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 Nitrogen Oxides (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 and evaporated oil from the crankcase and returns them 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 the entry of combustion backfiring into the crankcase. The PCV valve is serviced as part of the crankcase vent oil separator.
Scheme 24
| Item | Part Number | Description |
|---|---|---|
| 1 | 9424 | Intake manifold |
| 2 | 2420 | Power brake booster aspirator |
| 3 | PCV valve (part of 6A785) | |
| 4 | 9G641 | Evaporative Emission (EVAP) canister purge valve |
| 5 | 6A785 | Crankcase vent oil separator |
| 6 | 9R504 | Air Cleaner (ACL) outlet pipe |
| 7 | 6582 | Valve cover |
| 8 | 9032 | Fuel tank filler pipe |
| 9 | 9002 | Fuel tank |
| 10 | Vapor valve (part of 9002) (2 required) | |
| 11 | Fuel Limit Vent Valve (FLVV) (part of 9002) | |
| 12 | Fuel Tank Pressure (FTP) sensor (part of 9002) | |
| 13 | 9C985 | EVAP canister |
EMISSION CONTROL PART NUMBER REFERENCE
Refer to the INTRODUCTION - GASOLINE MODELS .
Material
| Item | Specification |
|---|---|
| Motorcraft® Metal Surface Prep ZC-31-A |
SURFACE PREP MATERIAL SPECIFICATION
Scheme 25
| Item | Part Number | Description |
|---|---|---|
| 1 | 8A582 | 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 |
EGR COMPONENTS PART NUMBER REFERENCE
- Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
- Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-356770) .
- 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 (177 lb-in).
- Clean the mating surfaces of any residual gasket material.
- To install, reverse the removal procedure. Install a new EGR valve gasket.
- Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
Scheme 26
| Item | Part Number | Description |
|---|---|---|
| 1 | W500214 | Crankcase vent oil separator bolt (8 required) |
| 2 | 6A785 | Crankcase vent oil separator |
| 3 | Bypass hose retainer clip (part of 8A582) | |
| 4 | 6B752 | Crankcase vent oil separator gasket |
| 5 | 8A582 | Bypass hose |
CRANK CASE VENT OIL SEPARATOR PART NUMBER REFERENCE
- Remove the intake manifold. For additional information, refer to «ENGINE - 2.0L»(ref-356734) .
- Remove 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.