E250
4.2l
160,000 miles
Intermittent Check Engine light, P0303 code


FTE comes through for me again!

After performing the vacuum test I pulled the upper intake and found all but the port for #3 fully blocked. I went for the quick fix and just used air. It did the trick.

By the way, when I did the vacuum test the engine did not noticeably respond - it just kept on idling nicely.

Thanks very much for the posts, especially Dusty and Longbed.

Red