Question about 1994 Ford Thunderbird

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94 t-bird 4.6L burning up plugs. suspect egr valve but cant get

Burning up plugs. suspect egr valve but cant get any tools to the nuts on the tube. how do i get it off? also hear a hiss when on a load and then miss's. About a year ago i suspected ignition system problems and replaced coil packs,plugs twice,plug wires,o2 censers, mass air flow censer, coolant censer and 2 injectors. Finally started getting raw fuel in the exhaust brought it in and found out it was a bad computer telling a fuel injector to stay open. Replaced computer with NEW one. Got it back and had small miss only during hard acceleration and continued to get worse. Book says egr valve. I hear some kind off vac leak only when in drive and accelerating but can not find one. only has 105,000 miles. HELP!!!

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  • gergg82 Oct 26, 2009

    I took it back to the shop that put the computer in and they claim 6 hours of searching for the problem with no luck finding it. But acknowledged there is one. They said the injectors seem to be spraying in an unusual sequence and that i need to bring it to the dealership. Not sure if they did the compression test but i would assume so.I never had this problem before the computer got replaced. It was women owned and ran like a champ. No problem for the tires to break lose. i have only put 6,000 miles on it. rarely hard. I'm wondering if the computer was programed wrong or how it could create this new problem.

  • gergg82 Oct 26, 2009

    Yes all plugs seem to be over burning the same.

  • gergg82 Oct 26, 2009

    Thanx for all your help. Your incite is very useful.

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  • Master
  • 770 Answers

Too much fuel should not create all these problems. Do you have the plug problem on all cylinders? Sounds like you have spent a considerable amount changing parts. Have you checked compression...You could have a burnt valve(S), that may not manifest itself except on acceleration, (more load, Higher rpm), That could explain the fuel in the exhaust. Not getting proper combustion at higher rpms. Could have a dead cylinder, but unless its caused by a valve float, it should occur even at lower rpms.

Posted on Oct 26, 2009

  • Hal Hallman Oct 26, 2009

    The more description you give, the more I start leaning toward computer related problems. And frankly, dealer svc incompetence. They should be able to diagnose and if there is admittadly a problem, check until the proper conclusion is reached. I fix many makes and models...they specialize in your car. Need to be accountable for reaching a vialble conclusion.When I worked at a dealership and our techs couldn't figuer it out... we brought in factory people. That is their job, the squeaky wheel gets the grease.

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1 Answer

What is a egr valve


  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

b9175c5.jpg

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

5fcd84e.jpg

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

4552fc2.jpg

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

b849310.jpg

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

795549d.jpg

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)

d8a563e.jpg

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.

Oct 12, 2012 | 1998 Nissan Maxima

1 Answer

I need written instructions for installing an EGR Valve on a 96 Ford Exploer Eddie Bauer V6 4.0 engine. Trying to pass emission inspection.


zjlimited_986.jpg

Fig. 4: Exploded view of the EGR system and related components for the 4.0L engine (click over pic for zoom)

REMOVAL & INSTALLATION

PFE/DPFE Sensor
This component is found on all engines, and is also referred to as the backpressure transducer.
  1. Disconnect the negative battery cable.
  2. Detach and label the wiring harness connector from the PFE/DPFE sensor.
  3. Disconnect all of the hoses from the sensor.
  4. Remove the mounting nuts, then separate the sensor from the mounting bracket.
  5. If necessary, remove the EVR solenoid and the PFE/DPFE mounting bracket from the upper intake manifold.
To install:
  1. If removed, install the EVR solenoid and mounting bracket onto the upper intake manifold.
  2. If applicable, install the EGR tube heat shield.
  3. Position the PFE/DPFE sensor on the mounting bracket, then install and tighten the mounting nuts until snug.
  4. Attach all necessary hoses and wiring to the sensor.
  5. Connect the negative battery cable.

EGR Vacuum Regulator (EVR) Solenoid
The EVR solenoid is mounted either on the same bracket as the PFE/DPFE sensor, attached to the upper intake manifold, or near the EGR valve on its own bracket.
  1. Disconnect the negative battery cable.
  2. Label and detach the wiring harness connector from the EVR solenoid.
  3. Detach the main emission vacuum control connector from the solenoid.
  4. Remove the retaining nuts, then separate the solenoid from the mounting bracket.
To install:
  1. Position the solenoid on its mounting bracket and install the retaining nuts.
  2. Attach the main emission vacuum control connector and the wiring harness connector to the EVR solenoid.
  3. Connect the negative battery cable.

EGR Valve
See Figures 6 and 7
  1. Disconnect the negative battery cable.
  2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
  3. Label and detach all vacuum hoses from the EGR valve.
  4. Label and detach any electrical wiring harness connectors from the EGR valve.
  5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
  6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
  7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
zjlimited_987.jpg

Fig. 6: Cutaway view of a base entry type EGR valve

zjlimited_988.jpg

Fig. 7: Cutaway view of a side entry type EGR valve

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 4-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-49 inch lbs. (1-18 Nm) on 5.0L engines.
  2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
  3. Connect all wiring or hoses to the EGR valve.
  4. Install the air inlet tube.
  5. Connect the negative battery cable.


Hope this helps, good luck (remember to rate this comments).

Apr 06, 2011 | Ford Explorer Cars & Trucks

1 Answer

Picture of egr valve and were it is located


dffc43b.jpg

Fig. 11: EGR valve and component mounting-3.0L engine


da251ab.jpg

Fig. 12: EGR valve and component mounting-3.8L engine

Removal:
  1. Disconnect the negative battery cable.
  2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
  3. Label and detach all vacuum hoses from the EGR valve.
  4. Label and detach any electrical wiring harness connectors from the EGR valve.
  5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
  6. Remove the EGR valve mounting fasteners, then separate the valve from the upper 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:
  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) on 3.8L engines, or to 106-159 inch lbs. (12-18 Nm) on 5.0L engines.
  2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
  3. Connect all wiring or hoses to the EGR valve.
  4. Install the air inlet tube.
  5. Connect the negative battery cable.

Hope this helps (remember comment and rated this).

Jul 27, 2010 | 1995 Ford Windstar

1 Answer

R&R EGR Valve 97 Nissan . After replacing the plugs, cap & rotor and wires the vehicle still runs rough stalls when turning it is 5 speed. All that to say, I was told to replace EGR Valve I can see...


It takes a 17 mm wrench to losen the tubing on both sides of the valve. Then it is a matter of unmounting the bracket and pulling off the vacuum line. Make sure that you losen both lines BEFORE unmounting the bracket or you will never get it off. Sometimes getting the tube fitting (flare nut) loose requires a flare nut spanner wrench. Some EGR vlaves on have one flare unt and have gasket under the EGR valve where it mates to the manifold. Make sure you replace the gasket if yours has one.

(flare nut spanner wrench)
http://t3.gstatic.com/images?q=tbn:JXlnPyZf9DSRLM:http://www.samstagsales.com/images/sw24-11x13.jpg

I also recommend that you use a long piece of solid copper wire #10 to push through the tubes to remove the carbon build up.

It really is a matter of time. The most difficult thing about changing an EGR valve is getting the flare nut(s) loose.

Thanks for using FixYa.

Kelly

Jun 22, 2010 | 1997 Nissan Pickup

4 Answers

How do I replace the EGR valve in my 1999 Ford E350 van?


Your vehicle has an EGR valve attached to the intake manifold. About how to replace an EGR Valve, check this procedure...
Parts:
1. EGR Valve

Tools:
1. Scan Tool
2. 3/8 in. Drive Ratchet
3. Wrench
4. Socket Set

Steps:
Step 1 Locate the OBD-I or OBD-II data link connector (DLC). Refer to your vehicle owner’s manual for the specific location.
o Tip: The OBD-I data link connector is usually located in the engine compartment near the battery or the fuse box. The OBD-II connector (post 1995 cars) is usually located beneath the instument panel next to the steering column.

Step 2 Turn your key to the“ON” position. Do not start the engine.

Step 3 Plug your scan tool into the DLC and follow the manufacturer's steps to read the diagnostic trouble code. Codes between P0400-P0408 are generic trouble codes for the EGR system.
o Tip: The OBD-II diagnostic trouble code (DTC) is a 5 character alphanumeric code. The first digit is a letter that indicates the component group, the second digit is OBD mandated or manufacturer specfic, the third digit is a subgroup, and the fourth and fifth digits define the component and basic problem.

Step 4 To test the EGR valve: Remove the vacuum line to the valve and install a manual vacuum pump. Start the engine and apply vacuum to the valve. If the engine idle speed drops, the EGR valve is working. If the engine idle speed does not change, the EGR system is not working. Most engines will stall if you fully open the EGR valve while idling.
o Tip: Some vehicles are equipped with electronically controlled EGR valves. Use a scan tool to test these valves.

