FORD MUSTANG 2003 Workshop Manual

z
the color stripe of the vacuum hoses.
The PCV system uses the intake manifold vacuum to ventilate the crankcase and return the fumes to
the intake manifold for combustion.
EGR System Components
The EGR system returns a portion of the exhaust gas to the intake manifold to reduce the combustion
temperature. This results in lower nitrous oxide formation.
The powertrain control module (PCM) controls the EGR vacuum regulator solenoid . The EGR vacuum
regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas
flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to exhaust
manifold tube and sends a signal to the powertrain control module. A metering orifice in the EGR valve
to exhaust manifold tube restricts the flow rate when the EGR valve is open.
The PCV valve:
zcontrols the amount of ventilating air and blow- by gases going to the intake manifold.
z prevents a backfire from reaching the crankcase.
The EGR valve to exhaust manifold tube:
zconnects the exhaust manifold to the EGR valve.
z has two tubes connecting to the EGR transducer for EGR flow monitoring.
The EGR transducer:
zmonitors the EGR flow rate through the EGR valve to exhaust manifold tube.
z sends an EGR flow rate signal to the powertrain control module.
The EGR vacuum regulator solenoid uses input from the powertrain control module to change the
EGR valve operation. Item Part Number Description
1 12A65 Powertrain control module
2 9J459 EGR vacuum regulator solenoid
3 9D475 EGR valve
4 9J433 EGR transducer
5 — Metering orifice
6 9D477 EGR valve to exhaust manifold tube Klj . 2 ba
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DIAGNOSIS AND TESTING
Engine Emission Control
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
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REMOVAL AND INSTALLATION
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 and the gasket.
4. NOTE: Install a new gasket.
To install, reverse the removal procedure.
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Cobra
Removal and Installation 1. Disconnect the accelerator cable and the speed control cable.
2. Remove the accelerator cable bracket bolts.
3. Release the clip and position the accelerator cable bracket and the cables aside.
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.
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5. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
6. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
7. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
8. Disconnect the vacuum hose from the EGR valve. Klj . 2 ba
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9. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness
aside.
10. Remove the vacuum accessory bracket mounting nut.
11. Remove the mounting bolts, and the vacuum accessory bracket. 12. Disconnect the exhaust manifold to EGR valve tube. Klj . 3 ba
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13.
NOTE: Discard the EGR valve gasket.
Remove the mounting bolts and the EGR valve.
14. NOTE: Install a new EGR valve gasket.
To install, reverse the removal procedure. Klj . 4 ba
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Mach I
Removal and Installation 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
2. Remove the exhaust gas recirculation (EGR) valve. 1. Disconnect the EGR tube upper fitting.
2. Disconnect the vacuum hose.
3. Remove the two bolts and remove the EGR valve and gasket.
3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges,
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces.
4. To install, reverse the removal procedure. zInstall a new gasket.
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