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

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.

All vehicles

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

Fig 1: Disconnecting EGR Valve Assembly Electrical Connector

Courtesy of FORD MOTOR CO.

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

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

Late build
Loosen the clamp and disconnect the charge air cooler duct.

Fig 3: Disconnecting Charge Air Cooler Duct
Courtesy of FORD MOTOR CO.

All vehicles
Disconnect the throttle position (TP) control module electrical connector.

Fig 4: Disconnecting Throttle Position (TP) Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the TP sensor electrical connector.

Fig 5: Disconnecting TP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Intake manifold removed for clarity.

Fig 6: Removing Intake Adapter

Courtesy of FORD MOTOR CO.

Remove the intake adapter.
Remove the throttle plate adapter.

Fig 7: Removing Throttle Plate Adapter
Courtesy of FORD MOTOR CO.

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

Fig 8: Removing Bolts And Rotate EGR Valve Counterclockwise

Courtesy of FORD MOTOR CO.

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

Fig 9: Installing Special Tool And Remove EGR Valve
Courtesy of FORD MOTOR CO.
Remove and discard the O-rings and the EGR gasket.

Fig 10: Discarding O-Rings And EGR Gasket
Courtesy of FORD MOTOR CO.
Vacuum out the ash and foreign material from inside the intake manifold.