This procedure covers the removal and replacement of the EGR (Exhaust Gas Recirculation) valve on the 3.5L EcoBoost V6 engine, including disconnecting the EGR tube and electrical connections.

Warnings

Tools required

Parts

• EGR valve × 1 — Use OEM specification
• EGR valve gasket × 1 — Use OEM specification
• EGR tube gasket × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and wait 2 minutes
3. Remove engine cover by pulling upward on cover retention grommets
4. If equipped, remove air intake tube between air filter housing and throttle body for additional working room
5. Apply penetrating oil to EGR valve bolts and EGR tube fitting, allow to soak 10-15 minutes

Procedure

1. 1

   Locate and access EGR valve
   The EGR valve is located on the passenger side of the engine, mounted to the intake manifold near the firewall. It has an electrical connector on top and a metal tube connecting it to the exhaust system. Verify you have clear access to both the valve mounting bolts and the tube connection.
2. 2

   Disconnect EGR valve electrical connector
   Press down on the connector locking tab while pulling the electrical connector away from the EGR valve. The connector may be stiff due to heat cycling. Rock gently side-to-side while pulling if necessary. Do not pull on the wiring harness itself.
3. 3

   Disconnect EGR tube from valve
   Locate the tube fitting nut where the EGR tube connects to the EGR valve body. Using a 13mm socket, loosen and remove the tube fitting nut. The tube may be stuck to the valve due to carbon buildup. Once the nut is removed, gently twist and pull the tube away from the valve. Remove and discard the old gasket from the tube fitting.
   Torque spec

   EGR Tube Fitting35 Nm (26 lb-ft)
4. 4

   Remove EGR valve mounting bolts
   Using a 10mm socket, remove the two bolts securing the EGR valve to the intake manifold. Support the valve with one hand while removing the second bolt to prevent it from falling. Note the bolt locations and any brackets that may be retained by these bolts.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
5. 5

   Remove EGR valve
   Pull the EGR valve away from the intake manifold mounting surface. The valve may stick due to gasket material or carbon deposits. Gently rock the valve while pulling to break the seal. Remove and discard the old gasket. Do not allow the gasket material to fall into the intake manifold opening.
6. 6

   Clean mounting surfaces
   Using a wire brush and shop towels, thoroughly clean the EGR valve mounting surface on the intake manifold. Remove all old gasket material and carbon deposits. The surface must be completely clean and flat for proper sealing. Stuff a clean shop towel into the intake manifold opening to prevent debris from entering, then remove it before installation.
7. 7

   Install new gasket and position new EGR valve
   Place the new EGR valve gasket onto the intake manifold mounting surface, ensuring proper alignment with the bolt holes and exhaust gas passage. Position the new EGR valve onto the gasket, aligning the mounting bolt holes. Ensure the valve electrical connector is oriented toward the top for easy access.
8. 8

   Install and torque EGR valve mounting bolts
   Thread both EGR valve mounting bolts by hand to prevent cross-threading. Ensure any brackets are properly positioned. Tighten the bolts in a cross pattern to 25.0 Nm (18.0 lb-ft) using a torque wrench. This ensures even gasket compression and proper sealing.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
9. 9

   Install new EGR tube gasket and connect tube
   Place the new EGR tube gasket onto the EGR valve fitting port. Guide the EGR tube into position and align it with the valve fitting. Thread the tube fitting nut onto the valve by hand until finger-tight. Ensure the tube is properly seated and not cross-threaded before final tightening.
   Torque spec

   EGR Tube Fitting35 Nm (26 lb-ft)
10. 10

    Torque EGR tube fitting
    Using a 13mm socket and torque wrench, tighten the EGR tube fitting nut to 35.0 Nm (26.0 lb-ft). Do not over-torque as this can damage the fitting threads or crush the gasket excessively.
    Torque spec

    EGR Tube Fitting35 Nm (26 lb-ft)
11. 11

    Reconnect electrical connector
    Push the electrical connector firmly onto the EGR valve until you hear and feel it click into place. Gently tug on the connector to verify it is fully locked. The connector should not pull off with moderate force.
12. 12

    Reinstall removed components
    Reinstall the air intake tube if removed, ensuring all clamps are tight. Reinstall the engine cover by pressing down firmly on each mounting grommet location until it clicks into place. Reconnect the negative battery cable.

Reassembly

1. Verify all electrical connections are secure and fully locked
2. Ensure no tools or shop towels are left in the engine compartment
3. Double-check that all bolts are torqued to specification
4. Verify the EGR tube connection is tight and properly aligned

Verification

• Start the engine and allow it to idle. Listen for any exhaust leaks near the EGR valve and tube connection
• Check for Check Engine Light (CEL). If present, scan for codes related to EGR system
• With engine at operating temperature, verify smooth idle with no surging or rough running
• Test drive the vehicle under light acceleration. EGR-related issues typically manifest as hesitation or stumbling at light throttle
• After test drive, re-inspect all connections for leaks or looseness while engine is still warm

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