How to remove EGR tube from exaust manifold

Heat the pipe up with a oxy-acedelene torch get it glowing red and unspin it

Hi thanks for your question' The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head ,

1. Remove electrical connector (5) at top of EGR valve solenoid.
2. Remove tube mounting bolt (1) at intake manifold.

1. Remove two bolts (4) connecting EGR tube (1) to valve assembly.
2. Remove gasket located between EGR tube flange and EGR valve assembly.
3. Remove two EGR valve mounting bolts (5).
4. Separate valve assembly (3) from engine.
5. Remove and discard metal gasket located between cylinder head and valve assembly.

INSTALLATION

1. Clean area at rear of left cylinder head where it joins base of EGR valve.
2. Clean EGR tube where it joins EGR valve.
3. Position new gasket between EGR valve and cylinder head.
4. Position EGR valve to cylinder head. Install and tighten two bolts (5). Refer to Torque Specifications.
5. Position new gasket between EGR tube flange and EGR valve assembly.
6. Position EGR tube (1) to side of EGR valve and into intake manifold.
   1. Install EGR tube flange bolt (1) at intake manifold. Tighten bolt. Refer to Torque Specifications.
   2. Connect electrical connector (5) to top of EGR valve solenoid (2).Do a final tightening of two EGR tube bolts (4). Refer to Torque Specifications

Oil Pan - REMOVAL & INSTALLATION

4.6L Engine
If your vehicle is equipped with air conditioning, refer to General Informatcion and Maintenance for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

1. Have the A/C system recovered by a MVAC-trained, EPA-certified, automotive technician.
2. Disconnect the battery cables, negative cable first, and remove the air inlet tube.
3. Relieve the fuel system pressure and disconnect the fuel lines; Drain the cooling system and remove the cooling fan and shroud.

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Remove the upper radiator hose. Remove the wiper module and support bracket.
2. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
3. Remove the engine harness connector from the retaining bracket on the brake vacuum booster and detach the connector and transmission harness connector.
4. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
5. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
6. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
7. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
8. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
9. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
10. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
11. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1 / 2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
12. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.
    

It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.

1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.

See Figures 1, 2 and 3

Fig. 1: Position of wood blocks under the engine mounts-4.6L engine

Fig. 2: Oil pump pickup tube-4.6L engine

Fig. 3: Oil pan bolt torque sequence-4.6L engine

To install:

1. Clean the oil pan and inspect for damage. Clean the sealing surfaces of the front cover and engine block. Clean and inspect the oil pickup tube and replace the O-ring.
2. If removed, position the oil pickup tube on the oil pump and hand start the 2 bolts. Install the bolt retaining the pickup tube to the main bearing stud spacer hand tight.
3. Tighten the pickup tube-to-oil pump bolts to 6-9 ft. lbs. (8-12 Nm), then tighten the pickup tube-to-main bearing stud spacer bolt to 15-22 ft. lbs. (20-30 Nm).
4. Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and rear seal retainer meets the cylinder block. Position the oil pan on the engine and install the bolts. Tighten the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
5. Position the jack and wood block under the oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack.
6. Install the engine mount through bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
7. Position the EGR valve and tube assembly in the vehicle and connect to the exhaust manifold. Tighten the line nut to 26-33 ft. lbs. (35-45 Nm).

Loosen the line nut at the EGR valve prior to installing the assembly into the vehicle. This will allow enough movement to align the EGR valve retaining bolts.

1. Cut the wire and position the exhaust system to the manifolds. Install the 4 nuts and tighten to 20-30 ft. lbs. (27-41 Nm). Make sure the exhaust system clears the crossmember. Adjust as necessary.
2. Install a new oil filter and lower the vehicle.
3. Install the bolt retaining the right engine mount to the lower engine bracket. Tighten to 15-22 ft. lbs. (20-30 Nm).
4. Install a new gasket on the EGR valve and position on the intake manifold. Install the 2 bolts retaining the EGR valve to the intake manifold and tighten to 15-22 ft. lbs. (20-30 Nm). Tighten the EGR tube line nut at the EGR valve to 26-33 ft. lbs. (35-45 Nm). Connect the vacuum hoses to the EGR valve and tube.
5. Install the blower motor resistor. Position the heater outlet hose, install the upper stud and tighten the upper and lower bolts to 15-22 ft. lbs. (20-30 Nm). Install the ground ******** the stud and tighten to 15-22 ft. lbs. (20-30 Nm).
6. Connect the heater outlet hose and the throttle valve cable. If necessary, adjust the throttle valve cable.
7. Attach the engine connector and transmission harness connector. Install the harness connector on the brake vacuum booster.
8. Connect the air conditioning compressor outlet hose to the compressor and install the bolt retaining the hose to the right coil bracket.
9. Install the upper radiator hose and connect the fuel lines. Install the wiper module and retaining bracket.
10. Install the cooling fan and shroud and fill the cooling system. Fill the crankcase with the proper type and quantity of engine oil.
11. Connect the negative battery cable and install the air inlet tube. Start the engine and check for leaks.
12. Have a MVAC-trained, EPA-certified, automotive technician evacuate and recharge the air conditioning system.

Hope this helps (remember to rate this helps).

1. Remove the upper radiator hose. Remove the wiper module and support bracket.

1. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
2. Remove the engine harness connector from the retaining bracket on the brake vacuum booster and detach the connector and transmission harness connector.
3. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
4. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
5. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
6. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
7. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
8. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
9. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
10. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1 / 2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
11. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.

It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.

1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.

Fig. 3: Oil pan bolt torque sequence-4.6L engine (click over pic fo zoom).


