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

Position the secondary fuel filter and install the bolts.

Fig 1: Positioning Secondary Fuel Filter
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Connect the fuel tubes at the secondary fuel filter.

Fig 2: Connecting Fuel Tubes At 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 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

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

Fig 5: Locating EGR Valve Assembly Electrical Connector
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NOTE: Clean and inspect the gasket. Install a new gasket if necessary.

Fig 6: Installing Intake Adapter

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Install the intake adapter and bolts.

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 CAC tube to prevent the tube from blowing off.

Fig 7: Locating Bracket Retaining Nuts

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

Fig 8: Identifying Oil Fill Tube At Valve Cover
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Install the bolts for the CAC tube and oil fill tube.

Fig 9: Locating CAC Tube And Oil Fill Tube Bolts
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Tighten the clamp for the turbocharger outlet pipe.

Fig 10: Installing Turbocharger Outlet Pipe Clamp
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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 11: Tightening Clamp For CAC Duct
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Position the cowl wiring harness. Install the bolts and connect the push pin retainer.

Fig 12: Positioning Cowl Wiring Harness
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Position the MAP sensor and install the bolt. Position the ground wire and install the bolt.

Fig 13: Installing MAP Sensor
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Install the CAC duct and tighten the clamps.

Fig 14: Installing CAC Duct
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NOTE: Air cleaner side shown, other side similar.

Fig 15: Identifying Air Cleaner Outlet Pipe & Clamp

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

Fig 16: Locating Coolant Hoses At 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 17: Locating Power Steering Fluid Indicator And Retainers
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Install the bolts for the power steering reservoir bracket.

Fig 18: Locating Power Steering Reservoir Bracket Retainers
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Install the upper air deflector and push pin retainers.

Fig 19: Identifying Pushpin Retainers And Upper Air Deflector
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Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .