Question about 2003 Ford Explorer Sport

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2003 4.0 V6 explorer with the vacume line off the egr it runs, but runs rough. when the vacume line is hooked up to the egr it cuts off. i put a new egr on and it did the same thing please asap..

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First. Check the vacum routing from the egr. facing the engine, the vac.
line should go to the right and connect to the egr vacum regulator
solenoid. The line from the solenoid to manifold vacum. The solenoid
is also connected to the powertrain ctrl. module And some models,
have a egr sensor. the two vac.lines from the sensor(if equipped)go to
the exaust below the egr valve. The three wires from the sensor go to the pcm. At this I would plug in the obd2 scanner if no vac.leaks or
bad connections have been found. This can narrow the field greatly.
You can stop by an autozone/napa etc. they will scan it for free.
I hope this helps. Good luck.

Posted on Feb 03, 2010

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Posted on Jan 02, 2017

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prev.gif next.gif Exhaust Gas Recirculation (EGR) Valve Removal & Installation 2.0L Zetec Engine NOTE: When the EGR tube is disconnected from the EGR valve, it must be discarded and a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged.
To Remove:
  1. Disconnect the negative battery cable.
  2. Remove and discard the exhaust manifold-to-EGR tube. Use the following as a guide:
  3. Raise and safely support the vehicle
  4. Remove the splash shield
  5. Disconnect the EGR tube fitting
  6. Lower the vehicle
  7. Remove the air cleaner outlet pipe
  8. Disconnect the EGR tube from the EGR valve.
  9. Detach the vacuum line and remove the two retainer bolts.
NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:
  1. Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.
  2. Install a new EGR valve tube.
Detach the vacuum line (#1) and unbolt the EGR valve - 2.0L 02-04_escape_emissions_022.gif

3.0L (4v) Engine To Remove:
  1. Disconnect the vacuum line.
  2. Disconnect the EGR tube.
  3. Remove the EGR valve and discard the gasket.
NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:
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Detach the vacuum line (#1), unthread the EGR tube (#2) and remove the EGR valve bolts (#3) - 3.0L (4V) 02-04_escape_emissions_023.gif

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