Hpe helps (remember to rate this).

Fig. 11: EGR valve and component mounting-3.0L engine




Fig. 12: EGR valve and component mounting-3.8L engine

Removal:

1. Disconnect the negative battery cable.
2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
3. Label and detach all vacuum hoses from the EGR valve.
4. Label and detach any electrical wiring harness connectors from the EGR valve.
5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-159 inch lbs. (12-18 Nm) on 5.0L engines.
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
3. Connect all wiring or hoses to the EGR valve.
4. Install the air inlet tube.
5. Connect the negative battery cable.

Hope this helps (remember comment and rated this).

EGR Valve Testing

1. Install a tachometer on the engine, following the manufacturer's instructions.
2. Detach the engine wiring harness connector from the Idle Air Control (IAC) solenoid.
3. Disconnect and plug the vacuum supply hose from the EGR valve.
4. Start the engine, then apply the parking brake, block the rear wheels and position the transmission in Neutral.
5. Observe and note the idle speed.
   

If the engine will not idle with the IAC solenoid disconnected, provide an air bypass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak. Do not allow the idle speed to exceed typical idle rpm.
Using a hand-held vacuum pump, slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve nipple.

1. If the idle speed drops more than 100 rpm with the vacuum applied and returns to normal after the vacuum is removed, the EGR valve is OK.
2. If the idle speed does not drop more than 100 rpm with the vacuum applied and return to normal after the vacuum is removed, inspect the EGR valve for a blockage; clean it if a blockage is found. Replace the EGR valve if no blockage is found, or if cleaning the valve does not remedy the malfunction.

EGR Valve Removal & Install
3.0L OHV (2 valve) and 3.4L SHO engines



Fig. : EGR mounting-3.0L OHV (2 valve) engine



Fig. : EGR mounting-3.4L (SHO) engine



Fig. : Remove the two retaining bolts and...



Fig.: ... remove the valve from the intake manifold



Fig.: Thoroughly clean the mating surfaces of the manifold and the EGR valve (if being reused)

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Using a 22mm wrench or crowfoot, disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 26-47 ft. lbs. (35-65 Nm).
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

3.0L OHC (4 valve)



Fig. : EGR mounting-3.0L OHC (4 valve) engine

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Remove the two EGR tube-to-EGR valve retaining nuts.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-EGR tube, then tighten the retaining nuts.
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

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Jack up the passengers side of the car, get a 1 1/16" wrench break loose the fitting to the manifold, hold a 24 mm wrench on the fitting to the manifold, loosen the flare nut on the tube. Then using a 10 mm socket, about 2 inches long, loosen the two nuts under the EGR valve, then take the both out, remove the vacuum hose to the top of the EGR valve, and the sensing line from the small tube. then completely remove the flare nut from the orifice fitting on the manifold. BE CAREFUL with the tube, do not bend it or break it, you may find PB blaster useful the night before on a cold engine loosen these fittings. Once the EGR valve is out, remove the orifice out of the manifold, remove the tube from the EGR valve, again be careful, mark the tube to EGR position before pulling this off, because the top fitting to EGR needs tightened before you put it back in, it will make the lower fitting difficult if you do not line it up right, dry fitting from under the car is helpful, mark it, and then tighten the top. Clean out the tube, be careful not to bend the little tube, either inside or outside the larger tube, it sticks out inside. Clean the orifice, clean the manifold face carefully not to score it, check for blockage there too. Apply anti-seize to the orifice, put it back in the manifold, then apply anti-seize to the bolts for the EGR valve, and the flare nuts both ends. Apply some silicon to the EGR valve face, just enough to hold the gasket in place, put the new gasket on, start the bolts two turns in the gasket, it will hold them in place, then start them in the manifold, then start the lower flare fitting to orifice, tighten the top bolts, and then the flare nut, connect the vacuum line, connect the sensing line. I just recently did this process, it works, if have other EGR issues, the valve is the easiest.

on the explorer the tube running to the egr valve should have two rubber hoses running off it going to the dpfe sensor, (the exhaust pressure sensor),try looking there and if it is not there mesg me back and i will be sure to find it for you.

The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head ,

1. Remove electrical connector (5) at top of EGR valve solenoid.
2. Remove tube mounting bolt (1) at intake manifold.

1. Remove two bolts (4) connecting EGR tube (1) to valve assembly.
2. Remove gasket located between EGR tube flange and EGR valve assembly.
3. Remove two EGR valve mounting bolts (5).
4. Separate valve assembly (3) from engine.
5. Remove and discard metal gasket located between cylinder head and valve assembly.

INSTALLATION

1. Clean area at rear of left cylinder head where it joins base of EGR valve.
2. Clean EGR tube where it joins EGR valve.
3. Position new gasket between EGR valve and cylinder head.
4. Position EGR valve to cylinder head. Install and tighten two bolts (5). Refer to Torque Specifications.
5. Position new gasket between EGR tube flange and EGR valve assembly.
6. Position EGR tube (1) to side of EGR valve and into intake manifold.
   1. Install EGR tube flange bolt (1) at intake manifold. Tighten bolt. Refer to Torque Specifications.
   2. Connect electrical connector (5) to top of EGR valve solenoid (2).Do a final tightening of two EGR tube bolts (4). Refer to Torque Specifications

the egr is located on the exaust side of the engine closest to the fire wall it will have a tube that is intergrated to the valve itself there will be a plug to it as well. the one tub will go to the intake manifold then to egr valve and there will be a tube to the exaust manifold the valve will be round in shape.. please rate this