Possible Causes:
* Failed EGR Valve: The most likely culprit. A hole suggests it's completely failed and not just sticking. The pressure from the exhaust system has blown a hole through it, indicating significant internal failure. Replace this immediately. Don't just replace the valve itself; consider replacing the gasket as well.
* Blocked or Restricted Exhaust System: A clogged catalytic converter, severely restricted muffler, or other exhaust restriction can build up immense back pressure. This back pressure could have caused the EGR valve to fail catastrophically. You may need to have your exhaust system inspected for blockages.
* Turbocharger Failure (if equipped): If your Escape has a turbocharger, a failure could lead to significant back pressure, potentially damaging the EGR valve. Listen for unusual noises from the turbocharger (whistling, knocking).
* Intake Manifold Problems: Cracks or blockages in the intake manifold can also create back pressure, contributing to EGR valve failure.
* Vacuum Leak: The EGR valve is often controlled by a vacuum system. A significant vacuum leak can cause incorrect operation and potentially lead to damage.
* Engine Problems: While less likely to *directly* cause the hole, a severely damaged engine (e.g., piston ring failure, valve problems) could lead to excessive pressure in the exhaust, ultimately causing the EGR valve to fail.
Troubleshooting Steps:
1. Visual Inspection: Carefully inspect the entire exhaust system from the engine to the tailpipe, looking for any blockages, rust, or damage. Pay close attention to the catalytic converter.
2. Replace the EGR Valve: This is the first thing to do, as a blown valve is the most likely cause.
3. Check for Vacuum Leaks: Inspect vacuum lines for cracks, holes, or loose connections.
4. Back Pressure Test (Professional): A professional mechanic can perform a back pressure test to determine if there's excessive restriction in the exhaust system. This is crucial to identify underlying issues causing the EGR failure.
5. Further Diagnostic Testing (Professional): If the issue persists after replacing the EGR valve and checking the exhaust, a professional mechanic should use diagnostic tools to further assess the engine's health, looking for issues like turbocharger malfunction, intake manifold problems, or other engine-related problems.
Important Note: Driving your Escape with a blown EGR valve is extremely risky. The engine might be running very poorly, or not running at all, but even a small amount of operation could cause further damage. Have the vehicle towed to a mechanic for proper diagnosis and repair. Ignoring the problem could result in significant and expensive engine damage.
