The exhaust gas recirculation (EGR) valve is part of the emission control system in your Ford Focus. It allows exhaust emissions to enter the exhaust manifold under specific driving conditions. It is common for the valve passages to become clogged and the valve stem to become bent. These problems can be repaired, but worn and broken parts make it necessary to replace the valve. Follow these steps to diagnose the valve and get rid of possible blockages.
Park your car in a safe place, start and warm up the engine to operating temperature. Then turn off the engine.
Open the hood and remove the air cleaner assembly to reach the EGR valve. Restart the engine. Be careful when performing these tests, as engine components may be hot.
From the engine compartment, pull the throttle linkage and increase the engine speed briefly to 2000 or 3000. Observe the EGR valve diaphragm stem and make sure it moves when operating the throttle. Shut off the engine. If the stem does not move, go to Step 5.
Disconnect the vacuum line above the EGR valve and lock it using a Phillips screwdriver. Attach a hand vacuum pump to the top of the valve and start the engine. When you apply vacuum to the valve with the hand pump, the engine should stop. This means the valve is working properly. Shut off the engine.
Remove the air cleaner assembly. Disconnect the tubing from under the EGR valve with a wrench, then remove the two valve mounting bolts with a wrench or a wrench and ratchet. Discard the valve gasket and clean the mating surfaces with a wire brush and plastic scraper.
Clean carbon deposits from inside the valve and from the valve passage in the engine mounting base with an awl and wire brush. Do not mark or damage mating surfaces.
Install EGR valve with new gasket. Connect mounting bolts and hand tighten first, then tighten and secure valve to engine with a wrench or ratchet. Repeat Step 3 and make sure the valve stem moves; if it does not, replace the valve. Repeat Step 4. If there is no change in engine operation when you apply vacuum to the valve, replace the valve.
Tips
You can borrow a hand vacuum pump from an auto parts store.