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Tech Article: EGR Cleaning and removal

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    Tech Article: EGR Cleaning and removal

    This is for 4.6's typically with an lack of flow code for the EGR system. (p1401, p0401, etc)

    These engines use a Differential Pressure Feedback system. What that means is that the DPFE sensor measures the pressures of the egr system to determine flow. On some of these vehicles the MIL can become illuminated with a DPFE flow code. This can be due to clogged EGR Ports in the intake manifold under the throttle body. The clogged EGR ports are more likely to get clogged on 99 and newer vehicles because of the design of the EGR flow.

    This first section is on cleaning the Ports for the 99 and new vehicles, as it is a quicker writeup:

    Tools needed:
    3/8" hand ratchet (or air ratchet if you have)
    6-10" 3/8" extension
    8mm 3/8drive socket
    1/4" hand ratchet + extension (for removal of engine cover)
    flat head screw driver
    small pick
    shop towel

    Parts needed:
    Throttle body gasket
    Throttle body cleaner

    Operation instructions:
    1. Remove engine cover
    2. Remove air inlet tube from throttle body
    3. Remove cruise control cable and throttle cable from throttle body
    4. Disconnect Throttle Position sensor
    5. Disconnect throttle return spring
    6. remove the 4 bolts for the throttle body
    7. shove shop rag in big hole under throttle body
    8. with the pick, clean out the carbon buildup from the ports around the big hole under the throttle body (in the intake manifold)
    9. VERY IMPORTANT STEP, REMOVE THE SHOP RAG!!
    10. installation is reverse of removal. install new tb gasket (not mandetory, but recommended)

    ----------------------------------------------------------

    EGR valve removal, 92-95

    Removal

    1. Remove air cleaner outlet tube
    2. Raise vehicle on hoist
    3. CAUTION: Use care not to damage EGR valve tube to manifold connector (9F485) .

    NOTE: Hold EGR valve tube to manifold connector with a wrench while disconnecting EGR valve to exhaust manifold tube (9D477) .

    Disconnect EGR valve to exhaust manifold tube from EGR valve (EGR valve) (9D475) and EGR valve tube to manifold connector .

    4. Lower vehicle.
    5. Disconnect EGR pressure sensor hoses from EGR valve to exhaust manifold tube .
    6. Disconnect vacuum hose from EGR valve .
    7. Remove two EGR valve retaining bolts.
    8. Remove EGR valve , EGR valve gasket (9D476) and EGR valve to exhaust manifold tube from vehicle.


    Installation

    1. Clean intake manifold sealing surface with a plastic-tipped scraper to remove any residual EGR valve gasket material.

    NOTE: Do not tighten EGR valve to exhaust manifold tube nut on EGR valve at this time.

    2. Position EGR valve to exhaust manifold tube into EGR valve and loosely connect EGR valve to exhaust manifold tube nut to EGR valve .

    3. Position EGR valve gasket , EGR valve and EGR valve to exhaust manifold tube into vehicle.

    4. Install two bolts retaining EGR valve to intake manifold . Tighten bolts to 20-30 Nm (15-22 lb-ft).

    5. Connect vacuum hose to EGR valve .

    6. Connect EGR pressure valve sensor hoses to EGR valve to exhaust manifold tube .

    7. Raise vehicle.
    NOTE: Hold EGR valve tube to manifold connector with a wrench while tightening EGR valve to exhaust manifold tube nut.

    8. Connect EGR valve to exhaust manifold tube to EGR valve tube to manifold connector . Tighten EGR valve to exhaust manifold tube nuts to 35-45 Nm (26-33 lb-ft).

    9. Lower vehicle.
    10. Install air cleaner outlet tube as outlined in Section 03-12.

    ------------------------------
    GMNRadio DJ, Podcast Co-Host
    1984 Ford LTD Crown Victoria - Drag Car.
    99 Ranger 2.5 - Parts hauler and Pit truck.
    03 Mustang 3.8 Convertable - Head Gaskets fukered up
    95 S10 93 Accord

    #2
    96 - 97 EGR Valve removal:

    Removal

    1. Remove air cleaner outlet tube cover.

    2. Disconnect vacuum hose from EGR valve.

    CAUTION: Use care not to damage exhaust manifold tube.

    3. Disconnect exhaust manifold tube from EGR valve.

    EGR mount bolts — Tighten to 25 Nm (18 Lb-Ft)
    EGR Tube to manifold — Tighten to 45-65 Nm (33-48 Lb-Ft)
    EGR Tube to Valve — Tighten to 35-45 Nm (26-33 Lb-Ft)


    4. Remove EGR valve assembly and gasket. Discard gasket.


    Installation

    1. Clean intake manifold sealing surface to remove any EGR valve gasket material.

    2. Install a new gasket and position EGR valve. Install bolts and tighten to 25 Nm (18 lb-ft).

    3. Connect vacuum hose to EGR valve.

    CAUTION: Use care not to damage the exhaust manifold tube.

