This procedure covers the removal and replacement of the EGR cooler on the 2011-2014 Ford F-150 5.0L V8 Coyote engine, including coolant drainage, exhaust component removal, and system reassembly.

Warnings

Tools required

Parts

• EGR cooler assembly × 1 — Use OEM specification
• EGR cooler gaskets × 2 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Coolant hose clamps × 2 — As needed

Fluids

• Motorcraft Orange Coolant — 3 qt

Preparation

1. Park vehicle on level surface and apply parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable and wait 5 minutes for system discharge.
3. Allow engine to cool completely (minimum 2 hours after last operation).
4. Raise front of vehicle and support securely on jack stands rated for vehicle weight.
5. Remove engine cover by pulling upward on clip fasteners.
6. Place drain pan under radiator drain valve and drain coolant to below level of upper radiator hose.
7. Relieve any residual cooling system pressure by slowly opening radiator cap.

Procedure

1. 1

   Remove air intake components
   Disconnect the mass airflow sensor electrical connector. Loosen clamps on air intake tube and remove air intake assembly from throttle body to air filter housing. Set aside to provide access to upper engine components.
2. 2

   Disconnect EGR cooler coolant hoses
   Locate the two coolant hoses connected to the EGR cooler. Use pliers to compress and slide hose clamps away from connections. Twist hoses gently to break seal, then pull off connections. Be prepared for residual coolant spillage. Cap or plug open coolant lines to prevent contamination.
3. 3

   Remove heat shield
   From above the engine, locate and remove the EGR cooler heat shield bolts. Remove heat shield and set aside. This provides access to the upper EGR cooler mounting points.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect EGR valve connector
   Locate the EGR valve on top of the EGR cooler assembly. Press the locking tab and disconnect the electrical connector. Move wiring harness aside to prevent damage during removal.
5. 5

   Remove oxygen sensor
   Working from below the vehicle, locate the oxygen sensor on the exhaust pipe near the EGR cooler. Disconnect the electrical connector. Use an oxygen sensor socket to remove the sensor. Note the condition of sensor threads for reinstallation preparation.
   ⚠Oxygen sensors are fragile. Do not drop or strike the sensor element. Contamination with oil or coolant will require sensor replacement.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
6. 6

   Disconnect exhaust pipe from manifold
   Locate the exhaust flange connection between the exhaust manifold and exhaust pipe downstream of the EGR cooler. Remove exhaust hanger bolts to provide flexibility. Remove exhaust flange bolts and separate the connection. Support exhaust pipe to prevent strain on remaining connections.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)

   Hanger Bolts25 Nm (19 lb-ft)
7. 7

   Remove EGR tube from cooler
   Locate the EGR tube connection at the EGR cooler outlet. Remove the flange bolts securing the EGR tube to the cooler. Separate the tube from the cooler and move aside. Remove and discard the old gasket.
   Torque spec

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

   Remove EGR cooler mounting bolts
   Locate all EGR cooler mounting bolts securing the cooler to the engine block and exhaust manifold. Remove mounting bolts while supporting the cooler assembly. Note bolt locations as they may be different lengths.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
9. 9

   Remove EGR cooler assembly
   Carefully maneuver the EGR cooler assembly away from the engine, navigating around coolant lines and exhaust components. Remove assembly from vehicle. Remove and discard all old gaskets from mating surfaces on engine and exhaust manifold.
10. 10

    Clean mating surfaces
    Use a wire brush or gasket scraper to thoroughly clean all gasket mating surfaces on the engine block, exhaust manifold, and EGR tube connection points. Remove all traces of old gasket material, carbon deposits, and corrosion. Wipe surfaces clean with a lint-free cloth. Inspect surfaces for damage or warping.
    ⚠Do not gouge or damage aluminum mating surfaces. Deep scratches can prevent proper sealing and cause exhaust or coolant leaks.
11. 11

    Install new EGR cooler
    Position new gaskets on all mating surfaces. Carefully position the new EGR cooler assembly into place, ensuring coolant ports align correctly and gaskets remain properly seated. Start all mounting bolts by hand to ensure proper thread engagement before tightening.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
12. 12

    Reconnect EGR tube
    Install new gasket between EGR tube and cooler outlet. Position EGR tube to cooler connection and install flange bolts. Tighten bolts in a cross pattern to ensure even gasket compression.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Reconnect exhaust components
    Install new exhaust flange gasket. Reconnect exhaust pipe to manifold, aligning flange holes. Apply anti-seize compound to exhaust flange bolt threads. Install and tighten flange bolts in a cross pattern. Reinstall exhaust hanger bolts.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Hanger Bolts25 Nm (19 lb-ft)
14. 14

    Install oxygen sensor
    Apply anti-seize compound to oxygen sensor threads only, keeping compound away from sensor element. Thread oxygen sensor into exhaust pipe by hand, then tighten with oxygen sensor socket. Reconnect electrical connector ensuring positive lock engagement.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
15. 15

    Reinstall remaining components and refill coolant
    Reconnect EGR valve electrical connector. Reinstall heat shield using new hardware if original bolts are damaged. Reconnect coolant hoses to EGR cooler and secure with clamps. Reinstall air intake assembly and connect mass airflow sensor. Close radiator drain valve. Refill cooling system with Motorcraft Orange Coolant to proper level. Install radiator cap. Reconnect negative battery cable. Lower vehicle from jack stands.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Always use new gaskets at all connection points. Reusing old gaskets will result in leaks.
2. Ensure all electrical connectors are fully seated with locking tabs engaged.
3. Double-check that all coolant hose clamps are properly positioned and tightened.
4. Verify exhaust components have adequate clearance and are not contacting heat shields or body components.

Verification

• Start engine and allow to reach operating temperature while monitoring for coolant or exhaust leaks.
• Check coolant level after engine reaches operating temperature and top off as necessary.
• Verify no exhaust leaks are present at EGR cooler connections and exhaust flange by listening for hissing sounds.
• Check for coolant leaks at EGR cooler hose connections and around cooler mounting points.
• Verify EGR system operation using a scan tool to monitor EGR valve position and flow rates during test drive.
• Confirm no coolant smell in cabin and no visible coolant loss after several heat cycles.
• Check engine codes using scan tool to ensure no EGR or oxygen sensor fault codes are present.

More procedures for this vehicle