I was working on my son's car EGR checked out ok but had to clean passages on the intake side, after removing throttle body, code gone now. I'm a little concerned about the torq specs for the EGR valve. Autozone told me 20ft-lbs, seems ok for lower bolts that plug into iron pipe, but a little high for the ones that screw into the intake manifold. I have 2 manuals and neither one give specifications for DOHC engine. Ones a Haynes and one a Chilton, strangely enough they have the same text and pics. I did find torq specs for a 2.4l Duratec engine. http://duratec.wikispaces.com/Bolt_Size_and_Torque
Was wondering what manual that covers this engine thourghly. I suspect about 10ft-lbs for upper EGR bolts, but would like further verification on this.
The EGR valve to upper intake manifold bolt torque spec is 15-22 lb-ft. The EGR valve to exhaust manifold nuts should be tightened to 89 lb-in and then turned an additional 90º. Before tightening the bolts install everything loosely first.
A factory service manual would cover all this in great detail. The Haynes/Chilton's manuals leave a lot of stuff out. You can buy a used service manual one online (e.g. eBay).
+1 on the factory manual. You can also get a subscription to alldata for $9.99 per month if you want which has data on many more cars, it's also searchable. However 5 months of that and you've paid for a factory manual.
2008 Mercury Sable Premier
2014 Ford Focus Electric
1997 Mercury Grand Marquis GS
Moved On: 2000 Sable LS Premium Duratec