Exhaust Gas Recirculation (EGR) Cooler - 6.0L Diesel: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Install the O-ring seal and gasket.

Fig 1: Installing O-Ring Seal And Gasket
Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the O-ring seal.

NOTE: Position the grommets and spacer prior to installing the EGR cooler.

Fig 2: Installing EGR Cooler And Stud Bolts Hand-Tight

Courtesy of FORD MOTOR CO.

Install the EGR cooler and stud bolts hand-tight.
Install the EGR cooler bolt.
- EGR cooler with a M6 bolt, tighten to 13 Nm (10 lb-ft).
- EGR cooler with a M8 bolt, tighten to 31 Nm (23 lb-ft)
Fig 3: Installing EGR Cooler Bolt
Courtesy of FORD MOTOR CO.
Tighten the EGR cooler stud bolts.

Fig 4: Tightening EGR Cooler Stud Bolts
Courtesy of FORD MOTOR CO.
Install the intake manifold. For additional information, refer to ENGINE 6.0L DIESEL .