Engine Emission Control System -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Engine Emission Control - 4.6L, 5.4L and 6.8L

Note. Do not permanently remove or render inoperative any part of the vehicle emission control system including related hardware. Failure to comply may violate applicable state and federal law.

The engine emission control system consists of the following

1. PCV system
2. EGR system (4.6L [2V] only)

EGR System

The EGR system

1. returns a small amount of exhaust gas into the engine for recombustion.
2. reduces the overall combustion temperature and provides a significant reduction of Nitrogen Oxides (NOX).

The EGR system module

1. is electronically controlled by the PCM.
2. is connected to the exhaust manifold by the EGR system module-to-exhaust manifold tube.
3. controls recirculated exhaust gas flow to the intake manifold.
4. monitors the flow of recirculated exhaust gases through the EGR valve-to-exhaust manifold tube.
5. returns a signal to the PCM.

The amount of recirculated exhaust gas depends on

1. engine rpm.
2. intake manifold vacuum.
3. exhaust back pressure.
4. engine coolant temperature.
5. throttle position.

PCV System

The PCV system

1. uses intake manifold vacuum to ventilate blow-by fumes from the crankcase.
2. returns the fumes to the intake manifold for combustion.

The PCV valve

1. varies the amount of blow-by gases returned to the intake manifold based on available engine vacuum.

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

Engine Emission Control - 6.0L Diesel

The EGR system includes

1. EGR valve actuator/pintle position sensor.
2. EGR cooler assembly.

The EGR system reduces the peak combustion temperatures and Nitrogen Oxides (NOX). The EGR valve is an electromechanical device that uses a linear actuator to control the relative position of the valve's pintle. This device also has a built-in pintle position sensor that functions to provide the PCM with a feedback signal. This output signal provides the information on the valve position relative to its seat. The advantage of this "closed loop" feedback is the ability to continuously vary exhaust gas flow to match operating conditions. The EGR cooler cools a portion of the engine exhaust gases and then recirculates them back into the inlet air stream. This increases the engine's tolerance for EGR and reduces the amount of smoke formed by exhaust gas dilution of the mixture.

Refer to the INTRODUCTION - GASOLINE MODELS .

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PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

Removal

1. Remove the exhaust manifold-to-EGR system module tube. For additional information, refer to «EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 4.6L»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#engine-emission-control-system-e-series) .
2. Disconnect the EGR system module electrical connector.
3. Disconnect the EGR system module vacuum line.
4. Remove the 2 bolts and EGR system module and discard the gasket.

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1. Carefully clean both sealing surfaces. Install a new EGR system module gasket with the side with the raised ring facing the intake manifold.
2. Install the EGR system module and 2 bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten an additional 90 degrees.
3. Connect the EGR system module vacuum line.
4. Connect the EGR system module electrical connector.
5. Install the exhaust manifold-to-EGR system module tube. For additional information, refer to «EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 4.6L»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#engine-emission-control-system-e-series) .

Removal and Installation

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Disconnect the upper exhaust manifold-to-EGR system module tube fitting nut. To install, tighten to 40 Nm (30 lb-ft).
3. Disconnect the lower exhaust manifold-to-EGR system module tube fitting nut. Remove the EGR system module tube. To install, tighten to 40 Nm (30 lb-ft).
4. To install, reverse the removal procedure.

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Injector Sleeve Brush Set 303-DS110 (D94T-9000-D) or equivalent Remover, EGR Valve 303-760

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Material

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the 6 pushpin retainers and upper air deflector.
3. Remove the 4 bolts for the power steering bracket.
4. Remove the 3 bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position it aside.
5. Disconnect the coolant hoses from the Air Cleaner (ACL) outlet pipe.
6. Loosen the clamps and remove the ACL outlet pipe.
7. Loosen the clamps and remove the Charge Air Cooler (CAC) tube.
8. Remove the 2 bolts and position the Manifold Absolute Pressure (MAP) sensor and the ground wire aside.
9. Remove the 3 bolts and disconnect the pushpin retainer. Position the cowl wiring harness aside.
10. Loosen the clamp for the CAC tube.
11. Remove the 3 bolts for the CAC tube and oil fill tube.
12. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
13. Loosen the clamp at the CAC tube.
14. Disconnect the oil fill tube at the valve cover.
15. Remove the 2 retaining nuts, CAC tube, oil fill tube and bracket.
16. Remove the 4 bolts and intake adapter. Cover the opening after the intake adapter is removed.
17. Remove the EGR baffle and gasket.
18. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover. Tighten to 14 Nm (124 lb-in).
19. Disconnect the fuel tubes at the secondary fuel filter and position them aside.
20. Remove the 2 bolts and position the secondary fuel filter assembly aside.
21. Disconnect the EGR valve assembly electrical connector.
22. Remove the 2 bolts and rotate the EGR valve counterclockwise.
23. Install the EGR Valve Remover and remove the EGR valve.
24. Remove and discard the O-ring seals and the EGR gasket.
25. Using the Injector Sleeve Brush Set, clean the EGR port. Vacuum the ash and foreign material from inside the intake manifold.

