Engine Emission Control Ford Cutaway E350

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

4.6L Exhaust Gas Recirculation (EGR) System Module

Scheme 1

The EGR system returns a portion of the exhaust gas to the intake manifold to reduce the combustion temperature. This results in lower nitrous oxide formation.

The PCM controls the EGR system module. When the EGR system module valve opens, exhaust gas flows to the intake manifold.

The EGR system module to exhaust manifold tube

1. connects the exhaust manifold to the EGR valve.

The EGR system module transducer

1. monitors the EGR system module flow rate through the EGR to exhaust manifold tube.
2. sends an EGR system module flow rate signal to the PCM.

The EGR vacuum regulator solenoid uses input from the PCM to change the EGR system module operation.

For further description and operation, See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL .

Scheme 2

5.4L EGR System

The 5.4L engines are equipped with an EGR system. The function of the EGR system is to reduce the emission of nitrogen oxide (NOx).

The EGR system returns a portion of the exhaust gas to the intake manifold to reduce the combustion temperature. This reduces the oxides of nitrogen (NOx) in the exhaust emissions.

The PCM controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The differential pressure feedback EGR sensor measures the flow through the EGR valve to exhaust manifold tube and sends a signal to the PCM. A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open.

For further description and operation, See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL .

Scheme 3

All Gasoline Engines

All gasoline engines are equipped with a positive crankcase ventilation (PCV) system. The function of the PCV system is to circulate blow-by gases from the engine crankcase to the engine intake.

The PCV system consists of

1. PCV valve
2. PCV tube

The PCV valve

1. controls the amount of ventilating air and blow-by gases going to the intake manifold.
2. prevents a backfire from reaching the crankcase.

For further description and operation, See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL .

The exhaust gas recirculation (EGR) system includes

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

The exhaust gas recirculation (EGR) system reduces the peak combustion temperatures and oxides of nitrogen (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 powertrain control module (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.

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See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL . .

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1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
3. Disconnect the vacuum line and EGR valve tube fitting.
4. Remove the bolts and EGR system module.

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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 bolts. Tighten the bolts in two stages. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
3. Connect the EGR valve tube fitting and vacuum line.
4. Connect the EGR system module electrical connector. Push in the red clip.
5. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

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1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the exhaust gas recirculation (EGR) valve tube upper fitting and EGR vacuum hose.
3. Remove the bolts and the EGR valve. Discard the gasket.

Scheme 12

1. Carefully clean both sealing surfaces. Install a new EGR gasket and the EGR valve.
2. Install the EGR valve. Tighten the bolts in two stages. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
3. Connect the EGR valve tube upper fitting and EGR vacuum hose.
4. Install the engine cover. For additional information, refer «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

Special Tool(s)

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

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Material

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the push pin retainers and upper air deflector.
3. Remove the bolts for the power steering bracket.
4. Remove the 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 outlet tube.
6. Loosen the clamps and remove the air cleaner outlet tube.
7. Loosen the clamps and remove the charge air cooler (CAC) duct.
8. Remove the bolts and position the manifold absolute pressure (MAP) sensor and the ground wire aside.
9. Remove the bolts and disconnect the push pin retainer. Position the cowl wiring harness aside.
10. Loosen the clamp for the CAC duct.
11. Remove the 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-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
13. Loosen the clamp at the turbocharger outlet hose.
14. Disconnect the oil fill tube at the valve cover.
15. Remove the retaining nuts, CAC tube, oil fill tube and bracket.
16. Remove the bolts and intake adapter. Cover the opening after the intake adapter is removed.
17. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover.
18. Disconnect the fuel tubes at the secondary fuel filter and position them aside.
19. Remove the bolts and position the secondary fuel filter assembly aside.
20. Disconnect the EGR valve assembly electrical connector.
21. Remove the bolts and rotate the EGR valve counterclockwise.
22. Install the special tool and remove the EGR valve.
23. Remove and discard the O-ring seals and the EGR gaskets.
24. Using the appropriate brush, 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 and install the bolts.
2. Connect the fuel tubes at the secondary fuel filter.
3. Install a new EGR gasket. Install new O-ring seals and lubricate with clean engine oil.
4. Install the EGR valve and bolts.
5. Connect the EGR valve assembly electrical connector.
6. Install the intake adapter and bolts.
7. Install the CAC tube, oil fill tube, bracket and retaining nuts.
8. Connect the oil fill tube at the valve cover.
9. Install the bolts for the CAC tube and oil fill tube.
10. Tighten the clamp for the turbocharger outlet pipe.
11. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
12. Tighten the clamp for the CAC duct.
13. Position the cowl wiring harness. Install the bolts and connect the push pin retainer.
14. Position the MAP sensor and install the bolt. Position the ground wire and install the bolt.
15. Install the CAC duct and tighten the clamps.
16. Install the air cleaner outlet tube and tighten the clamps.
17. Connect the coolant hoses to the air cleaner outlet tube.
18. Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and bolts, then install the power steering fluid indicator.
19. Install the bolts for the power steering reservoir bracket.
20. Install the upper air deflector and push pin retainers.
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

Scheme 41

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
3. To install, reverse the removal procedure.

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1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor hoses.
3. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

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1. Remove the intake manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the exhaust gas recirculation (EGR) cooler stud bolts.
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 O-ring seal and gasket.
2. Install the EGR cooler and stud bolts hand-tight.
3. Install the EGR cooler bolt.
4. Tighten the EGR cooler stud bolts.
5. Install the intake manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

Scheme 48

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Remove the differential pressure feedback exhaust gas recirculation (EGR) system. Disconnect the electrical connector. Disconnect the hoses. Remove the bolts.
4. To install, reverse the removal procedure.

Scheme 49

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Remove the exhaust gas recirculation (EGR) vacuum regulator solenoid. Disconnect the electrical connector. Disconnect the vacuum lines. Remove the nuts.
4. To install, reverse the removal procedure.

See also:
• INTRODUCTION - GASOLINE
• INTRODUCTION -- 6.0L DIESEL
• INTERIOR TRIM AND ORNAMENTATION
• BATTERY, MOUNTING AND CABLES
• ENGINE - 6.0L DIESEL