How to Replace an EGR Valve on Ford Cars

by Contributing Writer; Updated June 12, 2017

The Ford car which is the common name Ford car the Ford car is a full-sized vehicle designed and manufactured by the Ford car Motor Company. As in most vehicles, the Ford car has an exhaust gas recirculation (EGR) valve, which controls the amount of gases within the combustion chamber. The valve uses a plunger mechanism to direct the exhaust into the intake manifold, where the exhaust is then properly cooled to prevent the vehicle from overheating. When the EGR valve clogs, it fails to operate properly and affects overall performance. Replacement of the valve requires minimal tools and keeps the Ford car running efficiently.

Under The Hood:

 How to Replace an EGR Valve on a Ford Windstar

Replace the EGR valve on the Ford Windstar by finding it on top of the motor near the firewall. The EGR valve is a flat metal disk that is either black or silver and held onto the motor with two bolts.

Unfasten the metal vehicle emissions tube from the EGR valve by using an open-end wrench to loosen the nut on the end of the tube that is threaded into the valve. Carefully pull the tube out of the valve when the nut is loose.

Pull the vacuum hose off the top of the EGR valve by carefully pulling it straight up. Place the vacuum hose out of the way so that it does not get damaged.

Remove the EGR valve from the top of the motor by using a socket wrench to unfasten the bolts holding the valve in place. Take the valve off the engine and discard it.

Place the new EGR valve on the motor of your Ford Windstar and attach it with two bolts to the engine. Connect the vacuum hose to the vacuum port on the top of the EGR valve.

Thread the nut that is attached to the emissions tube into the side of the EGR valve by hand. Once the nut is hand-tightened, secure it the rest of the way with the open-end wrench.

Items you will need

  • Open-end wrench

  • Socket wrench set

 How to Replace the EGR Valve in an F-250 Ford

Removing the EGR Valve

Raise the hood of your F-250 and prop it open. Locate the battery on the passenger's side fender-wall over the wheel. Remove the negative (black) terminal from the battery with an adjustable wrench.

Remove the bolts that secure the accelerator control protector shield in the top center of the engine with a socket wrench. Lift the shield off the engine.

Loosen the inlet hose clamps with a screwdriver, then remove the electrical connectors from the air cleaner housing. Remove the air cleaner tube mounting bolts with an adjustable wrench. Remove the clamp from the air cleaner assembly. Lift the air cleaner element out of the housing, then lift the housing off.

Detach the vacuum line from the top of the EGR valve and remove the EGR pipe from the exhaust manifold. Remove the bolts that attach the EGR valve to the intake manifold with a socket wrench, then lift the valve off the manifold. Remove the gasket and discard it.

Replacing the EGR Valve

Clean the EGR valve mounting surface on the intake manifold to remove any traces of old gasket, dirt or exhaust deposits. Remove any dirt or deposit buildup from the inside of the valve outlet with a screwdriver.

Install the gasket supplied with the new EGR valve onto the EGR valve surface. Place the new EGR valve on the gasket and install the retaining bolts. Replace the EGR pipe and the vacuum line

Reinstall the air cleaner housing and the air cleaner element. Reattach the clamp on the air cleaner assembly. Reposition and tighten the air cleaner tube mounting bolts. Reattach the electrical connectors and the inlet hose clamps.

Reattach the accelerator control protector shield and install the retaining bolts. Reconnect the negative terminal on the battery and close the hood.

Start the engine to test the operation of the new EGR valve.

Items you will need

  • Adjustable wrench

  • Socket set

  • Screwdriver

 How to Replace an Egr Valve in a Ford Explorer

Raise the hood and locate the EGR valve, which is attached to the right rear on the intake manifold near the firewall. The intake manifold is attached to the side of the engine block.

Disconnect the single-prong terminal electrical connection that plugs into the EGR valve sensor. Detach the black rubber vacuum tube which plugs into the EGR valve. Inspect the tube and electrical connection for cracking and excessive wear. Replace these parts as necessary.

Take out the two mounting bolts located on the top and bottom sides of the valve. Detach the old valve from the manifold and gently tap it using a hammer to break the seal. Scrape off the old gasket using a paint scraper, being careful not to allow any debris to enter the manifold.

Apply a thin coat of gasket adhesive to the new gasket using your finger and place it onto the manifold. Make sure the bolt holes are properly aligned so that the new EGR valve will seat properly.