    4. Connect exhaust manifold tube to EGR valve. Tighten tube nut to 40 Nm (30 lb-ft).

    5. Install air cleaner outlet tube cover.



    Part numbers:
    Item Part Number Description
    1 W701232-S431 Bolt (2 Req'd)
    2 9430 RH Exhaust Manifold
    3 9F485 EGR Valve Tube to Manifold Connector
    4 9D477 EGR Valve to Exhaust Manifold Tube
    5 9D475 EGR Valve
    GMNRadio DJ, Podcast Co-Host
    1984 Ford LTD Crown Victoria - Drag Car.
    99 Ranger 2.5 - Parts hauler and Pit truck.
    03 Mustang 3.8 Convertable - Head Gaskets fukered up
    95 S10 93 Accord

    Comment


      #3
      99 - 2004
      EGR Valve
      Removal

      1. Remove the appearance cover.

      2. Loosen the clamp and remove the resonator.

      3. Remove the vacuum lines.

      4. Remove the cables from the intake manifold shield (9471).

      5. Remove the bolts from the intake manifold shield (9471).

      6. Remove EGR valve to exhaust manifold tube (9D477).

      7. Remove the bolts and the EGR valve (9D475).

      Installation

      1. To install, reverse the removal procedure.
      Attached Files
      GMNRadio DJ, Podcast Co-Host
      1984 Ford LTD Crown Victoria - Drag Car.
      99 Ranger 2.5 - Parts hauler and Pit truck.
      03 Mustang 3.8 Convertable - Head Gaskets fukered up
      95 S10 93 Accord

      Comment


        #4
        2005 and up

        Removal and Installation

        1. Disconnect the EGR system module electrical and vacuum connectors.

        2. Remove the 2 bolts and the intake manifold shield.
        2a.To install, tighten to 12 Nm (9 lb-ft).

        3. Disconnect the EGR system module tube-to-EGR system module fitting.
        3a. To install, tighten to 43 Nm (32 lb-ft).

        4. Remove the 2 bolts and the EGR system module.
        4a. To install, tighten to 25 Nm (18 lb-ft).

        5. Remove and discard the EGR system module gasket.

        6. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the exhaust gas recirculation (EGR) system module gasket.

        NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

        Clean the mating surfaces of any residual gasket material.

        7. To install, reverse the removal procedure.
        Install a new EGR system module gasket with the side that has the raised circle facing the intake manifold.
        GMNRadio DJ, Podcast Co-Host
        1984 Ford LTD Crown Victoria - Drag Car.
        99 Ranger 2.5 - Parts hauler and Pit truck.
        03 Mustang 3.8 Convertable - Head Gaskets fukered up
        95 S10 93 Accord

        Comment


          #5
          Thank you so much ,, getting the codes for EGR on the 94 gm

          Comment


            #6
            NP. on the older one's there isnt as much you can do for cleaning, but you can take a pick to the area on the intake where the egr valve mounts and clean out the passages there as well.
            GMNRadio DJ, Podcast Co-Host
            1984 Ford LTD Crown Victoria - Drag Car.
            99 Ranger 2.5 - Parts hauler and Pit truck.
            03 Mustang 3.8 Convertable - Head Gaskets fukered up
            95 S10 93 Accord

            Comment


              #7
              92-95 cars are notorious for cracking the EGR feed tube at the flexible joint on the tube. tube runs from the passenger side exhaust pipe up to the EGR valve. inspect the pipe for black exhaust stains to see if its leaking.
              2003 Town Car Signature - 3.27 RAR, Dual exhaust and J-mod - SOLD 9/2011
              89 Crown Victoria LX HPP -- SOLD 9/2010
              88 Grand Marquis LS - The Original -- Totaled 5/2006


              I rebuild AOD/AODE/4R70W/4R75E transmissions....Check out my Facebook page: https://www.facebook.com/pages/North...48414635312478

              Comment


                #8
                A "Low/Insufficent EGR flow" code on a '92-'95 car normally indicates clogged passages, not a bad EGR valve. If the flow code is the only code your getting, clean the passages as described above and you will be good to go. If, in addition to the flow code, you get a "sensor above/below minimum voltage code" then you will need to replace the PFE/DPFE sensor as well as clean the passages.

                Ray
                Car: 2004 Mercury Marauder
                Engine/Tranny: 49k miles and bone stock....for now

                Comment


                  #9
                  ok got a code 332 which is insufecent flow and 337 which is above voltage


                  So should i just get a clean and sensor or?? I do not have a lift and limited time and space to work on it. and looking at a a hard days run in a few weeks as I drive 1000 miles home for a visit/ mom haveing surgery and that 1 grand a day in miles then be back 1000 miles

                  Comment


                    #10
                    id personally just clean the passways AND replace the sensor. I guess you can clean it, clear codes, and see if it comes back. Its not like a bad EGR will leave you stranded.

                    Comment


                      #11
                      Yeah, I had a code on anges 95 GM. All it took was cleaning the passages.
                      Chris - A 20th Century Man \m/ ^.^ \m/

                      Comment

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