EGR port cleaning
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Junior Member
Joined: Mar 2005
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From: North Carolina
EGR port cleaning
Hi, newbie here.
I have '96 XLT - 5.0 4x4 and I keep getting an EGR insufficient flow code. I have replaced the EGR valve but the code remains. I want to clean the EGR port but it appears that to do this, I'll have to remove the upper intake manifold to access the port. The five bolts that secure the upper intake manifold don't appear to be a problem but the repair manual I'm using shows one screw that also hold the manifold down. That screw may present a problem, since I'm having a hard time locating it.
Has anyone done this (intake manifold removal/EGR port cleaning) before on a '96 with a similar arrangement? Any pointers or words of wisdom before I start disconnecting items? I've already taken some pictures of the motor from all angles for reference during reassembly.
Thanks,
Jon
I have '96 XLT - 5.0 4x4 and I keep getting an EGR insufficient flow code. I have replaced the EGR valve but the code remains. I want to clean the EGR port but it appears that to do this, I'll have to remove the upper intake manifold to access the port. The five bolts that secure the upper intake manifold don't appear to be a problem but the repair manual I'm using shows one screw that also hold the manifold down. That screw may present a problem, since I'm having a hard time locating it.
Has anyone done this (intake manifold removal/EGR port cleaning) before on a '96 with a similar arrangement? Any pointers or words of wisdom before I start disconnecting items? I've already taken some pictures of the motor from all angles for reference during reassembly.
Thanks,
Jon
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Joined: Jan 2003
Posts: 20
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I have on my 98 4.6 . It's a job to get at it .
The next thing was the most time consuming thing was to get at the egr valve to remove it . Get as much stuff out of the way to have plenty of room for the next step. The exhaust flow pipe is thight to the firewall. Up country we produce rust.
Use plenty of pb blaster ,rust eater or the they say coke eats rust up on the male connector that goes into the egr valve. Go to Tractor Supply or some place sells 1 1/16 combination wrench (I have a Thornson) . Cut the box end to make it a line wrench to just fit around the tubing. You may have to have a machinist cut the wrench because the steel is harden. Don't use an adjustable wrench if it slips an burrs the nut you are hurting. then no way to deburr the mess with a file, no room. Oh! by now in the story your back is killing you cause of the odd shapes of the fendor or surround stuff so the first thing is get acomfortable platform to work off of, I used sawhorses. When you think of it tap on the tubing connector with a brass hammer to help to get the penrtating oil deep into those threads. Don't hit hard cause if you look at the egr mount ain't very sturdy. Don't want to bust the expensive stuff. Put the home made line wrench over the tubing nut and try to get it loosened. If it won't budge be patient and keep the pennnitating oil flowing and keep tring sometime try to thighten a little then loosen. It will come loose. Once it does remove it from the valve.
Then remove the egr valve from the Air valve , use deep well 10mm.
Then take the air valve off the intake. Get some (alot of throtle body cleaner and a 5/16 drill and get all the tar out of the 2 ports that are pluged solid.
Get new gaskets and reassemble. Three days later you will
Good Luck
The next thing was the most time consuming thing was to get at the egr valve to remove it . Get as much stuff out of the way to have plenty of room for the next step. The exhaust flow pipe is thight to the firewall. Up country we produce rust.
Use plenty of pb blaster ,rust eater or the they say coke eats rust up on the male connector that goes into the egr valve. Go to Tractor Supply or some place sells 1 1/16 combination wrench (I have a Thornson) . Cut the box end to make it a line wrench to just fit around the tubing. You may have to have a machinist cut the wrench because the steel is harden. Don't use an adjustable wrench if it slips an burrs the nut you are hurting. then no way to deburr the mess with a file, no room. Oh! by now in the story your back is killing you cause of the odd shapes of the fendor or surround stuff so the first thing is get acomfortable platform to work off of, I used sawhorses. When you think of it tap on the tubing connector with a brass hammer to help to get the penrtating oil deep into those threads. Don't hit hard cause if you look at the egr mount ain't very sturdy. Don't want to bust the expensive stuff. Put the home made line wrench over the tubing nut and try to get it loosened. If it won't budge be patient and keep the pennnitating oil flowing and keep tring sometime try to thighten a little then loosen. It will come loose. Once it does remove it from the valve. Then remove the egr valve from the Air valve , use deep well 10mm.
Then take the air valve off the intake. Get some (alot of throtle body cleaner and a 5/16 drill and get all the tar out of the 2 ports that are pluged solid.
Get new gaskets and reassemble. Three days later you will
Good Luck