Step 5 Remove the vacuum line or electrical connector from the EGR valve.

Step 6 Remove the EGR mounting bolts. Remove the EGR valve.

Step 7 Using a new gasket, attach the new EGR valve with the original mounting bolts. Torque the bolts to the manufacturer's specifications.

Step 8 Reconnect the vacuum line or electrical connector.

Step 9 Erase any codes on the scan tool through the“delete” or“erase” command. Remove the scan tool.

Step 10 Road test your vehicle to verify the repair.
o Tip: If the check engine light returns, repeat the diagnostic process for additional DTCs or take your vehicle to a certified repair shop.

Check the RIGHT PART before to take off the parts. Its possible that you can find few TSB in your library or dealer about this LINK.

Hope helps.

Jun 16, 2010 | Ford E-Series Cars & Trucks

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

b9175c5.jpg

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

5fcd84e.jpg

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

4552fc2.jpg

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

b849310.jpg

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

795549d.jpg

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)

d8a563e.jpg

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

3 Answers

Location of EGR valve for 4.6 liter engine? how do you remove the EGR valve?


a887903.gif
EGR VALVE IS #2.

Please wait for second post to answer your second question....comes with a few pictures.

Nov 16, 2009 | 1992 Ford Crown Victoria

1 Answer

How to remove the egr valve on a 1993 mercury grand marquis


Jack up the passengers side of the car, get a 1 1/16" wrench break loose the fitting to the manifold, hold a 24 mm wrench on the fitting to the manifold, loosen the flare nut on the tube. Then using a 10 mm socket, about 2 inches long, loosen the two nuts under the EGR valve, then take the both out, remove the vacuum hose to the top of the EGR valve, and the sensing line from the small tube. then completely remove the flare nut from the orifice fitting on the manifold. BE CAREFUL with the tube, do not bend it or break it, you may find PB blaster useful the night before on a cold engine loosen these fittings. Once the EGR valve is out, remove the orifice out of the manifold, remove the tube from the EGR valve, again be careful, mark the tube to EGR position before pulling this off, because the top fitting to EGR needs tightened before you put it back in, it will make the lower fitting difficult if you do not line it up right, dry fitting from under the car is helpful, mark it, and then tighten the top. Clean out the tube, be careful not to bend the little tube, either inside or outside the larger tube, it sticks out inside. Clean the orifice, clean the manifold face carefully not to score it, check for blockage there too. Apply anti-seize to the orifice, put it back in the manifold, then apply anti-seize to the bolts for the EGR valve, and the flare nuts both ends. Apply some silicon to the EGR valve face, just enough to hold the gasket in place, put the new gasket on, start the bolts two turns in the gasket, it will hold them in place, then start them in the manifold, then start the lower flare fitting to orifice, tighten the top bolts, and then the flare nut, connect the vacuum line, connect the sensing line. I just recently did this process, it works, if have other EGR issues, the valve is the easiest.

Oct 13, 2009 | 1993 Mercury Grand Marquis

2 Answers

2005 Dodge 1500 code p0404 EGR valve.


The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head ,

  1. Remove electrical connector (5) at top of EGR valve solenoid.
  2. Remove tube mounting bolt (1) at intake manifold.
  1. Remove two bolts (4) connecting EGR tube (1) to valve assembly.
  2. Remove gasket located between EGR tube flange and EGR valve assembly.
  3. Remove two EGR valve mounting bolts (5).
  4. Separate valve assembly (3) from engine.
  5. Remove and discard metal gasket located between cylinder head and valve assembly.
INSTALLATION
  1. Clean area at rear of left cylinder head where it joins base of EGR valve.
  2. Clean EGR tube where it joins EGR valve.
  3. Position new gasket between EGR valve and cylinder head.
  4. Position EGR valve to cylinder head. Install and tighten two bolts (5). Refer to Torque Specifications.
  5. Position new gasket between EGR tube flange and EGR valve assembly.
  6. Position EGR tube (1) to side of EGR valve and into intake manifold.
    1. Install EGR tube flange bolt (1) at intake manifold. Tighten bolt. Refer to Torque Specifications.
    2. Connect electrical connector (5) to top of EGR valve solenoid (2).Do a final tightening of two EGR tube bolts (4). Refer to Torque Specifications

Feb 05, 2009 | 2005 Dodge Ram 1500

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