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

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Installing EGR Gasket And O-Rings
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 And Bolts

Courtesy of FORD MOTOR CO.

Install the EGR valve and bolts.

NOTE: Install a new press-in-place gasket.

Fig 3: Installing Intake Adapter

Courtesy of FORD MOTOR CO.

Install the intake adapter.

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 4: Charge Air Cooler Duct And Clamp - With Torque Specification

Courtesy of FORD MOTOR CO.

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

Fig 5: Locating EGR Valve Assembly Electrical Connector
Courtesy of FORD MOTOR CO.