EGR Tube

This procedure covers removal and replacement of the EGR (Exhaust Gas Recirculation) tube on the 3.5L EcoBoost V6 engine, including disconnection from the EGR valve and exhaust manifold.

Warnings

Tools required

Parts

• EGR tube assembly × 1 — Use OEM specification
• EGR tube gaskets × 2 — Usually included with tube assembly

Preparation

1. Ensure engine has been off for at least 2 hours and is cool to the touch
2. Disconnect negative battery cable to prevent electrical faults
3. Raise and support vehicle on jack stands if additional clearance is needed for access (RWD configuration provides decent top-side access)
4. Remove engine cover by pulling upward on the four retention clips
5. Spray all EGR tube fasteners with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Remove engine cover and locate EGR components
   Remove the plastic engine cover by firmly pulling upward on all four corners to release the retention clips. Locate the EGR valve on the passenger side of the engine and trace the EGR tube down to the exhaust manifold connection point beneath the turbocharger.
2. 2

   Disconnect EGR valve electrical connector
   Press the release tab on the EGR valve electrical connector and carefully pull the connector away from the valve. Move the wiring harness aside to provide clearance for tube removal.
3. 3

   Remove upper EGR tube mounting bolts
   Using a 10mm socket, remove the mounting bolts securing the EGR tube to the EGR valve. There are typically two bolts at this connection. Note the position of any brackets or supports attached to these bolts.
   ⚠Support the EGR tube by hand once the upper bolts are removed to prevent it from falling and damaging other components.
   Torque spec

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

   Access lower exhaust manifold connection
   Working from above or below (depending on clearance preference), locate the lower EGR tube connection at the exhaust manifold. This connection is beneath the turbocharger assembly on the passenger side. You may need to remove heat shields for better access.
5. 5

   Remove heat shield if necessary
   If a heat shield obstructs access to the lower EGR tube connection, remove the heat shield mounting bolts using a 10mm socket. Set the heat shield aside for reinstallation.
   Torque spec

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

   Remove lower EGR tube flange bolts
   Using a 13mm socket with extension, remove the two flange bolts connecting the EGR tube to the exhaust manifold. These bolts secure the tube with a gasket seal. Work carefully to avoid stripping bolts in the manifold.
   ⚠If bolts are seized, apply additional penetrating oil and allow to soak. Do not force bolts or the manifold threads may be damaged.
   Torque spec

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

   Remove EGR tube assembly
   Carefully maneuver the EGR tube out from between the engine components. The tube may need to be rotated or angled to clear the turbocharger, intercooler piping, and wiring harnesses. Remove and discard old gaskets from both connection points.
8. 8

   Clean mating surfaces
   Use a wire brush to thoroughly clean the EGR valve mounting surface and the exhaust manifold flange surface. Remove all carbon deposits and old gasket material. Inspect both surfaces for cracks or damage. Wipe clean with a shop towel.
9. 9

   Install new EGR tube with gaskets
   Position new gaskets at both the upper (EGR valve) and lower (exhaust manifold) connection points. Carefully route the new EGR tube into position, ensuring it clears all surrounding components. Start all mounting bolts by hand before tightening any of them.
   ℹ️Ensure the tube is not twisted or stressed during installation. It should sit naturally in position without forcing.
10. 10

    Torque lower flange bolts
    Apply a small amount of anti-seize compound to the threads of the lower flange bolts. Install and torque the flange bolts to specification in a criss-cross pattern to ensure even gasket compression.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Torque upper mounting bolts
    Install the upper mounting bolts connecting the EGR tube to the EGR valve. Torque these bolts to specification. If any support brackets were removed, reinstall them now.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Reinstall heat shield
    If the heat shield was removed in step 5, reinstall it now and torque the mounting bolts to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
13. 13

    Reconnect electrical connector
    Reconnect the electrical connector to the EGR valve, ensuring it clicks securely into place. Verify the connector lock tab is fully engaged.
14. 14

    Reinstall engine cover
    Align the engine cover with the four mounting posts and press down firmly on each corner until all retention clips snap into place. Reconnect the negative battery cable.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify no tools or materials were left in the engine bay
3. Double-check that all bolts are torqued to specification
4. Ensure heat shields are properly reinstalled to prevent heat damage to surrounding components

Verification

• Start the engine and allow it to idle for 2-3 minutes while monitoring for any exhaust leaks at the EGR tube connections
• Listen for hissing sounds that would indicate a leak at either the upper or lower gasket
• Check for any unusual engine noises or vibrations from the EGR tube area
• Use an OBD-II scanner to verify no EGR-related trouble codes are present
• Perform a test drive and verify normal engine performance with no check engine light
• After test drive, recheck all EGR tube connections for signs of exhaust leaks while engine is still warm

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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