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

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. 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. Refer to ENGINE - 6.0L DIESEL .