How to Replace an EGR in an F-150

The Acronym EGR stands for Exhaust Gas Recirculation or EGR system. The EGR system is responsible for reducing oxides of nitrogen which is a toxic gas produced whenever the engine temperature reaches 2500 F degrees. It reduces the toxic gases by introducing a controlled amount of spent exhaust gases into the intake manifold. This dilutes the air fuel mixture which lowers the combustion chamber temperature and in turn reduces the creation of this toxic gas. This system is used in 4.2L V6 Engines and 4.6L V8 engines. The EGR module is located on the right side of the intake manifold, between the throttle body and the plenum. The removal of the following EGR module pertains to 2004-2006 4.2L V6 models.

Things You'll Need

• Snub nose pliers
• Phillips screw driver
• Ratchet and socket set standard

Instructions

1. Detach the cable from the negative battery terminal with a pair of snub nose pliers.

2. Disconnect the vacuum connector form the EGR system module.

3. Disconnect the electrical connector from the EGR system module

4. Remove the exhaust manifold-to-EGR system module pipe.

5. Unscrew the threaded fitting that connects the exhaust manifold-to-EGR system module pipe to the right exhaust manifold with a Phillips screw driver.

6. Unscrew with a Phillips Screw driver the threaded fitting that connects the exhaust manifold-to-EGR system module pipe to the EGR system module.

7. Take out the two EGR system module mounting bolts and remove the EGR system module with a ratchet and socket set.

8. Remove and discard the old EGR system module gasket.
   Clean off the gasket mating surfaces of the EGR system module and the intake manifold.
   Installation is the reverse of removal.

Tips & Warnings

• The exhaust manifold to EGR system module pipe connects the right exhaust manifold

• The Engine must be completely cooled to perform procedure

References

• Ford Pick Ups 2004-2006 Repair Manual, Chilton, Mike Stubblefield, Haynes Publishing Group, 2006