05 Focus - P0400 and a misfire

Hey all, first post. I love diagnosing stuff, but I’m kinda stumped and could REALLY use the help.

05 Ford Focus ZX4 ST
2.5 Fusion swap - block and head
2.5 dual stage manifold

First fire up after the swap, had a misfire. Compression test 60 psi on cyl 2; Found a blue shop rag paper towel in one of the valves.

Compression test after: 140, 135, 142, 140

Still misfiring, sounds like vac leak. P0400 popped up. EGR insufficient flow. Pulled the EGR and put a block off plate on it just to diag. Tested the ohms between pins on the EGR, and the power  coming in. Everything looked good.

Still had misfire. Pulled the EVAP line off the manifold, capped it off. IT FIXED IT.

So I think I have it narrowed down to a leak in the EVAP system, bad purge valve etc.

If you have any insight or suggestions, I’d love to hear any input. Thanks guys! I have forscan also.

Does the line that you disconnected from the intake trace back to the EVAP purge valve?

 

If so, the valve may be stuck open. Unplug the electrical connector, disconnect both lines and attempt to blow through the valve. If you can, the valve is stuck open.

Ok, so I don’t think that the evap system is the issue now. Yea, that’s what the line I capped off went to.

After more tinkering, I swapped the MAP sensor, and that took care of all of the misfires. I think…

But, I still have what sounds like a vac leak when hot.
Hooked the EVAP system line back up, I can’t blow through EVAP purge valve when it’s off the car.

Put an EGR block off plate (temporary, still gotta pass inspection), no more idle surge. Reinstalled EGR, idle surge came back when hot.
Disconnected it, idle surge stopped.

Bad EGR? Ordered another, trying a new one today.

Just replaced EGR, still misfiring. Ugh

Could REALLY use some help