It is a good idea to clean the Exhaust Gas Recirculation (EGR) valve at least once a year. This helps avoid rough idle, stalling and poor fuel economy due to block passages from carbon deposits. Sometimes, small rocks will fly during road travel and find their way into the valve case, causing diaphragm malfunction, specially on four-wheel drive models. Use this guide to clean the EGR valve on your Ford vehicle and replace the gasket, if necessary.
Open the bonnet and locate the EGR valve. On most Ford models, you will see the valve mounted on one side of the engine, towards the front or back of the engine. Depending on your particular Ford model, the valve may resemble a flat, metal mushroom, of about 2 to 3 inches in diameter with a vacuum hose on top; or a small plastic component with a rounded hat on top and an electrical connector.
Unplug the vacuum hose or electrical connector from the top of the valve, depending on your particular model.
Unscrew and remove the two mounting valve-to-engine bolts using a wrench or ratchet and socket.
Disconnect the pipe from the bottom of the EGR valve using a wrench or adjustable wrench, being careful not to damage the connecting nut.
Lift the valve away from the engine compartment and remove the gasket.
Detach the EGR solenoid from the top of the valve, if your particular model comes equipped with one. Remove the four screws using a Phillips screwdriver.
Remove carbon deposits from the bottom passage on the valve using a scratch awl.
Remove carbon deposits from the pipe and engine valve passages using the scratch awl.
Remove any gasket material from the bottom of the valve and engine-mounting base using a plastic scraper to avoid damage to the mating surfaces.
Attach the EGR solenoid to the top of the valve, if your particular model comes equipped with one.
Set the valve in place on the engine, along with a new gasket if necessary.
Start the two mounting valve-to-engine bolts by hand to avoid thread damage.
Start the pipe-to-valve nut by hand to avoid thread damage.
Tighten the two mounting bolts and the pipe nut.
Plug the vacuum hose or the valve sensor electrical connector.