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1. Position the secondary fuel filter housing and install the 2 bolts. Tighten to 24 Nm (18 lb-ft).
2. Connect the fuel tubes at the secondary fuel filter. Tighten to 26 Nm (19 lb-ft).
3. Install a new EGR gasket. Install new O-ring seals and lubricate with clean engine oil.
4. Position the EGR valve and install the 2 bolts. Tighten to 13 Nm (115 lb-in).
5. Connect the EGR valve assembly electrical connector.
6. Install the gasket and EGR baffle.
7. Install the intake adapter and 4 bolts. Tighten to 13 Nm (115 lb-in).
8. Install the CAC tube, oil fill tube, bracket and 2 retaining nuts.
9. Connect the oil fill tube at the valve cover.
10. Install the 3 bolts for the CAC tube and oil fill tube.
11. Tighten the clamp for the CAC tube. Tighten to 12 Nm (106 lb-in).
12. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
13. Tighten the clamp for the CAC tube. Tighten to 12 Nm (106 lb-in).
14. Position the cowl wiring harness. Install the 3 bolts and connect the pushpin retainer. Tighten to 2 Nm (18 lb-in).
15. Position the MAP sensor and install the bolt. Position the ground wire and install the bolt. Tighten the MAP sensor bolt to 5 Nm (44 lb-in). Tighten the ground wire bolt to 8 Nm (71 lb-in).
16. Install the CAC tube and tighten the clamps. Tighten to 12 Nm (106 lb-in).
17. Install the ACL outlet pipe and tighten the clamps.
18. Connect the coolant hoses to the ACL outlet pipe.
19. Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and 3 bolts, then install the power steering fluid indicator.
20. Install the 4 bolts for the power steering reservoir bracket.
21. Install the upper air deflector and 6 pushpin retainers.
22. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. Remove the intake manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) .
2. Remove the EGR cooler bolt and stud bolt.
3. Remove the bolt and the EGR cooler.
4. Remove and discard the gasket and O-ring seal.

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1. Install the new O-ring seal and gasket.
2. Install the EGR cooler and stud bolt and bolt hand-tight.
3. Install the EGR cooler bolt. Tighten to 13 Nm (115 lb-in).
4. Tighten the EGR cooler stud bolt and bolt. Tighten to 13 Nm (115 lb-in).
5. Install the intake manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) .

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PARTS DESCRIPTION CHART

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Disconnect the PCV valve tube quick-connect fitting and position the PCV tube aside.
3. Rotate the PCV valve counterclockwise and remove the PCV valve. Discard the PCV valve.
4. To install, reverse the removal procedure. Install a new PCV valve.

Scheme 109

PARTS DESCRIPTION CHART

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Disconnect the PCV valve tube quick-connect fitting and position the PCV tube aside.
3. Rotate the PCV valve counterclockwise and remove the PCV valve. Discard the PCV valve.
4. To install, reverse the removal procedure. Install a new PCV valve.

Scheme 110

PARTS DESCRIPTION CHART

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Disconnect the PCV valve tube quick-connect fitting and position the PCV tube aside.
3. Rotate the PCV valve counterclockwise and remove the PCV valve. Discard the PCV valve.
4. To install, reverse the removal procedure. Install a new PCV valve.

See also:
• INTRODUCTION - GASOLINE MODELS
• INTERIOR TRIM AND ORNAMENTATION
• BATTERY, MOUNTING AND CABLES
• ENGINE - 6.0L DIESEL
• EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 4.6L