Exhaust Gas Recirculation (EGR) Valve - 5.4L (2V): Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The EGR valve sealing surfaces are soft metal.

Carefully clean both sealing surfaces.
- Install a new gasket.
Install the EGR valve.
- Tighten the bolts in two stages.
- Stage 1: Tighten the bolts to 20 Nm (15 lb-ft).
- Stage 2: Tighten the bolts an additional 90 degrees.
  
  Fig 1: Installing EGR Valve and Two Bolts
  Courtesy of FORD MOTOR CO.
Connect the vacuum line.

Fig 2: Connecting Vacuum Line
Courtesy of FORD MOTOR CO.
Connect the EGR tube fittings.
1. Connect the differential pressure feedback EGR sensor hoses.
2. Connect the EGR valve tube fittings.
  
  Fig 3: Connecting EGR Valve Tube Fittings
  Courtesy of FORD MOTOR CO.
Install the air cleaner outlet tube. Refer to INTAKE AIR DISTRIBUTION & FILTERING .