Cat Converter

[mightymoose_22]

OK... So I ordered a new catalytic converter for a 94 Escort 1.9.
This new aftermarket cat shows up and is a proper fit... but it came with an EGR port on the outlet end of the converter.
On this car the EGR already connects to the exhaust manifold.
I am no emissions expert, so my question is this- would it be any better to make a modification and reroute the EGR to connect after the cat, or should I just plug the new EGR port and leave it all connected as is to the manifold?
I don't know that there would be any noticeable benefit to making the change.

[denisond3]

Last month I towed home an early 91 LX 1.9L, and knowing that my 92 LX did NOT have an EGR valve or tubing at all - I was surprised to find the 91 did. It ran from the back of the intake manifold, (same location as our 94 LX has its EGR valve), vertically downward to plug into the downstream end of the catylitic converter. So I imagine the converter you got is merely made to eliminate stocking another variant of the Escort cat. converter.
The way the EGR system is constructed on our 94 makes it easier to work on than it does on the 91. With the EGR tube fitting on the downstream end of the cat.conv, its harder to get a wrench on the flare nut to loosen it. In fact, the metal tube had been cut in the middle and (poorly) welded back together. With that EGR fitting on the front of the exhaust manifold, its much easier to reach, and to heat it with the acetylene torch if need be.
I cant imagine Ford would have used a setup that was less effective for the later cars, so the way the 94 does it is probably better, if only for maintenance actions on the EGR system.

[mightymoose_22]

Cool, thanks.
I figured I would just let it be and plug up the EGR outlet on the new cat. I was just unsure if there was any benefit to changing it. In fact, I have never seen an Escort with the EGR connected that way...

Now I just have to find something big enough to plug it with... its a pretty big hole!

[denisond3]

I think its a standard thread for whatever it is - like a tubing fitting for a 5/8" tube, or whatever the tube diameter is. Its not a pipe thread. If you own an acetylene torch its a simple matter to braze or silver solder a plug for that EGR tube bung'.

That '91' Escort was made in 10/90, & came with the square toothed timing belt. They switched to the round tooth belts after March 91 apparently. I am changing the pulleys to all be the round toothed kind, as I think the round tooth belts seem a stronger design.

[mightymoose_22]

I had to hunt for it but found a 22x1.5 that fit... or was it a 20mm... I forgot already... most places had nothing bigger than 16.

[denisond3]

Thanks for the info. I'll keep looking for a bolt thread that size too - just in case.

[mightymoose_22]

Well as I had said, the only reason I needed it was because the aftermarket converter came with an EGR port that I did not need since my EGR connects to the exhaust manifold. Apparently some models connect to the cart though... it would have been convenient if the company had supplied the plug since they had already welded on the bung.
I got the plug I needed from Fastenal.