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

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 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: Locating O-Rings And 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.

Install the EGR valve and bolts.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 2: Locating EGR Valve And Bolts
  Courtesy of FORD MOTOR CO.

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

Install the intake adapter and bolts.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 3: Locating Intake Adapter And Bolts
  Courtesy of FORD MOTOR CO.

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.

Install the charge air cooler duct and tighten the clamp.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 4: Locating Air Cooler Duct Bolt
  Courtesy of FORD MOTOR CO.
Connect the EGR valve assembly electrical connector.

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