ive heard this is quite a simple mod that can release a few hp, n bin told about blocking the piping from the solenoid so that the gases dont get re-circulated.

any help or guides would be much appreciative

Thanks

Gaz

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TAY

the bungs are available from ford..as to what they are originally intended for i dont know..i think they are meant as gearbox level bungs, but as i say i cant remember. bung the holes in the manifold, and remove the pipe to the solenoid and go from there. i think theres a pipe tyo bung up from the inlet manifold to stop it pulling in excess air. sorry i cant be more help i kind of put alot of std bits in the bin...this being one of them. theres no provision for it on any of the new bits

hope thats shed some light on it

Jam

i presume its like an si's system if so here's a guide

viewtopic.php?f=16&t=7664

thanks guys, it does make it easier, gona have a closer look at mine to make sure its all the same n see wots wot before ripping bits off lol

anymore ideas or guides welcome

thanks

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TAY

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Some people are like slinkies. Not really good for anything, but bring a smile to your face when pushed down the stairs!

From the moment I picked up your book until I laid it down, I was convulsed with laughter. Some day I intend reading it.

waste of time dont bother mate

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rs2k powerd escort mk4.....figured id be different!
http://WWW.S2RS.CO.UK

_________________
Daily isn't so Special. And it makes me sad.
Need space and time and I'll crack on with Jams si!

Catch me on Facebook as I'm rarely on here.

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Some people are like slinkies. Not really good for anything, but bring a smile to your face when pushed down the stairs!

From the moment I picked up your book until I laid it down, I was convulsed with laughter. Some day I intend reading it.

ok please correct me if im missing something here but the "egr" fitted to the zetec is not actually an egr system, people just call it that when really its not a true egr system. its meerly putting "fresh" air down into the exhaust system to increase the volume of exhaust gas in the system thus lowering the % of harmfull gases coming out of the tailpipe compared to when the system is not on. ive driven cars with it unplugged and then plugged back in with making no difference so i cant see how this will make any difference if its broken or not wheras an actuall EGR valve recirculates exhaust gase back through the inlet system when the vehicle is not under load i.e. cruising on motorway. this will effect the engine if broken but only if the valve is stuck open, alowing exhaust gas into the inlet system when not cruising or during WOT.
if the si has a genuine EGR valve system then why did mine not have it and why did my 130 spec zetec not have one, and why did the rs2000 engine not have one, they all just had the air injection system into the exhaust manifold???
the newer ford i.e. focus im assuming have a genuine egr system, just as i change them on range rover sports and disco 3s regularly and these engines were made by ford/landrover

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rs2k powerd escort mk4.....figured id be different!
http://WWW.S2RS.CO.UK

Not sure if they are a true EGR, not fussed
But the ones on the zetecs are meant to work at a certain time, off idle or something or other
When they are faulty they will run when not supposed to, thus making the zetec run like a bag of nails, killing idle etc

Yes they make no noticeable difference when left on or taken off the engine, but I'd prefer to get rid of it altogether to save any problems if it does go tits up, and also to free up engine bay space in the already cramped fiesta engine bay

My RS1800 engine had an EGR from factory. Yours must have had it removed previously.

_________________
Daily isn't so Special. And it makes me sad.
Need space and time and I'll crack on with Jams si!

Catch me on Facebook as I'm rarely on here.

with it removed its a piece of piss to get to the CPS, with it on its a fooking wh0re bag

you have to have a hand and fingers like a mong! doing becks' CPS was a bitch!

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Some people are like slinkies. Not really good for anything, but bring a smile to your face when pushed down the stairs!

From the moment I picked up your book until I laid it down, I was convulsed with laughter. Some day I intend reading it.

ok so where is this EGR system that is supposedly on the zetecs, if its not the air injection into the manifold then where is it, cz ill be dammed if ive seen one on a silver top zetec!
the reason i said about the emissions is because that is what i was told by one of our master techs who was previously a master tech at ford when the rs1800 fiesta was available, warming up of the cats will also effect emissions so im thinking its most likely both rather than to be just to warm up the cats as the percentage of harmfull gases will be lowerd if the amount of exhaust passing through the system is increased. however the rs2000 owners club website contradicts this saying like you said it is meerly to aid in heating up the cats so i shall be querying him again about this tomorrow.
i know egr valves are designed to lower the combustion temperature but what people are refering to on here is not an egr system, it is a pulsed air injection system into the manifold so it makes it irrelevant to the discussion surely?
the system in which people are refering to as EGR is this system marked 2 correct? (this is an rs2000 manifold but just imagine a zetec cast manifold rather than a tubed 4 branch)

if this is the case this is NOT an EGR system.
Dirtect quote from rs2000-16v.com
Exhaust Air Pulse System removal

Guide by Gavin Dent

The exhaust manifold on the rs2000 16v escorts is well known for being restrictive. The reasons for this are partly to do with the construction method of it and also due to the air pulse System (APS). This system is also incorrectly known as the EGR (exhaust gas recycling) system, which it is not, that is a completely different type of system.

The APS's job is solely to speed up the heating of the Catalyst in order for it to work efficiently, that's all.

This system is only used on the warm up cycle and it does not affect the emissions come MOT time as this reading should be done when the car is at working temperature. Due to this fact many rs2k owners remove this system. First you need to remove the manifold.

We will start with the APS and below is a diagram and a list of parts:

1) Manifold

2) Pulse air tubes

3) Pulse air valves

4) Air control system

5) Pulse air filter

6) Lambda/hego sensors x2.

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rs2k powerd escort mk4.....figured id be different!
http://WWW.S2RS.CO.UK

Getting a little too technically for what I care

Ive just commented on why I removed the EGR system on my zetec. Ford call it EGR so in my eyes, its an EGR

_________________
Daily isn't so Special. And it makes me sad.
Need space and time and I'll crack on with Jams si!

Catch me on Facebook as I'm rarely on here.

sorry i got a bit of a issue, if i think something is something and im then told its not i HAVE to find out which is true, its not a matter of who is right who is wrong its a matter of knowing the correct answer to me, cant be in the motortrade and learn something thats wrong as it has knock on effects on advice i then give to customers and work that i do on their cars, ok i dont work on fords but a lot of out of hours work is done on fords so i kinda need to know which is right!
anyways spoke to him again today and he says offically the air injection system is there to warm up the cats but unofficially it is meant to show lower emissions, the car will pass fine without but supposedly it was some experimental thing they were trying for several years to put to use if they couldnt lower emissions any other way, its all a bit shady so it could be true but then it couldnt but seeing as hes not with ford and hasnt been for a while ill never know

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rs2k powerd escort mk4.....figured id be different!
http://WWW.S2RS.CO.UK