Ford Mustang (1999-2004) Service Manual: Exhaust Gas Recirculation (EGR) Valve - Cobra

Removal and Installation

1. Disconnect the accelerator cable and the speed control cable.

Exhaust Gas Recirculation (EGR) Valve - Cobra

2. Remove the accelerator cable bracket bolts.

Exhaust Gas Recirculation (EGR) Valve - Cobra

3. Release the clip and position the accelerator cable bracket and the cables aside.

Exhaust Gas Recirculation (EGR) Valve - Cobra

4. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.

Exhaust Gas Recirculation (EGR) Valve - Cobra

5. Disconnect the vacuum hoses from the differential pressure feedback EGR system.

Exhaust Gas Recirculation (EGR) Valve - Cobra

6. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the actuator.

Exhaust Gas Recirculation (EGR) Valve - Cobra

7. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.

Exhaust Gas Recirculation (EGR) Valve - Cobra

8. Disconnect the vacuum hose from the EGR valve.

Exhaust Gas Recirculation (EGR) Valve - Cobra

9. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside.

Exhaust Gas Recirculation (EGR) Valve - Cobra

10. Remove the vacuum accessory bracket mounting nut.

Exhaust Gas Recirculation (EGR) Valve - Cobra

11. Remove the mounting bolts, and the vacuum accessory bracket.

Exhaust Gas Recirculation (EGR) Valve - Cobra

12. Disconnect the exhaust manifold to EGR valve tube.

Exhaust Gas Recirculation (EGR) Valve - Cobra

13. NOTE: Discard the EGR valve gasket.

Remove the mounting bolts and the EGR valve.

Exhaust Gas Recirculation (EGR) Valve - Cobra

14. NOTE: Install a new EGR valve gasket.

To install, reverse the removal procedure.

    Exhaust Gas Recirculation (EGR) Valve
    Removal and Installation NOTE: The 4.6L, 2V is shown. The 3.8L is similar. 1. Disconnect the vacuum hose. 2. Disconnect the EGR tube from the EGR valve. 3. Remove the two bolts, the EGR valve an ...

    Exhaust Gas Recirculation (EGR) Valve - Mach I
    Removal and Installation 1. Remove the air intake scoop. For additional information, refer to Section. 2. Remove the exhaust gas recirculation (EGR) valve. 1. Disconnect the EGR tube upper fi ...

    Other materials:

    Electronic Leak Detection
    Special Tool(s) H10PM Refrigerant Leak Detector With Battery 216-00001 or equivalent CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refri ...

    Engine (Removal)
    Special Tool(s) Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Heavy Duty Floor Crane 014-00071 or equivalent Removal WARNING: Do not smoke or ...

    Removal
    Both mounts 1. Disconnect the battery ground cable. For additional information, refer to Section. 2. Remove the coolant bypass tube. For additional information, refer to Section. 3. Rotate the drive belt tensioner clockwise and detach the drive belt from th ...