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

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Position the secondary fuel filter housing and install the bolts.
- Tighten to 24 Nm (18 lb-ft).

Fig 1: Locating Secondary Fuel Filter Assembly Bolts

Courtesy of FORD MOTOR CO.

Connect the fuel tubes at the secondary fuel filter.
- Tighten to 26 Nm (19 lb-ft).

Fig 2: Secondary Fuel Filter Fuel Tubes

Courtesy of FORD MOTOR CO.

Install a new EGR gasket. Install new O-ring seals and lubricate with clean engine oil.

Fig 3: Locating O-Rings And EGR Gasket

Courtesy of FORD MOTOR CO.

CAUTION: Failure to completely seat the EGR valve into the intake manifold before inserting the mounting bolts may result in engine damage.

Position the EGR valve and install the 2 bolts.
- Tighten to 13 Nm (10 lb-ft).
Connect the EGR valve assembly electrical connector.

NOTE: Clean and inspect the gasket. Install a new gasket if necessary.

Install the intake adapter and bolts.
- Tighten to 13 Nm (10 lb-ft).

Fig 4: Locating Intake Adapter Bolts

Courtesy of FORD MOTOR CO.

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.

Install the CAC tube, oil fill tube, bracket and retaining nuts.

Fig 5: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket

Courtesy of FORD MOTOR CO.

Connect the oil fill tube at the valve cover.

Fig 6: Identifying Oil Fill Tube At Valve Cover

Courtesy of FORD MOTOR CO.

Install the bolts for the CAC tube and oil fill tube.

Fig 7: Locating CAC Tube And Oil Fill Tube Bolts

Courtesy of FORD MOTOR CO.

Tighten the clamp for the turbocharger outlet pipe.
- Tighten to 12 Nm (9 lb-ft).

Fig 8: Turbocharger Outlet Hose & Clamp

Courtesy of FORD MOTOR CO.

Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
Tighten the clamp for the CAC duct.
- Tighten to 12 Nm (9 lb-ft).

Fig 9: Charge Air Cooler (CAC) Duct Clamp

Courtesy of FORD MOTOR CO.

Position the cowl wiring harness. Install the bolts and connect the pushpin retainer.
- Tighten to 2 Nm (18 lb-in).

Fig 10: Bolts & Pushpin Retainer

Courtesy of FORD MOTOR CO.

Position the MAP sensor and install the bolt. Position the ground wire and install the bolt.
1. Tighten the MAP sensor bolt to 5 Nm (44 lb-in).
2. Tighten the ground wire bolt to 8 Nm (71 lb-in).

Fig 11: Manifold Absolute Pressure (MAP) Sensor, Ground Wire & Bolts

Courtesy of FORD MOTOR CO.

Install the CAC duct and tighten the clamps.
- Tighten to 12 Nm (9 lb-ft).

Fig 12: Charge Air Cooler (CAC) Duct & Clamps

Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, other side similar.

Install the air cleaner outlet tube and tighten the clamps.

Fig 13: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Connect the coolant hoses to the air cleaner outlet tube.

Fig 14: Locating Coolant Hoses & Air Cleaner Outlet Pipe

Courtesy of FORD MOTOR CO.

Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and bolts, then install the power steering fluid indicator.

Fig 15: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts

Courtesy of FORD MOTOR CO.

Install the bolts for the power steering reservoir bracket.

Fig 16: Locating Power Steering Reservoir Bracket Retainers

Courtesy of FORD MOTOR CO.

Install the upper air deflector and pushpin retainers.

Fig 17: Locating Pushpin Retainers

Courtesy of FORD MOTOR CO.

Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.