Question about 1986 Ford F 250

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Broken EGR pipe

I have a 302 in a 86 ford f-250 4x4, i found that the pipe from the manifold to the EGR was broken when i changed the Valve cover gaskets, am wondering how to replace it, has nev er been removed, any help will be much appreciated. thanks Kenneth

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  • misquito Oct 26, 2008

    thanks, I will try that.



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I start the car and let it get some heat in it and spray a good penetrating oil on the part. I then use a large wrench or a crescent wrench and break the pipe loose and unscrew it.

Posted on Oct 26, 2008


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My car sounds like a airplane when it idles up

-Possible broken exhaust gasket. depend on where the sounds came from...?

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Engin light #po406 2005 ram quad cab

P0406 - Exhaust Gas Recirculation Sensor A Circuit High

Early Models : The EGR valve control the amount of exhaust gas routed to the intake manifold. Vacuum is applied to the EGR valve in response to the throttle opening. The vacuum control the movement of the taper valve connected to the vacuum diaphragm in the EGR valve.


Late Models : The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening.


- Engine Light ON (or Service Engine Soon Warning Light)
- Engine hesitation

Possible causes
- Harness or connectors (EGR volume control valve circuit is open or shorted.)
- EGR volume control solenoid valve
- EGR temperature sensor and circuit

Possible solution
- Repair EGR harness or connector
- Replaced EGR volume control solenoid valve
- Replaced EGR volume control valve
When is the code detected?
- An improper voltage signal is sent to ECM through the valve

Hope helps.

Mar 06, 2011 | 2005 Dodge Ram

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Failed egr flow (failed inspection)

EGR is fed via a hard metal pipe from the exhaust manifold to the EGR valve, that pipe gets clogged with soot. You need to clean out with carb cleaner and a brush or piece of wire. Soak it and reinstall. EGR also has a vacuum line to it, make sure that is still attached and not broken or leaking.

Oct 15, 2010 | 2001 Mitsubishi Galant

1 Answer

Egr valve when does it operate

The EGR (exhaust gas recirculation) valve

What is it? This is a device that reduces engine emissions of nitric oxides by allowing a measured amount of exhaust gas to re-enter the intake manifold and mix with the air prior to entering the cylinders. The EGR can be vacuum or electrically driven or a combination of both.

Where is it located? The EGR is most often associated with the intake manifold. The EGR will be sited at a point of contact with both the exhaust and intake manifolds. If the exhaust manifold is remote, for example on the other side of the engine to the intake manifold, there will often be an exhaust feed pipe leading from the exhaust manifold to the EGR sited on the intake manifold.

How does it work? Generally intake manifold vacuum acting on a diaphragm draws up on a valve to open a connection between an entry port from the exhaust gases and an exit port to the intake manifold. An open EGR port makes starting difficult so the valve operation is often impeded by an electrical over-ride until the engine has warmed up, as signaled to the ECU by the coolant temperature sender. In some cases, a differential pressure feedback exhaust (DPFE) sensor fed by pipes from the exhaust feed to the EGR informs the ECU when and by how much the EGR should be open.

Symptoms of faulty EGR

The EGR has two possible fault modes either it is a) open when it should be closed or b) closed when it should be open. (some EGR faults are in fact more likely to be DPFE related)
  • Poor idling: ‘hunts’ at idle and generally rough engine performance. This is due to the air ingress through the split diaphragm or the EGR valve being left open, either event compromises the intake manifold vacuum and in turn this interferes with the ECU’s ability to deliver accurate fuel to air ratio for a given engine speed.
  • Misfire and ‘pinking’: if the EGR is jammed closed or the exhaust feed pipe is blocked (e.g. gummed up with baked carbon) the engine ignition runs lean and very hot, so hot in fact that the fuel air mix can spontaneously ignite causing a misfire. The misfire if pronounced can, in turn, be detected by the engine knock sensors and this gives the appropriate on board diagnostic error codes along with the check engine light. Due to the diesel engines creating more soot in the exhaust a blocked EGR is a much more common complaint in diesels than petrol cars.
  • Surging: A sticking EGR valve can lead to an effect of rhythmic surging a bit like the MAF fault, especially in turbo charged engines. Normally on a warmed up engine the vacuum from the inlet manifold opens the EGR. If the EGR fails to open promptly the turbo can be subject to a slight boost. Extra fuel/air mix is pushed into the inlet manifold as a result, increasing pressure (decreasing the vacuum). Without vacuum in the inlet manifold the EGR closes again but if sticky does so only slowly. This may allow inlet gases to flow through the EGR into the exhaust manifold for a split second. There is a time lag in the sequence of these events leading the engine to surge in cyclical manner.

