Material
| Item | Specification | Fill Capacity |
|---|---|---|
| Motorcraft Metal Surface Prep ZC-31 |
Material
Engine Emission Control
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 laws.
The engine emission control system consists of the
- EGR system.
- PCV system.
EGR System - The EGR system returns a small amount of exhaust gas into the intake manifold. This reduces the overall combustion temperature. Cooler combustion temperatures provide a significant reduction of the oxides of nitrogen (NOx) in the exhaust emissions.
The engine incorporates a stepper motor-controlled EGR valve which receives its signal from the PCM. Engine coolant is used to cool the EGR valve. The EGR valve and stepper motor are serviced as an assembly.
The amount of recirculated exhaust gas depends on
- engine rpm.
- intake manifold vacuum.
- exhaust backpressure.
- engine coolant temperature (ECT).
- throttle position (TP).
PCV System - The PCV system uses intake manifold vacuum to ventilate blow-by vapors from the crankcase and return the vapors to the intake manifold for combustion. The PCV valve varies the amount of blow-by vapors returned to the intake manifold based on available engine vacuum. The PCV valve also prevents backfiring into the crankcase.
The PCV valve is serviced as part of the crankcase vent oil separator.
Scheme 1
| Item | Part Number | Description |
|---|---|---|
| 1 | 9424 | Intake manifold |
| 2 | 9J559 | Swirl control valve solenoid |
| 3 | 9L492 | Swirl control valve actuator |
| 4 | PCV valve (part of 6A785) | |
| 5 | 6A785 | Crankcase vent oil separator |
| 6 | 9E652 | Air cleaner outlet pipe |
| 7 | 6582 | Valve cover |
| 8 | 9G641 | Evaporative emission (EVAP) canister purge valve |
| 9 | 9002 | Fuel tank |
| 10 | Fuel tank pressure (FTP) sensor (part of 9K164) | |
| 11 | 9034 | Fuel tank filler pipe |
| 12 | 9E857 | EVAP canister |
Scheme 2
| Item | Part Number | Description |
|---|---|---|
| 1 | 9424 | Intake manifold |
| 2 | PCV valve (part of 6A785) | |
| 3 | 6A785 | Crankcase vent oil separator |
| 4 | 9E652 | Air cleaner outlet pipe |
| 5 | 6582 | Valve cover |
| 6 | 9G641 | Evaporative emission (EVAP) canister purge valve |
| 7 | 9002 | Fuel tank |
| 8 | Fuel tank pressure (FTP) sensor (part of 9K164) | |
| 9 | 9034 | Fuel tank filler pipe |
| 10 | 9E857 | EVAP canister |
Refer to the INTRODUCTION - GASOLINE MODELS article.
Exhaust Gas Recirculation (EGR) Valve
| Item | Specification |
|---|---|
| Motorcraft Metal Surface Prep ZC-31 |
Material
Scheme 3
| Item | Part Number | Description |
|---|---|---|
| 1 | 18C266 | Heater hose |
| 2 | W527302 | Heater hose clamp |
| 3 | 8K556 | Coolant outlet adapter |
| 4 | 8B274 | Upper radiator hose |
| 5 | Upper radiator hose clamp (part of 8B274) | |
| 6 | 9D476 | EGR valve gasket |
| 7 | 9D475 | EGR valve |
| 8 | W500225 | EGR valve bolt (2 required) |
| 9 | 14A464 | EGR valve electrical connector |
| 10 | 14A624 | Engine wiring harness electrical connector (2 required) |
| 11 | 14A301 | Engine wiring harness electrical connector bracket |
| 12 | 14A464 | PCM electrical connector |
| 13 | 12A650 | PCM |
- Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) .
- Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
- Disconnect the 2 engine wiring harness electrical connectors and release them from the bracket.
- Disconnect the center PCM electrical connector.
- Disconnect the EGR valve electrical connector.
- Release the clamp and remove the upper radiator hose from the coolant outlet adapter.
- Release the clamp and remove the heater hose from the EGR valve.
- Remove the 2 bolts and the EGR valve. Discard the gasket. To install, tighten to 20 Nm (15 lb-ft).
- Clean the mating surfaces of any residual gasket material.
- To install, reverse the removal procedure.
- Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) .
Scheme 4
| Item | Part Number | Description |
|---|---|---|
| 1 | W500214 | Crankcase vent oil separator bolt (8 required) |
| 2 | 6A785 | Crankcase vent oil separator |
| 3 | Retainer clip (part of 6A785) | |
| 4 | 6B752 | Crankcase vent oil separator gasket |
| 5 | 18C266 | Bypass hose |
- Remove the intake manifold. For additional information, refer to «ENGINE - 2.0L»(ref-357159) .
- Release the bypass hose from the retainer clip and position aside.
- Remove the 8 bolts, crankcase vent oil separator and the gasket. To install, tighten to 10 Nm (89 lb-in).
- To install, reverse the removal procedure.