Ford 1S7Z-9D475-A
EGR Valve

The exhaust gas recirculation (EGR) service requires placing a vehicle on a hoist within NEUTRAL gear. Start by emptying the cooling system while removing the outlet pipe for the air cleaner. The EGR valve requires electrical connector separation followed by disconnecting the upper radiator hose at the coolant outlet and the coolant hose from the EGR valve position. The two securing bolts on the EGR valve should be removed followed by disposal of the gasket material. The new EGR valve needs to be tightened to 20 Nm (15 lb-ft) torque during installation while completing the reverse installation process by cleaning the mating surfaces for the EGR gasket. The service completion requires you to fill and perform a bleed procedure on the cooling system.

As a first step in EGR valve servicing you need to drain the cooling system fluid. The service starts with removing the battery tray before loosening clamps on the vent tube and continuing with air cleaner outlet pipe removal. The electrical connector needs removal before you loosen the hose clamp to disconnect the tube which should then be placed out of the way. When servicing the EGR valve start by disconnecting the coolant hose after unclamping it. The EGR valve becomes accessible by removing its securing bolts followed by removing the valve from its position. The removal procedure should be reversed after inspecting and cleaning the gasket mating surfaces. The cooling system requires final filling together with bleeding to conclude the service.

Service of the Exhaust Gas Recirculation (EGR) valve starts by severing both the electrical connector and EGR tube fitting from the valve component. The service of the EGR valve requires detaching its two securing bolts along with the replacement of its gasket. The new valve should receive bolt torques set at 25 Nm (18 lb-ft). Metal scrapers along with wire brushes and power abrasive discs should always be avoided for cleaning sealing surfaces as they generate scratches which become leak points; a plastic scraping tool serves well for removing EGR system module gasket residues. The surfaces are suitable for metal surface prep cleanup if there exists no remaining gasket material. Clean the EGR valve properly before installation by tightening it to 40 Nm (30 lb-ft).

Draining the cooling system should be the starting point before servicing the EGR valve. Your initial step should involve removing the air cleaner outlet pipe before uninstalling the two engine wiring harness retainers at their base position. First disconnect the EGR valve electrical connector before you release the clamp and pull out the upper radiator hose from the coolant outlet. The service procedure involves freeing the clamp before removing the coolant hose from the EGR valve. Unfasten the two EGR valve retaining bolts. Install the new EGR valve while fastening the mount bolts with 20 Nm force rating (15 lb-ft). Cleaning the sealing surfaces with plastic scraping tools represents the only acceptable method since metal scrapers and wire brushes, power abrasive discs and all abrasive tools will produce scratches and gouges that lead to leaks. Metal surface prep becomes an alternative cleaning option when there is no remaining gasket material on the surface. Take out the EGR valve gasket for removal while disposing of it; after cleaning examine the EGR gasket mating surfaces. Complete the installation by following the removal steps in reverse and perform a cooling system filling and bleeding process.

The exhaust gas recirculation (EGR) valve requires servicing by starting with vehicle hoisting in NEUTRAL position and disconnection of the ground cable from the battery. The cooling system needs draining before removing the air cleaner inlet pipe. The EGR valve electrical connector needs disconnection before the clamp releases to extract the upper radiator tube at the coolant outlet. After freeing the clamp you should take the coolant hose off from the EGR valve. The EGR valve requires removal of its two bolts then discarding the gasket material. Firmly torque the new valve to 25 Nm (18 lb-ft) when installing. Excessive force and abrasive tools should never be used for cleaning sealing surfaces since they create leaks by generating scratches and gouges; a plastic scraper must be used instead to eliminate old gasket traces. Workers should clean the surfaces with metal surface prep in cases where gasket residue has not been detected. The mating surface cleaning operations should end with the cooling system fill-up and bleeding process.

Fill and bleed the cooling system.

Position the vehicle on a hoist with it in NEUTRAL.

If equipped, disconnect and position the secondary air injection (AIR) valve inlet hose aside.

Release the clamp to detach the EGR coolant outlet hose from the EGR valve.

Begin by draining the cooling system.

Disconnect the electrical connector from the EGR valve.

Remove the air cleaner outlet pipe.

Use a plastic scraping tool to remove any remnants of the EGR valve gasket.

Position the vehicle on a hoist with it in NEUTRAL.

The EGR valve is secured by two bolts that need to be removed.

No, do not reuse the EGR valve gasket; remove and discard it.