How to check? With the engine running it may be possible to force the EGR valve open by pressing on the diaphragm with one’s fingers. Failing that pulling off the vacuum line to the EGR, blocking the pipe on the inlet manifold and applying vacuum to the EGR to monitor function will determine if the diaphragm is split. Removal of the EGR assembly and examination of the ports and valve mechanism will reveal any carbon build up.

How to fix? If the diaphragm is split then the EGR needs to be replaced. Most EGR problems are linked to carbon soot build up and this can be cleaned using a cloth, brush and carburetor choke cleaner spray. If the exhaust feeder pipe is blocked this can be cleaned using a piece of frayed hand brake cable as an internal brush. This makeshift brush can be further enhanced by mounting it in a drill to sweep dirt from the interior of lengths of pipe. Some cars (Hondas are a good example) have an elaborate passage way system to provide exhaust gas to each inlet pipe runner. The only way to clean these out is by removing the blanking plugs (no easy task) and then using the makeshift rotary wire brush and carburetor choke spray. New blanking plugs have to be reinstated to make good the passage ways assembly.

Jul 14, 2010 | 1992 Ford Explorer

1 Answer

Ford focus 2002, When accelerating sounds like exhaust is blowing. Replaced exhaust but noise still there, any ideas?

Check the EGR valve pipe connection and mounting gasket, also check the EGR pipe connection at the exhaust manifold. Check the exhaust manifold for cracks and gasket leaks, hope this helps, let me know.

Jul 01, 2010 | 2002 Ford SVT Focus

3 Answers

EGR Valve not working

EGR Valve Testing
  1. Install a tachometer on the engine, following the manufacturer's instructions.
  2. Detach the engine wiring harness connector from the Idle Air Control (IAC) solenoid.
  3. Disconnect and plug the vacuum supply hose from the EGR valve.
  4. Start the engine, then apply the parking brake, block the rear wheels and position the transmission in Neutral.
  5. Observe and note the idle speed.
If the engine will not idle with the IAC solenoid disconnected, provide an air bypass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak. Do not allow the idle speed to exceed typical idle rpm.
Using a hand-held vacuum pump, slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve nipple.
  1. If the idle speed drops more than 100 rpm with the vacuum applied and returns to normal after the vacuum is removed, the EGR valve is OK.
  2. If the idle speed does not drop more than 100 rpm with the vacuum applied and return to normal after the vacuum is removed, inspect the EGR valve for a blockage; clean it if a blockage is found. Replace the EGR valve if no blockage is found, or if cleaning the valve does not remedy the malfunction.

EGR Valve Removal & Install
3.0L OHV (2 valve) and 3.4L SHO engines


Fig. : EGR mounting-3.0L OHV (2 valve) engine


Fig. : EGR mounting-3.4L (SHO) engine


Fig. : Remove the two retaining bolts and...


Fig.: ... remove the valve from the intake manifold


Fig.: Thoroughly clean the mating surfaces of the manifold and the EGR valve (if being reused)
  1. Disconnect the negative battery cable.
  2. Remove the vacuum hose from the EGR valve.
  3. Using a 22mm wrench or crowfoot, disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
  4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
  5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
To install:
  1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
  2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 26-47 ft. lbs. (35-65 Nm).
  3. Connect the vacuum hose to the EGR valve.
  4. Connect the negative battery cable.

