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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 1282 (Engine Emission Control) >> Removal And Installation >> Exhaust Gas Recirculation (EGR) Valve - 6.0L Diesel >> Removal

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

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.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  2. Remove the pushpin retainers and upper air deflector.
    3. Fig 1: Locating Pushpin Retainers
    GF0044581Courtesy of FORD MOTOR CO.
  3. Remove the bolts for the power steering bracket.
    4. Fig 2: Locating Power Steering Reservoir Bracket Retainers
    G03887857Courtesy of FORD MOTOR CO.
  4. Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position it aside.
    5. Fig 3: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts
    G03887858Courtesy of FORD MOTOR CO.
  5. Disconnect the coolant hoses from the air cleaner outlet tube.
    6. Fig 4: Locating Coolant Hoses & Air Cleaner Outlet Pipe
    G03887859Courtesy of FORD MOTOR CO.
    NOTE: Air cleaner side shown, other side similar.
  6. Loosen the clamps and remove the air cleaner outlet tube.
    7. Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp
    G03887860Courtesy of FORD MOTOR CO.
  7. Loosen the clamps and remove the charge air cooler (CAC) duct.
    8. Fig 6: Charge Air Cooler (CAC) Duct & Clamps
    GF0012026Courtesy of FORD MOTOR CO.
  8. Remove the bolts and position the manifold absolute pressure (MAP) sensor and the ground wire aside.
    9. Fig 7: Manifold Absolute Pressure (MAP) Sensor, Ground Wire & Bolts
    GF0012027Courtesy of FORD MOTOR CO.
  9. Remove the bolts and disconnect the pushpin retainer. Position the cowl wiring harness aside.
    10. Fig 8: Bolts & Pushpin Retainer
    GF0012028Courtesy of FORD MOTOR CO.
  10. Loosen the clamp for the CAC duct.
    11. Fig 9: Charge Air Cooler (CAC) Duct Clamp
    GF0012029Courtesy of FORD MOTOR CO.
  11. Remove the bolts for the CAC tube and oil fill tube.
    12. Fig 10: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  12. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
  13. Loosen the clamp at the turbocharger outlet hose.
    14. Fig 11: Turbocharger Outlet Hose & Clamp
    GF0011838Courtesy of FORD MOTOR CO.
  14. Disconnect the oil fill tube at the valve cover.
    15. Fig 12: Identifying Oil Fill Tube At Valve Cover
    G03887098Courtesy of FORD MOTOR CO.
  15. Remove the retaining nuts, CAC tube, oil fill tube and bracket.
    16. Fig 13: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
    G03887099Courtesy of FORD MOTOR CO.
    NOTE: Intake manifold removed for clarity.
  16. Remove the bolts and intake adapter.
    • Cover the opening after the intake adapter is removed.
    17. Fig 14: Locating Intake Adapter Bolts
    GF0005996Courtesy of FORD MOTOR CO.
  17. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover.
    • Tighten to 14 Nm (10 lb-ft).
    18. Fig 15: Secondary Fuel Filter Cover
    GF0012030Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel tubes at the secondary fuel filter and position them aside.
    19. Fig 16: Secondary Fuel Filter Fuel Tubes
    GF0012031Courtesy of FORD MOTOR CO.
  19. Remove the 2 bolts and position the secondary fuel filter assembly aside.
    20. Fig 17: Locating Secondary Fuel Filter Assembly Bolts
    G03887121Courtesy of FORD MOTOR CO.
    NOTE: The EGR valve assembly has an internal exhaust gas recirculation position (EGRP) sensor.
  20. Disconnect the EGR valve assembly electrical connector.
    21. CAUTION: Do not attempt to remove the EGR valve without the use of the EGR valve removal tool or damage to the EGR valve may occur.
  21. Remove the bolts and rotate the EGR valve counterclockwise.
  22. Install the special tool and remove the EGR valve.
    23. Fig 18: Removing EGR Valve
    GF0012032Courtesy of FORD MOTOR CO.
  23. Remove and discard the O-ring seals and the EGR gaskets.
    24. Fig 19: Locating O-Rings And EGR Gasket
    G03888271Courtesy of FORD MOTOR CO.
  24. Using the appropriate brush, clean the EGR port. Vacuum the ash and foreign material from inside the intake manifold.
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