Answers: You will still enjoy the EGR code when you finish. I have replaced individual a handful of EGR valves for a EGR flow problem surrounded by the past 19 years, but own replaced thousands of DPFE sensors, which more than likely be the cause of the P0401 or P0402 or other EGR code that you own, and is very adjectives on the Ford engines. No, you will not damage any o-rings by letting them fire by cranking the engine, in recent times lightly lube the o-rings beside a small amount of vaseline or lithium grease before rinstalling and manufacture sure the holes they go contained by are free from dirt and debris. Make definite that the vacuum regulator for the EGR valve on the gone rear of the intake several was not dilapidated or unplugged while replacing the wires. One more thing on this precise engine that I have see many times. The EGR ports that front into the cylinder heads will become clogged beside carbon. This clogging forces all the EGR gas for the engine to run into one or two cylinders surrounded by which the ports remain open, cause a misfire due to excessive EGR gas in the cylinders that are not clogged. One agency to test the ports is to connect a vacuum guage to the vacuum port on the EGR stopcock and apply vacuum to it to open the spigot at idle. The unemployed of the engine should take a crucial nosedive and possibly even kill the engine. If it does not affect the unexploited very much, in attendance are EGR ports clogged. You would need to remove the upper and lower intake and physically verbs out the EGR ports on the cylinder heads. They are brass colored and in the order of the size of a dime with a hole contained by the center. Clean them out with a pick and get hold of all the carbon out and follow by spraying respectively with some Gum Cutter or similar, and blow them out near shop air if available and reinstall the intake. If the unemployed does dip and change drastically when the vacuum is applied to the EGR stopcock, I would continue next to the fuel and ignition diagnosis.
The problem is most likely carbon build up inside the intake. These engines own a EGR passage that runs through the lower intake beside a little orfice at respectively cylinders intake runner. When these ports get plugged adjectives of the EGR gas goes to with the sole purpose one or two cylinders which also could be the cause of your misfire. Remove upper intake and verbs out these ports and make sure to use brand new gaskets for the plenum.(they are a rubber o-ring type and are also known to exact vacuum leaks when cold/misfire) Hope this help.
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