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.
Removal and Installation
2009 Ford Fusion SEL, 3.0 1, FWDSECTION Removal and Installation
WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum connector.
- Remove the 2 bolts and the intake manifold shield.
- To install, tighten to 12 Nm (9 lb-ft).
- Disconnect the EGR tube fitting from the EGR system module.
- To install, tighten to 40 Nm (30 lb-ft).
- Remove the 2 bolts and the EGR system module.
- To install, tighten to 25 Nm (18 lb-ft).
- Remove the EGR system module gasket and discard.
CAUTION:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the EGR system module gasket.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.