OK, if you replaced the EGR hose, did you go all the way to change the EGR Valve? A stuck open EGR Valve can cause a rough idle and almost make it cut off.
Also, a vacuum leak on the EGR valve can cause a rough idle.
Exhaust Gas Recirculation (EGR) Valve
Removal & Installation
2.0L Zetec Engine
NOTE: When the EGR tube is disconnected from the EGR valve, it must be discarded and a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged.
To Remove:
- Disconnect the negative battery cable.
- Remove and discard the exhaust manifold-to-EGR tube. Use the following as a guide:
- Raise and safely support the vehicle
- Remove the splash shield
- Disconnect the EGR tube fitting
- Lower the vehicle
- Remove the air cleaner outlet pipe
- Disconnect the EGR tube from the EGR valve.
- Detach the vacuum line and remove the two retainer bolts.
NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:
- Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.
- Install a new EGR valve tube.
Detach the vacuum line (#1) and unbolt the EGR valve - 2.0L
3.0L (4v) Engine
To Remove:
- Disconnect the vacuum line.
- Disconnect the EGR tube.
- Remove the EGR valve and discard the gasket.
NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:
- Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.
Detach the vacuum line (#1), unthread the EGR tube (#2) and remove the EGR valve bolts (#3) - 3.0L (4V)
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