How to Replace an Egr Valve in a Ford Explorer

by Brett Johnson

The Exhaust Gas Recirculation (EGR) valve in your Ford Explorer is an exhaust regulating device attached to the intake manifold of the engine. It was first introduced to the United States in the 1960's and has continued to progress in improving fuel efficiency and reducing smog. It works by allowing small measured amounts of exhaust to enter the combustion chamber (pistons), thus reducing the temperature in the chamber. A malfunctioning EGR valve remains open and causes the temperature in the pistons to increase, allowing nitrogen oxide (smog forming emissions) to enter the atmosphere. Replacing the EGR valve in the Ford Explorer is a moderately easy repair to perform.

Step 1

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.

Step 2

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.

Step 3

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.

Step 4

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.

Step 5

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.

Step 6

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.

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