Does anyone know where I can find the instructions for replacing the EGR
valve in a 96 Explorer V8? None of the typical manuals (Chiltons,
Haynes) cover the V8 in enough detail for this to be included.
manual. On page 6-26 is a pretty detailed procedure for R&R of the valve.
You only need to remove 2 bolts, a vacuum hose and the pipe retaining nut.
You might need to tap on the valve to break it loose. Once it's out, remove
the old gasket material. If the mounting flange is dirty, clean it with some
fine steel wool.
Use a new gasket (should come with the new valve). Replace the bolts, vac
hose and pipe, tighten everything up, and you're done.
Yes, you're correct - I assumed that the valve would be the same regardless
of engine. I'm surprised that it is different. I've replaced EGR valves on
my cars starting with a '78 Chevy that I bought new, and they've all been
essentially the same - two bolts at the base, and a vac line to the
diaphragm. Not all have had a pipe, tho.
Sorry I can't be more helpful!
I had my EGR valve, EGR sensor and the Vaccum control valve on my 96
V8 Explorer replaced by the dealer and it cost over $300. I felt
ripped off. Since I requested my original parts to be saved, I feel
confident in doing it myself next time.
The following the is the procedure that I would use. Buy parts or
examine the parts used. From this examination it can be seen that the
EGR sensor mounts on the back of the EGR value by three small nuts.
Before starting I WOULD DISCONNECT THE BATTERY FIRST. I would
carefully remove these three nuts first and then remove the electrical
connector from the sensor(because it is held top and bottom by the
electrical connector?s slip clips, I see that I can?t easily get to
the lower clip when the sensor is mounted on the back of the EGR
Valve). Although the quarters are tight, the bottom retaining bolt or
nut on the EGR Valve should be now be accessible with either a
universal joint/socket combination or a special purpose wrench. After
removing the EGR valve and cleaning the surface. The installation of a
new EGR could be done in reverse order. I would attach the electrical
cable to the EGR sensor after it is mounted to the back of the EGR
valve. This way should allow me more room to install the three small
EGR sensor nuts. Although, I haven?t performed the above installation
myself this is the approach I would use if my EGR valve needs
I have a 96 Explorer 5.0L V8. Although your layout is different, it
looks close enough to mine to assume the valve?s location is the same.
In your third picture look at the nut that is approximately three
inches down from the end of your transmission check dip stick and
directly in front of it. That is the top nut which attaches the EGR
valve to the extreme corner of your intake manifold on the passenger
side as shown in your picture(On mine there is also a lower attaching
nut.). The nut is also right next to your EGR vaccum control valve.
This is the round black plastic unit with the six slotted cutouts,
which from your picture is approximately two to three inches to the
right of the red wire. Assuming that your EGR valve is at least
visually the same as mine, there should be a plastic EGR valve sensor
attached to the back of your EGR valve with an electrical cable
attached. If you are going to clean it only you might want to buy a
new gasket for your re-installing it. If you still have trouble
identifying it I suggest a visit to your Ford and ask to examine one.
Forgot to mention, see that curved silver painted elbow-like part in
the first and third picture? That part is called an "EGR Spacer" the
EGR valve is mounted on the backside of that part facing the firewall
On 14 Mar 2005 19:34:56 -0500, phoeneous
I don?t have a picture of my installation. What is the make and year
of your vehicle? With this info I can look up the part nos. for your
EGR Valve and the EGR Valve Position Sensor that mounts on the back of
it (assuming yours is the same as mine). If the parts number are the
same as mine I can give you a website which shows actual views of the
parts. Even if yours aren?t the same as mine and if views are
available for your vechile, I will provide you the info for locating
the views so you can use them to locate the parts on your vehicle.
The unit that you circled on your first picture is most likely a part
of your heating system, because it looks like its attached to the
heater hoses, as in my vehicle.
You need to state the year and make of your vehicle. For instance the
EGR valve in my 96 Explorer 5.0L looks like the info that I provided
you and applies to my year and make. My car?s ianstallation is also
like the info Fred2 provided you. However, for instance, at the site
which I previously provided you, it lists two
different Ford(Motorcraft) Valve Part Nos. for a 97 Explorer 5.0L and
they are significantly different. One is exactly like mine and the
other is very different and doesn?t use an EGR valve position sensor.
For your vehicle, you must look at this site and determine which one
you have. Hopely, yours is like the second one and not like mine.
First the second one is smaller, half the price and doesn?t require an
EGR valve position sensor.
Fred has shown you where on your intake manifold it is and you need to
compare yours to the 97 example that I gave to determine which one
your vehicle has.
Thank you to everyone who posted pics and provided information. I
finally got this finished, though it was tough getting the bottom nut
back on the EGR valve.
In the process, I noticed that one of the lines that runs to the
canister attached to the EGR spacer (vapor control solenoid?) was
cracked and broken. I managed to get it reconnected. My question is -
what does this part do? One line is connected to the EGR valve. I
wasn't able to trace the broken one. Am I liable to run into future
problems because of this?