This procedure covers removal and replacement of the EGR cooler on the 3.5L EcoBoost engine, including disconnection of exhaust components, coolant system draining, and removal of interfering components.

Warnings

Tools required

Parts

• EGR cooler assembly × 1 — Use OEM specification
• EGR cooler gasket × 1 — Use OEM specification
• EGR valve gasket × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification
• EGR cooler coolant hose O-rings × 2 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 3 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable
3. Remove engine cover by pulling upward on cover tabs
4. Apply penetrating oil to all exhaust flange bolts and oxygen sensor threads
5. Position drain pan under radiator drain valve

Procedure

1. 1

   Drain cooling system
   Open radiator drain valve and drain approximately 3 quarts of coolant into drain pan. Close drain valve when coolant stops flowing. This partial drain is sufficient for EGR cooler removal without complete system drainage.
2. 2

   Remove air intake components
   Disconnect mass airflow sensor electrical connector. Loosen air intake tube clamps and remove intake tube from throttle body to air filter housing. Remove air filter housing mounting bolts and remove housing assembly to provide access to EGR components.
3. 3

   Disconnect EGR valve electrical connector
   Locate EGR valve on passenger side of engine near firewall. Press release tab and disconnect electrical connector from EGR valve. Move wiring harness aside to prevent damage during removal.
4. 4

   Remove oxygen sensors
   Remove upstream oxygen sensors from both exhaust manifolds using oxygen sensor socket. Turn counterclockwise to remove. Note sensor positions for reinstallation. Inspect sensor threads and exhaust manifold threads for damage.
   ⚠Never apply anti-seize to oxygen sensor body or tip. Apply only to threads as specified.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
5. 5

   Remove exhaust heat shields
   Remove heat shield bolts securing exhaust manifold heat shields on both banks. Remove heat shields to access exhaust manifold flange bolts. Set shields aside in order for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
6. 6

   Support exhaust system
   Support exhaust Y-pipe with jack stand or suitable support to prevent stress on remaining connections. Loosen but do not remove exhaust hanger bolts to allow system movement.
7. 7

   Disconnect exhaust at EGR cooler
   Remove exhaust flange bolts connecting EGR cooler outlet to exhaust Y-pipe. Remove bolts connecting EGR inlet to passenger side exhaust manifold. Separate exhaust components and remove old gaskets completely. Use wire brush to clean mating surfaces.
   ⚠If bolts resist removal, stop and apply additional penetrating oil. Broken exhaust studs require manifold removal for extraction.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
8. 8

   Disconnect EGR coolant lines
   Using flare nut wrench, carefully disconnect coolant supply and return lines from EGR cooler. Allow residual coolant to drain into pan. Cap or plug coolant lines to prevent contamination. Inspect O-rings and replace if damaged or hardened.
9. 9

   Remove EGR valve and tube
   Remove mounting bolts securing EGR valve to intake manifold. Disconnect EGR tube from EGR valve and EGR cooler by removing flange bolts. Remove EGR valve and tube assembly as a unit. Inspect all gasket surfaces and clean thoroughly.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Remove EGR cooler assembly
    Remove remaining EGR cooler mounting bolts securing cooler to engine block. Carefully maneuver EGR cooler assembly out of engine bay. Inspect old cooler for internal coolant leaks, cracks, or carbon blockage. Remove and discard all old gaskets from mounting surfaces.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Clean and inspect mounting surfaces
    Thoroughly clean all gasket mating surfaces on engine block, exhaust manifold, and intake manifold using wire brush and gasket scraper. Ensure surfaces are completely free of old gasket material, carbon deposits, and corrosion. Inspect for cracks or warping.
    ℹ️Do not use aggressive abrasives on aluminum surfaces. Hand-clean only to prevent gouging.
12. 12

    Install new EGR cooler
    Install new gasket on EGR cooler mounting surface. Position new EGR cooler assembly into location and start all mounting bolts by hand. Tighten mounting bolts to specification in cross-pattern sequence to ensure even gasket compression and proper sealing.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect EGR valve and tube
    Install new gaskets on EGR valve and tube connections. Reconnect EGR tube to EGR cooler and EGR valve using new gaskets. Install and tighten flange bolts to specification. Install EGR valve to intake manifold with new gasket and tighten mounting bolts to specification.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Reconnect exhaust connections
    Install new exhaust flange gaskets at EGR cooler inlet and outlet connections. Apply anti-seize compound to exhaust flange bolt threads. Connect exhaust components and install bolts, tightening to specification in cross-pattern. Ensure proper alignment before final torque.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
15. 15

    Install oxygen sensors and finalize assembly
    Apply small amount of anti-seize compound to oxygen sensor threads only, avoiding sensor tip. Install oxygen sensors and tighten to specification. Tighten exhaust hanger bolts to specification. Reinstall heat shields and tighten bolts to specification.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

    Hanger Bolts23 Nm (17 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect EGR valve electrical connector ensuring positive lock engagement
2. Reconnect coolant supply and return lines to EGR cooler with new O-rings, tightening securely
3. Reinstall air filter housing and intake tube, ensuring all clamps are properly tightened
4. Reconnect mass airflow sensor electrical connector
5. Refill cooling system with Motorcraft Orange Coolant to proper level using vacuum fill method if available
6. Reinstall engine cover
7. Reconnect negative battery cable

Verification

• Start engine and allow to reach operating temperature while monitoring for coolant leaks at EGR cooler connections
• Check for exhaust leaks at all disturbed flange connections by listening for abnormal exhaust noise
• Verify coolant level is correct after engine reaches operating temperature and thermostat opens
• Use scan tool to verify no EGR-related diagnostic trouble codes are present
• Perform test drive and monitor engine temperature gauge for normal operation
• After test drive, recheck all exhaust flange bolts and coolant connections for signs of leakage
• Verify coolant is not present in exhaust system by checking for white residue or steam from tailpipe

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