How do you replace the EGR valve in a 95 ford aerostar?

Answer 1

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.