EGR Systems
Ford Explorer XLT
Ford F-250

How do you remove the EGR tube from an exhaust manifold?

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2006-10-24 20:42:15
2006-10-24 20:42:15

I have a 1989 240sx with a 2.4 liter engine and I looked into this problem, and found that the only wrench I had that could fit it was 1-1/4 inches. I think that it is really 30 mm. I would think that yours would be the same size. Its located really close to the firewall though, so its a pain to remove with so little room.

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that my friend is the tube that goes from the exhaust manifold to the egr valve make...

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as hot as the exhaust manifold there are exhaust gases passing through it

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Disconnect the frontand rear o2 sensor electrical connectors. Separate the catalytic converter from the flex-pipe. Remove the fasteners between the catalytic converter and the exhaust manifold. Disconnect the EGR tube from the catalytic converter. Remove band from the front of the catalytic that holds it to the bracket on the front of the engine block. Remove fasteners holding exhaust manifold to head.

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The EGR valve is easy to remove. Just take out the two bolts holding it in. The problem is the exhaust tube leading into it. Follow the tube to the exhaust manifold. There you will see two nuts holding it on. Remove those two nuts and then all you have to do is maneuver the assy from the engine compartment...

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4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable. 4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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Removal Remove the air cleaner outlet tube. Disconnect the mass air flow (MAF) sensor electrical connector. Disconnect the breather pipe. Remove the air cleaner. Fully loosen the exhaust gas recirculation (EGR) valve to exhaust manifold tube nut from the bottom of the EGR valve. Disconnect the vacuum line from the top of the EGR valve. Remove the EGR valve. Remove and discard the EGR valve gasket. Installation NOTE: Use a new EGR valve gasket when installing the EGR valve. To install, reverse the removal procedure.

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4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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-------------------------------------------------------------------------------- 4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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= EGR Valve = 4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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= EGR Valve = 4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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= EGR Valve = 4.2L, 4.6L, 5.4L and 6.8L Engines 1. Disconnect the negative battery cable. 2. Remove the vacuum hose from the EGR valve. 3. On the 4.6L engine, remove the nut and brake booster bracket. 4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube. 5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve. 6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold. 7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold. To Install: 8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts. 9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm). 10. Connect the vacuum hose to the EGR valve. 11. On the 5.7L engine, install the DPFE sensor. 12. On the 4.6L engine install the brake booster bracket and the retaining nut. 13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.

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EGR Valve4.2L, 4.6L, 5.4L and 6.8L Engines1. Disconnect the negative battery cable.2. Remove the vacuum hose from the EGR valve.3. On the 4.6L engine, remove the nut and brake booster bracket.4. On the 5.4L engine, remove the DPFE sensor retaining nuts and place the sensor to the side to allow access to the EGR tube.5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.6. Remove the EGR valve mounting bolts, then separate the valve from the intake manifold.7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.To Install:8. Install the EGR valve, along with a new gasket, on the manifold, then install and tighten the mounting bolts.9. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 25-35 lbs. (34-47 Nm).10. Connect the vacuum hose to the EGR valve.11. On the 5.7L engine, install the DPFE sensor.12. On the 4.6L engine install the brake booster bracket and the retaining nut.13. Connect the negative battery cable.


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