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

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Locating EGR Valve Assembly Electrical Connector

Courtesy of FORD MOTOR CO.

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

Fig 2: Loosening Clamp And Disconnect Charge Air Cooler Duct
Courtesy of FORD MOTOR CO.

NOTE: Intake manifold removed for clarity.

Remove the intake adapter.
- Remove and discard the press-in-place gasket.
  
  Fig 3: Removing Intake Adapter
  Courtesy of FORD MOTOR CO.

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

Fig 4: 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 5: Removing EGR Valve
Courtesy of FORD MOTOR CO.
Remove and discard the O-rings and the EGR gasket.

Fig 6: Removing O-Rings And EGR Gasket
Courtesy of FORD MOTOR CO.
Using an appropriate brush, clean the EGR port. Vacuum out the ash and foreign material from inside the intake manifold.