How to Fix the EGR Valve on My 2001 Ford Expedition if the Engine Light Is On

The 2001 Ford Expedition came with a 4.6-liter V-8 or a 5.4-liter V-8 engine. The exhaust gas recirculation valve, on either engine, is responsible for the induction of a small amount of exhaust gas into the intake manifold for the purpose of lowering emissions. The EGR valve is located on the left side of the engine and can be easily accessed from the top side of the vehicle.

Instructions

4.6-Liter EGR Valve Replacement

1

Park the vehicle on a level surface and set the parking brake. Open the Expedition's hood. Allow the engine to cool completely before continuing.

2

Remove the three bolts for the engine cover with the socket and ratchet. Remove the engine cover and set it aside. Find the EGR valve; it is on the driver side of the engine directly above the crankcase ventilation elbow that is connected to the valve cover.

3

Disconnect the vacuum line that is connected to the top of the EGR valve. Remove the brake booster tube bracket nut with the socket and ratchet. Push the bracket away from the EGR valve. Loosen the fitting nut for the EGR tube with the box-end wrench. Disconnect the EGR tube from the EGR valve.

4

Remove both of the EGR valve mounting bolts with the socket and ratchet. Remove the EGR valve from the engine bay and discard it. Clean the EGR valve mating surface with the wire brush; make sure there is no leftover gasket material.

5

Slide the EGR valve bolts through the mounting holes on the new EGR valve. Place the EGR valve gasket over the EGR valve bolts and hold the gasket to the EGR valve. Set the EGR valve into position and tighten the bolts hand tight. Tighten the EGR valve-mounting bolts to 15 foot-pounds with the torque wrench, and then tighten an additional quarter turn.

6

Install the EGR valve tube to the EGR valve and tighten the fitting nut hand tight. Tighten the EGR valve tube fitting nut to 26 to 33 foot-pounds with the torque wrench and crowfoot attachment.

7

Position the brake booster bracket onto the EGR valve stud. Install the retaining nut and tighten it to 8 foot-pounds with the torque wrench. Connect the vacuum line to its fitting on the top of the EGR valve. Install the engine cover and tighten the mounting bolts 89 inch-pounds with the inch-pounds torque wrench

5.4-Liter EGR Valve Replacement

8

Park the vehicle on a level surface and set the parking brake. Open the vehicle's hood. Allow the engine to cool completely before continuing.

9

Loosen the clamps for the air intake tube with the socket and ratchet. Remove the air intake tube from the air cleaner and throttle body. Position the air cleaner tube aside.

10

Locate the EGR valve; it is on the drive side of the engine, close to the firewall. Disconnect the vacuum line that connects to the top of the EGR valve. Loosen the EGR valve tube with the box-end wrench. Disconnect the EGR valve tube from the EGR valve.

11

Remove the EGR valve-mounting bolts with the socket and ratchet. Remove the EGR valve from the engine and discard. Clean the EGR valve-mating surface with the wire brush.

12

Put the bolts through the EGR valve mounting holes. Place the new EGR valve gasket over the bolts and hold the gasket to the EGR valve. Set the EGR valve into position and hand tighten the mounting bolts. Tighten the mounting bolts to 15 foot-pounds with the torque wrench. Tighten the EGR valve bolts an additional half turn.

13

Connect the EGR valve tube to the EGR valve and tighten the fitting nut hand tight. Tighten the tube fitting nut to 30 to 44 foot-pounds with the torque wrench and crowfoot attachment. Install the vacuum line to the top of the EGR valve.

14

Install the air intake tube to the throttle body and air cleaner housing. Tighten the air intake tube clamps with the socket and ratchet.