EGR valve and tube 2004 Montana

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erndog72

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My 2004 Montana has had a code in for the EGR valve for many years now. Of course, the engineers put it in a place that is next to impossible to access. I started to do the job several times, but got beat every time. After MUCH grief and anxiety I finally managed to get all the bolts off of the EGR valve so I can change it out. I was ecstatic, even though I doubt I will ever be able to get them back in.
I have a new hurdle now. The exhaust tube is stuck in the EGR valve really well. I have tried prying, twisting (carefully), and cussing, but it won't budge. I tried spraying it with liquid wrench penetrant and later brake cleaner, followed by a good soaking with liquid wrench penetrant again. I plan on letting it sit for a couple of days like that and then try it again. I did consider disconnecting the other end of the tube from the exhaust, but that looks at least as difficult and fruitless.
Does anyone out there have a good suggestion on how to separate these two buggers, other than pulling the engine, or using heat (too many things that can melt)??

Desperate
 
you seem to be on the right track, letting it sit soaking in liquid wrench for a few days.
 
Well, I finally got it off after three days.
So, in the process of trying to install the new EGR valve, I snapped of the heater outlet hose at the quick connect. Such a tight place to work it was probably inevitable. Also, somehow disconnected the 1/2" tube that runs from the intake horn back to the rear of the engine. Fortunately it didn't break and I managed to reinstall it.
I guess I am going to need to remove a lot more components before I will be able to manipulate the bolts for the EGR valve. Awfully awfully tight space!
My new question is:
Can anyone tell me how to manipulate the heater hose quick connect so I can replace the hose?
 
the bolts for the EGR seem to be accessible if you are using a universal joint or swivel socket. Another party mentioned removing the coil packs.
are you aware of the quick connect tool you have to use?
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The bolts are very inaccessible. Not sure how I got the bolts out, but it involved a ratcheting combo, one click at a time, and finger tips. Universal idea didn't work for me. No idea how I'm going to get them back in. Coil pack removal would help if I can get to those bolts, too.
 
Well, I got the hose off. It does not use the tool shown in these videos. As as matter of fact, it doesn't even require a tool. Just a squeeze and a push/pull. I had to go to a Ford site to find that out.
 
Finally finished the job! I replaced three of the six heater hoses and one of two tees while I was at it because I had to cut the hoses in order to remove them to replace a bad tee. I would have done all six hoses, but didn't want to push my luck in the nether reaches of this van.
While reinstalling the EGR valve I somehow managed to cross-thread one of the mounting bolts. Tapping a hole back there is not much easier than any other part of the job! For the record it is an 8mm x 1.25 thread.
This was BY FAR the most frustratingly difficult job on a vehicle I have ever had the mis-pleasure of doing!! However, it is done and the engine runs fine and no hose leaks as far as I can tell.
If you ever need to do this job, my advice is Good Luck! You're going to need it. Oh, and maybe alcohol.
 
Have you cleaned the duct between the throttle body and the EGR?. If it's obstructed you will continue obtaining codes
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