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

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Position the secondary fuel filter and install the bolts.

Fig 1: Installing Bolts
Courtesy of FORD MOTOR CO.
Position the fuel tubes and connect at the secondary fuel filter.

Fig 2: Connecting Secondary Fuel Filter
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Install a new EGR gasket. Install new O-ring seals and lubricate with clean engine oil.

Fig 3: Installing New EGR Gasket
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CAUTION: Failure to completely seat the EGR valve into the intake manifold before inserting the mounting bolts may result in engine damage.

Fig 4: Installing EGR Valve And Bolts

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Courtesy of FORD MOTOR CO.

Install the EGR valve and bolts.
Connect the EGR valve assembly electrical connector.

Fig 5: Connecting EGR Valve Assembly Electrical Connector
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Install the throttle plate adapter and bolts.

Fig 6: Installing Throttle Plate Adapter And Bolts
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Connect the TP sensor electrical connector.

Fig 7: Connecting TP Sensor Electrical Connector
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Connect the TP control module electrical connector.

Fig 8: Connecting TP Control Module Electrical Connector
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Install the intake adapter and bolts.

Fig 9: Installing Intake Adapter And Bolts
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CAUTION: Use care not to damage the turbocharger outlet hose when installing the CAC tube.

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

Fig 10: Installing CAC Duct, Oil Fill Tube, Bracket And Retaining Nuts

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Courtesy of FORD MOTOR CO.

Install the CAC duct, oil fill tube, bracket and retaining nuts.
Connect the oil fill tube at the valve cover.

Fig 11: Connecting Oil Fill Tube At Valve Cover
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Install the bolts for the CAC duct and oil fill tube.

Fig 12: Installing Bolts For CAC Duct
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Tighten the clamp for the turbocharger outlet pipe.

Fig 13: Tightening Clamp For Turbocharger Outlet Pipe
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Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
Tighten the clamp for the CAC duct.

Fig 14: Tightening Clamp For CAC Duct
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Position the cowl wiring harness. Install the bolts and connect the push pin retainer.

Fig 15: Connecting Push Pin Retainer
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Position the MAP sensor and install the bolt. Position the ground wire and install the bolt.

Fig 16: Installing Bolt
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Install the CAC duct and tighten the clamps.

Fig 17: Tightening Clamps
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NOTE: Air cleaner side shown, other side similar.

Fig 18: Tightening Clamps

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Courtesy of FORD MOTOR CO.

Install the air cleaner outlet tube and tighten the clamps.
Connect the coolant hoses to the air cleaner outlet tube.

Fig 19: Connecting Coolant Hoses To Air Cleaner Outlet Tube
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Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and bolts, then install the power steering fluid indicator.

Fig 20: Installing Power Steering Fluid Indicator
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Install the bolts for the power steering reservoir bracket.

Fig 21: Installing Bolts For Power Steering Reservoir Bracket
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Install the upper air deflector and push pin retainers.

Fig 22: Installing Upper Air Deflector And Push Pin Retainers
Courtesy of FORD MOTOR CO.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .