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

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.

NOTE: The exhaust gas recirculation (EGR) valve assembly has an internal exhaust gas recirculation position (EGRP) sensor.

Fig 1: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the EGR valve assembly electrical connector.
Loosen the clamp and disconnect the charge air cooler duct.

Fig 2: Locating Charge Air Cooler Duct Bolt
Courtesy of FORD MOTOR CO.

NOTE: Intake manifold removed for clarity.

Remove the intake adapter.
- Remove and discard the press-in-place gasket.
  
  Fig 3: Locating Intake Adapter Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Do not pull the EGR valve out or damage to the EGR valve will occur.

Fig 4: Removing EGR Valve Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and rotate the EGR valve counterclockwise.
Install the special tool and remove the EGR valve.

Fig 5: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Remove and discard the O-rings and the EGR gasket.

Fig 6: Locating O-Rings And EGR Gasket
Courtesy of FORD MOTOR CO.
Using the appropriate brush, clean the EGR port. Vacuum out the ash and foreign material from inside the intake manifold.