Insert the new replacement EGR valve into the manifold opening being careful not to damage the EGR valve sensor attached on the top of the EGR valve. Secure the replacement EGR valve in place using the two bolts and reattach the single-prong terminal wire.

Disconnect the battery and wait 4-6 hours to reset the check engine light indicator. Reconnect the battery and see if the check engine light comes on again.

Items you will need

  • New EGR valve and gasket

  • Gasket adhesive

  • Paint scraper

  • Socket wrench

 How to Replace the EGR Valve on a Ford Crown Vic

Place the Crown Vic in "Park." If the vehicle has recently run, allow it to cool for a half hour to ensure all components are cool to the touch.

Open the hood of the Crown Vic. Look for a mushroom-type valve behind the throttle body. Note that it has two small hoses attached at the top.

Remove the two hoses by pulling them gently from the valve by hand, one at a time. Do not use any tools to disconnect the hoses, as this could cause damage.

Loosen and remove the bolts securing the valve to the valve mount using a 22 mm wrench. Once the bolts have been removed, lift the valve from the mount. Removal may require some force if carbon buildup is present. Discard the old valve.

Clean the valve mount by spraying carburetor cleaner onto the mount. Clear away any debris or carbon residue using a wire brush and clean rag.

Install the replacement valve by placing it onto the valve mount. Align the holes on the valve with the holes on the mount to ensure the bolts fit properly. Tighten the four bolts using the socket wrench. Reconnect the hoses to the top of the valve by pushing them into place. Close the hood of the Crown Vic. Repeat these steps when a new valve is needed.

Items you will need

  • Socket wrench

  • EGR valve

  • Carburetor cleaner

  • Wire brush

  • Rag

 How to Replace the EGR Valve in a Ford Probe

Removing the EGR Valve

Open the hood and locate the EGR valve connected to the intake manifold. The valve looks like a metal, flatten mushroom, between 2 and 3 inches in diameter and, depending on your particular model, with one or two vacuum hoses connected to it.

Disconnect the ground (black) battery cable from the battery using a wrench.

Detach the vacuum hose from the EGR valve by hand. If your particular valve has two vacuum hoses, label and detach them.

Unplug the EGR position sensor electrical connector, if your valve is equipped with this sensor.

Disconnect the water hose(s) from the valve, if your model is equipped with them, using a pair of rib joint pliers.

Unfasten the exhaust pipe retaining nuts at the EGR valve and exhaust manifold, if your model is equipped with it, using an open wrench.

Unfasten and remove the two valve mounting bolts using a ratchet, ratchet extension and socket.

Remove the EGR valve and gasket from the intake manifold.

Clean the intake manifold mounting surface using a plastic scraper and a wire brush, if necessary.

Installing the New EGR Valve

Position the new EGR valve and gasket on the intake manifold, and install the two mounting bolts hand-tight.

Connect the exhaust pipe to the exhaust manifold and EGR valve hand-tight.

Tighten the two valve mounting bolts using the ratchet, ratchet extension and socket.

Tighten the exhaust-pipe retaining nuts using the open wrench.

Connect the water hose(s) to the valve, if your model is equipped with them, using the rib joint pliers.

Plug in the EGR position sensor electrical connector, if your valve comes equipped with this sensor.

Attach the vacuum hose(s) to the EGR valve.

Connect the ground (black) battery cable to the battery using the wrench.

Items you will need

  • Wrench

  • Rib joint pliers (optional)

  • Open wrench

  • Ratchet

  • Ratchet extension

  • Socket

  • Plastic scraper (optional)

  • Wire brush (optional)

  • New gasket

 How to Replace an EGR Valve in a 2002 Ford Focus

Allow the Ford Focus engine to cool down. This will give the components within the vehicle ample time to cool, preventing burns.

Open the hood of the Focus. Notice the EGR valve, which is a circular valve located on the engine intake manifold. It is secured in place by bolts. Refer to the Ford Focus manual for a diagram, if needed.

Use a socket wrench and remove the bolts holding the EGR valve in place. Lift the valve off the manifold. Use carburetor cleaner and clean the valve mount where the old EGR valve sat. Wipe the area clean with a rag.

Install the new valve by placing it onto the valve mount on the engine intake manifold. Place each bolt in place and tighten using the wrench. Close the hood of the Focus.

Items you will need

  • Socket wrench

  • Carburetor cleaner

  • Clean rag

  • Replacement EGR valve