Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD2004FREESTAR V6-4.2L VIN 2REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTEMISSION CONTROL SYSTEMSDESCRIPTION AND OPERATIONENGINE EMISSION CONTROL
2004 Ford Freestar V6-4.2L VIN 2
Engine Emission Control
2004 Ford Freestar V6-4.2L VIN 2SECTION Engine Emission Control
Engine Emission Control
CAUTION: Do not remove any part of the engine emission control system. Operating the engine without the engine emission control system will reduce fuel economy and engine ventilation. This will weaken engine performance and shorten engine life.
The engine emission control system consists of the:
^ positive crankcase ventilation (PCV) system.
^ exhaust gas recirculation (EGR) system.

Typical Vehicle Emission Control Information (VECI) Decal
The Vehicle Emission Control Information (VECI) decal shows:
^ components of the emission control system.
^ the correct vacuum hose routing.
^ the color stripe of the vacuum hoses.
The PCV system uses 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 system module to exhaust manifold tube and sends a signal to the powertrain control module.
The PCV valve:
^ controls the amount of ventilating air and blow-by gases going to the intake manifold.
^ prevents a backfire from reaching the crankcase.
The EGR system module to exhaust manifold tube:
^ connects the exhaust manifold to the EGR valve.
The EGR system module transducer:
^ monitors the EGR system module flow rate through the EGR to exhaust manifold tube.
^ sends an EGR system module flow rate signal to the powertrain control module.
The EGR vacuum regulator solenoid uses input from the powertrain control module to change the EGR system module operation.
CAUTION: Do not remove any part of the engine emission control system. Operating the engine without the engine emission control system will reduce fuel economy and engine ventilation. This will weaken engine performance and shorten engine life.
The engine emission control system consists of the:
^ positive crankcase ventilation (PCV) system.
^ exhaust gas recirculation (EGR) system.
Typical Vehicle Emission Control Information (VECI) Decal
The Vehicle Emission Control Information (VECI) decal shows:
^ components of the emission control system.
^ the correct vacuum hose routing.
^ the color stripe of the vacuum hoses.
The PCV system uses 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 system module to exhaust manifold tube and sends a signal to the powertrain control module.
The PCV valve:
^ controls the amount of ventilating air and blow-by gases going to the intake manifold.
^ prevents a backfire from reaching the crankcase.
The EGR system module to exhaust manifold tube:
^ connects the exhaust manifold to the EGR valve.
The EGR system module transducer:
^ monitors the EGR system module flow rate through the EGR to exhaust manifold tube.
^ sends an EGR system module flow rate signal to the powertrain control module.
The EGR vacuum regulator solenoid uses input from the powertrain control module to change the EGR system module operation.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- β’ You smell fuel, burning insulation, or see smoke.
- β’ Brakes feel soft, pull hard to one side, or make grinding noises.
- β’ The engine overheats, stalls repeatedly, or misfires under load.
- β’ You are missing required tools, torque specs, or safe lifting equipment.
- β’ You are not confident in the next step or safety outcome.