hinchcliffe
07-04-2011, 11:53 AM
To replace the EGR, look at the new one and see where the bolts are. You'll need a 4" extension on a 13mm socket. Remove the bolts first and swing the EGR up and around pulling the exhaust breather (bent steel tube with a heat jacket on) out of the side of the manifold (be careful not to pull to hard, but pull it striaght to the driverside fender). The hose for the PCV has an end that looks like a spark plug wire disconnect it and feed it between the exhaust breather and EGR body. Once you get it close enough pull the plug on the EGR (slide the red plastic lock and push on the plug top to unlock it). Once out use an 8mm socket and remove the Exhaust breather. Make sure you have the paper/metal gasket off the manifold and the paper gasket from the breather tube.
Installation is easier once you get your fat hands back in there. Put the breather on with the new gasket and only tighten it so you can still rotate it a bit as needed for reassembly. Use new bolts (if provided) and install them into the new EGR with new gasket (holes in the gasket should just hold the bolts in place so you don't lose them). Squeeze it in and push in the breather. Pull the bottom of the EGR towards you when installing the bolts to make sure they acually thread in correctly. Tighten them down (not sure the torque spec) then tighten the breather screws. Lastly plug it in and you're good to go.
Notes: You do not need to remove the air box on top of the motor unless you want a better view, not going to get you much though. Yes it is very frustrating the first time but take your time (do not cross thread holes cause you'll never reach them easily). Since I did it twice now it only takes about 20 minutes, but figure a good hour the first time. Best safe to do it on a cold engine, but I only burnt my finger tips twice.
BTW the PCV on the 2006 4.7 is on the driverside rear just past the spark plugs.
Installation is easier once you get your fat hands back in there. Put the breather on with the new gasket and only tighten it so you can still rotate it a bit as needed for reassembly. Use new bolts (if provided) and install them into the new EGR with new gasket (holes in the gasket should just hold the bolts in place so you don't lose them). Squeeze it in and push in the breather. Pull the bottom of the EGR towards you when installing the bolts to make sure they acually thread in correctly. Tighten them down (not sure the torque spec) then tighten the breather screws. Lastly plug it in and you're good to go.
Notes: You do not need to remove the air box on top of the motor unless you want a better view, not going to get you much though. Yes it is very frustrating the first time but take your time (do not cross thread holes cause you'll never reach them easily). Since I did it twice now it only takes about 20 minutes, but figure a good hour the first time. Best safe to do it on a cold engine, but I only burnt my finger tips twice.
BTW the PCV on the 2006 4.7 is on the driverside rear just past the spark plugs.