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Old 03-08-2010, 12:42 PM   #11
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Re: Changing Top Fuel Filter

As hard as this part is to get to, I would get o-rings ahead of time. Mine were $12 and easy to put on in a couple of seconds.

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Old 03-09-2010, 10:15 AM   #12
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Re: Changing Top Fuel Filter

This is a pretty good video on cleaning the EGR Valve - rest of video is not relevant:

mms://multimedia.ford.com/seopts/Tech_31_250k.wmv
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Old 11-07-2011, 10:19 PM   #13
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Re: Changing Top Fuel Filter & EGR

Well, I was getting nervous about my EGR cleanliness so I went at it. Much easier than I thot. I bought this Ford kit for O-rings and gasket.

Good thing I did as the gasket came apart during removal.
My valve really wasn't too bad. This is with 61,000 miles on the engine.

Pretty much all the carbon was very powdery and loose. Most of it came off with a tooth brush, but I soaked the valve (Lower part only! Keep all liquid out of the upper part of the valve!!) and brushed it some more to get everything off. The two seats were clean, so I'm pretty sure the valve was working just fine.
Here's a photo of the front of the engine so you can see what I had to remove to get in there.

I put duct tape over the turbo charger outlet hole in the intake manifold to be sure I didn't drop anything in there.
By the way, this is also an excellent time to change the upper fuel filter too. Much easier with everything removed.
The job took me around three hours total. As I said, I don't think it really needed it yet, but I'll drive much happier knowing it's clean.
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Old 08-19-2015, 07:09 PM   #14
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Re: Changing Top Fuel Filter & EGR

Thread back from the dead....

I want to clean my EGR valve since I'm getting higher than normal error % on the EGR flow. Before I dive in, I have a question.

It looks like I have no choice but to remove the intercooler elbow from the intake manifold. Is there a gasket between the elbow and the the manifold?

if there is a gasket, does anyone know the part number? I couldn't find one on RockAuto.com.
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