96 5.0L (V8) EGR Valve Location and Removal

[gsw]

My check engine light intermitently was coming on and off for the past few months. It finally began to stay on more and more permanently until it stayed on. I bought a scanner and received the code P0402 which states "the EGR valve has excessive exhaust flow." However, in my Haynes manual it does not show where the EGR valve is located on the 5.0L engine. I believe it is located back near the firewall, closer to the passenger side than the driver, but near the middle of the engine. There are 2 EGR looking parts back there, but I believe it is the larger, since the smaller version doesn't appear to have a vacuum tube going into it. First question, am I looking at the EGR valve, and if so, how do you get it off? I am able to get to the top bolt easily, but the bottom bolt is very difficult to get a wrench on. Also, I have read many nightmare posts about EGR-type engine codes, but it was actually something else. Is there a way for me to test the EGR valve to determine if it is the true problem? By the way, I have reset the code twice, but it continues to come back.

 

[Hai Le]

Am having the identical problems/issues, with the same OBD2 code:

1. access to and removal of the EGR (between the engine block and the firewall; it's about 1/3 the size of a small soup can, sitting on top of a 2-bolt bracket...)
2. how to determine whether it is actually the EGR: am told it could be the EGR itself, the vacuum hoses, and/or the 2 sensors on either side of it (sorry, but don't remember the name of the sensors; one is upstream of the EGR, the other downstream.)
3. am told (but have not verified) that if you can get a long enough vacumm hose onto to the EGR, a vacumm check would definitively pinpoint the problem. (My problem is being able to put a vacumm hose on it.)

Any help is appreciated!

 

[BFGorilla]

Do all Explorer's have EGR's ? If not which do and which don't?

 

[asp84]

They didnt start putting EGR'son the older explorer 4.0's until 1994 (possibly 93)

All 96+ Explorer 5.0'shad EGR's located on the elbow.