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

Warnings

Tools required

Parts

• EGR cooler assembly × 1 — Use OEM specification
• EGR cooler inlet gasket × 1 — Use OEM specification
• EGR cooler outlet gasket × 1 — Use OEM specification
• EGR valve to cooler gasket × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after shutdown)
2. Disconnect negative battery cable
3. Remove engine cover by pulling upward on front clips and lifting assembly
4. Raise and safely support vehicle on jack stands
5. Remove front skid plate if equipped
6. Place large drain pan under radiator and drain cooling system via petcock on driver side of radiator
7. Remove air intake tube from turbocharger inlet to air filter housing

Procedure

1. 1

   Remove right-side oxygen sensor
   Disconnect electrical connector from right bank upstream oxygen sensor. Using oxygen sensor socket, remove sensor from exhaust manifold. Note: Sensor is located in the right turbocharger outlet pipe just after the turbine housing.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Disconnect EGR valve electrical connector
   Locate EGR valve on top of the EGR cooler assembly. Depress connector tab and disconnect electrical connector from EGR valve. Move wiring harness aside to prevent damage.
3. 3

   Remove EGR valve from cooler
   Remove the mounting bolts securing EGR valve to the top of the EGR cooler. Lift EGR valve away and remove gasket. Inspect valve for carbon buildup. Cover opening in cooler to prevent debris entry.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Disconnect EGR cooler coolant hoses
   Using hose clamp pliers or pick tool, release clamps on inlet and outlet coolant hoses connected to EGR cooler. Have drain pan positioned as residual coolant will drain. Twist hoses gently to break seal, then pull straight off fittings. Cap or plug hoses to prevent further coolant loss.
5. 5

   Remove heat shield
   Remove heat shield bolts securing the EGR cooler heat shield. Remove heat shield and set aside. Note orientation and location of any spacers or washers.
   Torque spec

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

   Remove right turbocharger outlet pipe
   From underneath vehicle, remove exhaust flange bolts connecting right turbocharger outlet pipe to downstream exhaust system. Support pipe weight. Remove flange bolts connecting outlet pipe to turbocharger turbine outlet. Remove pipe and gaskets.
   ⚠Support exhaust components to prevent stress on hangers and catalytic converter connections.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove EGR tube to exhaust manifold connection
   Locate EGR cooler inlet tube connection to right exhaust manifold (between cylinders 1-3). Remove flange bolts securing EGR inlet pipe to exhaust manifold. Remove and discard gasket.
   Torque spec

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

   Remove EGR cooler mounting fasteners
   Remove all remaining mounting bolts and brackets securing EGR cooler assembly to engine block and cylinder head. Note location and orientation of each bracket for reinstallation. There are typically 3-4 mounting points around the cooler body.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Remove EGR cooler assembly
   Carefully maneuver EGR cooler assembly out of engine bay. Assembly removes upward and toward passenger side. Tip cooler to drain remaining coolant into drain pan. Inspect mounting surfaces and remove old gasket material with plastic scraper. Clean surfaces with brake cleaner.
10. 10

    Install new EGR cooler
    Install new gaskets on EGR cooler inlet and outlet connections. Position new EGR cooler assembly into mounting location, ensuring coolant fittings are oriented correctly. Install mounting bolts and brackets finger-tight initially. Torque mounting bolts in progressive pattern to specification.
    Torque spec

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

    Reconnect EGR inlet to exhaust manifold
    Install new gasket on exhaust manifold EGR port. Position EGR cooler inlet tube to manifold flange. Install flange bolts with anti-seize on threads and torque to specification.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Install heat shield and EGR valve
    Reinstall heat shield with all spacers and washers in original positions. Torque heat shield bolts to specification. Install new gasket on EGR cooler top surface. Position EGR valve and install mounting bolts, torquing to specification. Reconnect EGR valve electrical connector.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

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

    Reconnect coolant hoses
    Inspect coolant hose ends for damage or cracking. Push coolant hoses firmly onto EGR cooler fittings until fully seated. Install hose clamps and position clamps away from hose ends (minimum 6mm from end).
14. 14

    Reinstall turbocharger outlet pipe
    Install new exhaust gaskets at turbocharger turbine outlet and downstream connection points. Position right turbocharger outlet pipe. Apply anti-seize to exhaust flange bolt threads. Install and torque exhaust flange bolts to specification.
    Torque spec

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

    Install oxygen sensor
    Apply anti-seize compound to oxygen sensor threads only, keeping compound away from sensor tip. Thread oxygen sensor into turbocharger outlet pipe by hand, then torque to specification using oxygen sensor socket. Reconnect electrical connector.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

Reassembly

1. Reinstall air intake tube to turbocharger inlet and secure all clamps
2. Reinstall engine cover by aligning rear tabs and pressing front clips until seated
3. Reinstall front skid plate if equipped
4. Close radiator petcock and refill cooling system with Motorcraft Orange Coolant to proper level
5. Use coolant vacuum fill tool if available to eliminate air pockets from system
6. Reconnect negative battery cable

Verification

• With cooling system filled, start engine and allow to idle. Monitor for coolant leaks at EGR cooler hose connections
• Check for exhaust leaks at all disturbed connections while engine is running. Listen for hissing or observe with white paper near joints
• Allow engine to reach normal operating temperature. Verify cooling fans cycle normally and temperature gauge reads normal range
• Monitor coolant level in reservoir after engine reaches operating temperature. Top off if necessary and verify level remains stable
• Perform test drive and verify no check engine light illumination and no loss of power
• Recheck all coolant connections and exhaust joints for leaks after test drive while engine is still warm
• Use scan tool to verify no EGR-related diagnostic codes are present and EGR system is operating within normal parameters

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