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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 808 (Engine Emission Control 6.0L (99P E-Series)) >> Removal And Installation >> Exhaust Gas Recirculation (EGR) Valve - 6.0L Diesel >> Removal

Exhaust Gas Recirculation (EGR) Valve - 6.0L Diesel: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the push pin retainers and upper air deflector.
    Fig 1: Removing Pushpin Retainers And Upper Air Deflector
    G03887856Courtesy of FORD MOTOR CO.
  3. Remove the bolts for the power steering bracket.
    Fig 2: Locating Power Steering Reservoir Bracket Retainers
    G03887857Courtesy of FORD MOTOR CO.
  4. Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position it aside.
    Fig 3: Locating Power Steering Fluid Indicator And Retainers
    G03887858Courtesy of FORD MOTOR CO.
  5. Disconnect the coolant hoses from the air cleaner outlet tube.
    Fig 4: Locating Coolant Hoses At Air Cleaner Outlet Tube
    G03887859Courtesy of FORD MOTOR CO.
    6. NOTE: Air cleaner side shown, other side similar.
    Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp
    G03887860Courtesy of FORD MOTOR CO.
  6. Loosen the clamps and remove the air cleaner outlet tube.
  7. Loosen the clamps and remove the charge air cooler (CAC) duct.
    Fig 6: Removing Charge Air Cooler (CAC) Duct
    G03888256Courtesy of FORD MOTOR CO.
  8. Remove the bolts and position the manifold absolute pressure (MAP) sensor and the ground wire aside.
    Fig 7: Removing Manifold Absolute Pressure (MAP) Sensor
    G03888257Courtesy of FORD MOTOR CO.
  9. Remove the bolts and disconnect the push pin retainer. Position the cowl wiring harness aside.
    Fig 8: Disconnecting Push Pin Retainer
    G03888258Courtesy of FORD MOTOR CO.
  10. Loosen the clamp for the CAC duct.
    Fig 9: Loosening Clamp For CAC Duct
    G03888259Courtesy of FORD MOTOR CO.
  11. Remove the bolts for the CAC tube and oil fill tube.
    Fig 10: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  12. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  13. Loosen the clamp at the turbocharger outlet hose.
    Fig 11: Removing Turbocharger Outlet Hose
    G03887191Courtesy of FORD MOTOR CO.
  14. Disconnect the oil fill tube at the valve cover.
    Fig 12: Identifying Oil Fill Tube At Valve Cover
    G03887098Courtesy of FORD MOTOR CO.
  15. Remove the retaining nuts, CAC tube, oil fill tube and bracket.
    Fig 13: Locating Bracket Retaining Nuts
    G03887099Courtesy of FORD MOTOR CO.
    16. NOTE: Intake manifold removed for clarity.
  16. Remove the bolts and intake adapter.
    • Cover the opening after the intake adapter is removed.
      Fig 14: Removing Intake Adapter
      G03888264Courtesy of FORD MOTOR CO.
  17. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover.
    Fig 15: Installing Fuel Filter And Cover
    G03887134Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel tubes at the secondary fuel filter and position them aside.
    Fig 16: Disconnecting Fuel Tubes At Secondary Fuel Filter
    G03888266Courtesy of FORD MOTOR CO.
  19. Remove the bolts and position the secondary fuel filter assembly aside.
    Fig 17: Removing Secondary Fuel Filter Assembly
    G03887121Courtesy of FORD MOTOR CO.
    20. NOTE: The exhaust gas recirculation (EGR) valve assembly has an internal exhaust gas recirculation position (EGRP) sensor.
    Fig 18: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  20. Disconnect the EGR valve assembly electrical connector.
    21. CAUTION: Do not pull the EGR valve out or damage to the EGR valve will occur.
    Fig 19: Rotating EGR Valve Counterclockwise
    G03888269Courtesy of FORD MOTOR CO.
  21. Remove the bolts and rotate the EGR valve counterclockwise.
  22. Install the special tool and remove the EGR valve.
    Fig 20: Removing EGR Valve
    G03888270Courtesy of FORD MOTOR CO.
  23. Remove and discard the O-ring seals and the EGR gaskets.
    Fig 21: Discarding O-Ring Seals
    G03888271Courtesy of FORD MOTOR CO.
  24. Using the appropriate brush, clean the EGR port. Vacuum the ash and foreign material from inside the intake manifold.
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