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

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.
  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 Push Pin Retainers And Upper Air Deflector
    G02761682Courtesy of FORD MOTOR CO.
  3. Remove the bolts for the power steering bracket.
    Fig 2: Removing Bolts For Power Steering Bracket
    G02761683Courtesy 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: Removing Bolts Of Power Steering Fluid Indicator
    G02761684Courtesy of FORD MOTOR CO.
  5. Disconnect the coolant hoses from the air cleaner outlet tube.
    Fig 4: Disconnecting Coolant Hoses From Air Cleaner Outlet Tube
    G02761685Courtesy of FORD MOTOR CO.
    6. NOTE: Air cleaner side shown, other side similar.
    Fig 5: Removing Air Cleaner Outlet Tube
    G02761686Courtesy 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
    G02761687Courtesy of FORD MOTOR CO.
  8. Remove the bolts and position the manifold absolute pressure (MAP) sensor and the ground wire aside.
    Fig 7: Removing Bolts
    G02761688Courtesy 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
    G02761689Courtesy of FORD MOTOR CO.
  10. Loosen the clamp for the CAC duct.
    Fig 9: Loosening Clamp For CAC Duct
    G02761690Courtesy of FORD MOTOR CO.
  11. Remove the bolts for the CAC duct and oil fill tube.
    Fig 10: Removing Bolts For CAC Duct
    G02761691Courtesy 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: Loosening Clamp At Turbocharger Outlet Hose
    G02761692Courtesy of FORD MOTOR CO.
  14. Disconnect the oil fill tube at the valve cover.
    Fig 12: Disconnecting Oil Fill Tube At Valve Cover
    G02761693Courtesy of FORD MOTOR CO.
  15. Remove the retaining nuts, CAC duct, oil fill tube and bracket.
    Fig 13: Removing Retaining Nuts
    G02761694Courtesy of FORD MOTOR CO.
    16. NOTE: Intake manifold removed for clarity.
    Fig 14: Removing Bolts And Intake Adapter
    G02761695Courtesy of FORD MOTOR CO.
  16. Remove the bolts and intake adapter.
  17. Disconnect the TP sensor electrical connector.
    Fig 15: Disconnecting TP Sensor Electrical Connector
    G02761696Courtesy of FORD MOTOR CO.
  18. Disconnect the throttle position (TP) control module electrical connector.
    Fig 16: Disconnecting Throttle Position (TP) Control Module Electrical Connector
    G02761697Courtesy of FORD MOTOR CO.
  19. Remove the bolts and throttle plate adapter.
    • Cover the opening after the throttle plate adapter is removed.
    Fig 17: Removing Bolts And Throttle Plate Adapter
    G02761698Courtesy of FORD MOTOR CO.
  20. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover.
    Fig 18: Removing Secondary Fuel Filter And Drain Housing
    G02761699Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel tubes at the secondary fuel filter and position them aside.
    Fig 19: Disconnecting Fuel Tubes At Secondary Fuel Filter
    G02761700Courtesy of FORD MOTOR CO.
  22. Remove the bolts and position the secondary fuel filter assembly aside.
    Fig 20: Removing Bolts
    G02761701Courtesy of FORD MOTOR CO.
    23. NOTE: The exhaust gas recirculation (EGR) valve assembly has an internal exhaust gas recirculation position (EGRP) sensor.
    Fig 21: Disconnecting EGR Valve Assembly Electrical Connector
    G02761702Courtesy of FORD MOTOR CO.
  23. Disconnect the EGR valve assembly electrical connector.
    24. CAUTION: Do not pull the EGR valve out or damage to the EGR valve will occur.
    Fig 22: Removing Bolts
    G02761703Courtesy of FORD MOTOR CO.
  24. Remove the bolts and rotate the EGR valve counterclockwise.
  25. Install the special tool and remove the EGR valve.
    Fig 23: Removing EGR Valve
    G02761704Courtesy of FORD MOTOR CO.
  26. Remove and discard the O-ring seals and the EGR gaskets.
    Fig 24: Removing O-Ring Seals
    G02761705Courtesy of FORD MOTOR CO.
  27. Using an appropriate brush, clean the EGR port. Vacuum the ash and foreign material from inside the intake manifold.
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