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

by Jeremy Holt
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The exhaust gas recirculation (EGR) valve on a Ford F-250 is part of the emissions and engine control system. The EGR system consists of the EGR valve, the EGR vacuum regulator, the differential feedback pressure sensor and various pipes and pressure lines. The system lowers nitrogen oxide emissions that are created by high-temperature combustion. The EGR system recirculates some of the gases back into the intake manifold, lowering the temperature in the combustion chamber and reducing nitrogen oxide levels. A malfunctioning EGR valve may cause the engine to idle roughly or overheat.

Removing the EGR Valve

Step 1

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.

Step 2

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.

Step 3

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

Step 1

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.

Step 2

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

Step 3

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.

Step 4

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.

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