3.0L OHC (4 valve)


Fig. : EGR mounting-3.0L OHC (4 valve) engine
  1. Disconnect the negative battery cable.
  2. Remove the vacuum hose from the EGR valve.
  3. Remove the two EGR tube-to-EGR valve retaining nuts.
  4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
  5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
To install:
  1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
  2. Connect the EGR valve-to-EGR tube, then tighten the retaining nuts.
  3. Connect the vacuum hose to the EGR valve.
  4. Connect the negative battery cable.

Tell us news.

May 04, 2010 | 1999 Mercury Sable

1 Answer

Location of EGR Valve

Found the info!!

This Dodge EGR valve is a certain kind of device that is mounted right on your intake manifold which controls the amount of exhaust gasses back into your engine.
On a 2005 Dakota with 4.7 liter engine (non-HO), the EGR valve is located near the intake manifold on the driver's side right up against the firewall. It's hard to spot as it sits lower than the intake manifold. To change it, remove the electrical connector. There's a red tab that needs to be pushed to one side and then you have to squeeze down on a tab to get it free. Using a 13 mm socket, remove the bolt that you can see. I had to use a 3 inch wobble extention and then a 8 inch extension with a deep well socket to reach it with my 3/8 inch ratchet. There's a second bolt that you can't see between the EGR valve and the firewall. With a little trial and error and a lot more luck, you can reach the hidden bolt with the 3 inch wobble extension and a 13 mm deep well socket. Attach the ratchet after the socket is on and remove. This one isn't easy and if there's any Dodge engineers reading this one, a couple of extra inches of clearance between the valve and the firewall wouldn't have killed you no matter what the cost accountants said. With both bolts removed, you should be able to pull out the metal pipe that connects the manifold to the EGR valve out of the manifold (Pull to the right) and then you can lift the valve out. For assembly, the metal pipe connecting the intake manifold the EGR valve has to be removed and reinstalled on the new valve. It's held on with 2 5/16th" bolts. You should put the rear bolt on tight, but leave the front bold loose for the reinstall as some adjustment is necessary to get it put back together and the rear is a pain to tighten when installed. Line up the bolts that attach the valve and get the rear 13 mm bolt (The one you couldn't see on disassembly) started. Do not start the other 13 mm bolt as you'll need to pivot the valve and pipe to the left in order to reinsert the pipe into the intake manifold. Once the pipe is in the intake manifold. Start the other 13 mm bolt and tighten both 13 mm bolts and then the 5/16" bolts holding the pipe onto the valve. Reinstall the electrical connection. Please don't forget to rate!!!!

Mar 14, 2009 | 2005 Dodge Dakota

1 Answer

EGR valve code initiated check engine light.

If you are getting an Insufficient EGR flow code, it is likely the DPFE sensor is bad or the EGR ports are plugged in the Intake. Very rarely do these trucks actually need the valve replaced. But it is located on top of the engine,under that plastic cover that covers the throttle body. It is round, about 3 inches in diameter. It has one vac line going to the top of it and a metal pipe from the exhaust manifold going to the side.

Mar 09, 2009 | 1998 Ford Expedition

1 Answer


  1. Turn OFF the ignition.
  2. Disconnect the EGR valve electrical connector.
  3. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back.
  4. Remove the EGR valve retaining bolts.
  5. Remove EGR valve assembly.
  6. Remove the gasket.
  1. Install the EGR valve with a new gasket to the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions.
  2. Reinstall the bolts through the EGR valve into the intake manifold. Tighten Tighten the EGR bolts to 30 N.m (22 lb ft).
  3. Connect the exhaust pipe assembly to the EGR valve.
  4. Reinstall the exhaust pipe bolt. Tighten Tighten the nuts to 30 N.m (22 lb ft).
  5. Connect the EGR valve electrical connector

May 28, 2008 | 2000 Chevrolet Impala

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