Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 906 (ENGINE EMISSION CONTROL SYSTEM)REMOVAL AND INSTALLATIONEXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE - 4.0L SOHCREMOVAL AND INSTALLATION

2004 Ford Econoline E150, Van Cargo, 4.6 W

Removal and Installation

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors.
Disconnect the EGR system module-to-exhaust manifold tube upper fitting.
- To install, tighten to 40 N.m (30 lb-ft).

NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold.

Remove the bolts, the EGR system module and the gasket. Discard the gasket.
- To install, tighten to 25 N.m (18 lb-ft).
  
  Fig 1: Identifying EGR System Module Gasket
  Courtesy of FORD MOTOR CO.

NOTE: The EGR system module sealing surfaces are soft metals.

Carefully clean the EGR system module sealing surfaces.
To install, reverse the removal procedure.
- Install a new EGR system module gasket.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.