Exhaust Gas Recirculation (EGR) System Module - 4.6L: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The EGR valve sealing surfaces are soft metals.

Carefully clean both sealing surfaces.
- Install a new EGR system module gasket with the side with the raised ring facing the intake manifold.
  
  Fig 1: Identifying EGR System Module Gasket
  Courtesy of FORD MOTOR CO.
Install the EGR system module and bolts.
- Tighten the bolts in two stages.
  - Stage 1: Tighten to 20 Nm (15 lb-ft).
  - Stage 2: Tighten an additional 90 degrees.
    
    Fig 2: Installing EGR System Module
    Courtesy of FORD MOTOR CO.
Connect the EGR valve tube fitting and vacuum line.

Fig 3: Connecting EGR Valve Tube Fitting And Vacuum Line
Courtesy of FORD MOTOR CO.
Connect the EGR system module electrical connector.
- Push in the red clip.
  
  Fig 4: Connecting EGR System Module Electrical Connector
  Courtesy of FORD MOTOR CO.
Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .