Exhaust Gas Recirculation (EGR) Valve: Installation

WARNING: This page is about a different variant/trim than selected.

WARNING: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the exhaust gas recirculation (EGR) valve gasket.

WARNING: Make sure that the mating faces are clean and free of foreign material.

Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Install the EGR valve mounting bracket and tighten the fasteners.
Torque: 1: 71 lb.in (8 Nm) 2: 89 lb.in (10 Nm)

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Connect the lower coolant hose to the EGR valve assembly and install the EGR valve assembly. Refer to: Quick Release Coupling .

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Install the EGR valve fasteners.
Torque: 89 lb.in (10 Nm)

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Loosen the EGR valve bracket fasteners.

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- Install the new o-ring.
- Lubricate the o-ring seal with clean engine oil.
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- Install the new gasket.
- Install the EGR valve outlet tube.
- Install the fasteners and hand tighten at this stage.
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Tighten the EGR outlet tube fasteners.
Torque: 89 lb.in (10 Nm)

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Tighten the EGR outlet tube fasteners.
Torque: 89 lb.in (10 Nm)

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1. Tighten the EGR valve bracket fasteners.
  Torque: 71 lb.in (8 Nm)
2. Tighten the EGR valve bracket fastener.
  Torque: 89 lb.in (10 Nm)
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- Install the new gasket.
- Install the EGR valve inlet tube.
- Install the fasteners and hand tighten at this stage.
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1. Install the EGR inlet tube nut and hand tighten at this stage.
2. Install the fastener and hand tighten at this stage.
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Tighten the EGR inlet tube fasteners.
Torque: 89 lb.in (10 Nm)

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1. Tighten the EGR inlet tube nut.
  Torque: 30 lb.ft (40 Nm)
2. Tighten the EGR inlet tube bracket fastener.
  Torque: Stage 1: 177 lb.in (20 Nm) Stage 2: 45 deg.
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Connect the EGR valve electrical connector and attach the retainer to the EGR valve bracket.

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Connect the quick release coupling. Refer to: Quick Release Coupling .

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Install the differential pressure feedback EGR sensor. Refer to: Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor .
Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .