Exhaust Gas Recirculation (EGR) Valve - 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.

All vehicles

Install a new EGR gasket. Install new O-rings and lubricate with clean engine oil.

Fig 1: Installing EGR Gasket
Courtesy of FORD MOTOR CO.

CAUTION: Failure to completely seat the EGR valve into the intake manifold before inserting the mounting bolts may result in engine damage.

Fig 2: Installing EGR Valve

Courtesy of FORD MOTOR CO.

Install the EGR valve and bolts.

NOTE: Clean and inspect the gaskets. Install new gaskets if necessary.

Fig 3: Installing Throttle Plate Adapter

Courtesy of FORD MOTOR CO.

Install the throttle plate adapter.
Install the intake adapter.

Fig 4: Installing Intake Adapter
Courtesy of FORD MOTOR CO.
Connect the TP sensor electrical connector.

Fig 5: Connecting TP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the TP control module electrical connector.

Fig 6: Connecting TP Control Module Electrical Connector
Courtesy of FORD MOTOR CO.

Early build

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.

Fig 7: Installing Charge Air Cooler Duct

Courtesy of FORD MOTOR CO.

Install the charge air cooler duct and tighten the clamps.
Late build

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.

Fig 8: Installing Charge Air Cooler Duct

Courtesy of FORD MOTOR CO.

Install the charge air cooler duct and tighten the clamp.
All vehicles
Connect the EGR valve assembly electrical connector.

Fig 9: Connecting EGR Valve Assembly Electrical Connector
Courtesy of FORD MOTOR CO.