This procedure covers removal and replacement of the EGR valve on the 3.5L EcoBoost V6 engine, including disconnection of electrical connectors, EGR tube, and mounting hardware.

Warnings

Tools required

Parts

• EGR valve × 1 — Use OEM specification
• EGR valve gasket × 1 — Usually included with valve
• 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 to release push clips
4. Apply penetrating oil to EGR tube fittings and allow 10-15 minutes soak time

Procedure

1. 1

   Locate and access EGR valve
   The EGR valve is mounted on the passenger side of the engine, below and behind the turbocharger assembly. Use a flashlight to identify the valve and trace the EGR tube connection. You may need to move wiring harnesses aside for better access.
2. 2

   Disconnect EGR valve electrical connector
   Press the locking tab on the electrical connector and pull straight off the EGR valve. The connector may be stiff; use a flathead screwdriver to gently release the tab if needed. Move the connector aside to prevent damage during removal.
3. 3

   Remove EGR tube fitting
   Using a 13mm socket, loosen the EGR tube fitting nut that connects the tube to the EGR valve. If the fitting is seized, apply additional penetrating oil and wait. Work the nut back and forth slightly to break free, then remove completely. Pull the tube away from the valve and support it to prevent stress on other connections.
   ⚠Do not force seized fittings. Excessive force can strip threads or crack the tube flange.
   Torque spec

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

   Remove EGR valve mounting bolts
   Locate the two mounting bolts securing the EGR valve to the engine. Using a 10mm socket with extension, remove both bolts completely. Keep bolts organized for reinstallation. Note the position of any ground wires or brackets under the bolt heads.
   Torque spec

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

   Remove EGR valve from engine
   Carefully pull the EGR valve away from the mounting surface. The valve may be stuck due to gasket adhesion. Gently twist and pull to break the seal. Once free, remove the valve from the engine bay.
6. 6

   Clean mounting surfaces
   Using a plastic scraper or shop towel, clean all gasket material from the engine mounting surface and EGR tube mating surface. Ensure surfaces are completely clean and free of debris. Inspect mounting holes for damage or stripped threads.
   ℹ️Do not use metal scrapers that could gouge aluminum surfaces. Use only plastic scrapers or abrasive pads.
7. 7

   Install new EGR valve gasket
   Position the new EGR valve gasket on the engine mounting surface. Ensure gasket alignment holes match the bolt holes. The gasket should sit flat without wrinkles or folds.
8. 8

   Install new EGR valve
   Position the new EGR valve onto the mounting surface, aligning the bolt holes. Start both mounting bolts by hand to ensure proper thread engagement. Do not tighten yet.
9. 9

   Torque EGR valve mounting bolts
   Using a torque wrench and 10mm socket, tighten the EGR valve mounting bolts in an alternating pattern to 25.0 Nm (18.0 lb-ft). This ensures even gasket compression and proper sealing.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
10. 10

    Install EGR tube gasket and connect tube
    Install the new EGR tube gasket onto the EGR valve port. Position the EGR tube to the valve and start the fitting nut by hand. Ensure the tube is properly aligned and not cross-threaded before tightening.
11. 11

    Torque EGR tube fitting
    Using a torque wrench and 13mm socket, tighten the EGR tube fitting to 35.0 Nm (26.0 lb-ft). Support the tube during tightening to prevent stress on other connections.
    Torque spec

    EGR Tube Fitting35 Nm (26 lb-ft)
12. 12

    Reconnect electrical connector
    Push the electrical connector firmly onto the EGR valve until you hear or feel a positive click. Tug gently to verify the connector is fully seated and locked.
13. 13

    Reinstall engine cover and battery
    Reposition any wiring harnesses that were moved. Reinstall the engine cover by aligning the push clips and pressing down firmly until all clips engage. Reconnect the negative battery cable.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify EGR tube has no kinks or excessive stress at connection points
3. Double-check that engine cover is fully seated on all mounting clips

Verification

• Start the engine and verify no EGR-related trouble codes are present using a scan tool
• Allow engine to reach operating temperature and verify no exhaust leaks at EGR valve or tube connections
• Listen for abnormal hissing sounds that would indicate a vacuum or exhaust leak
• Perform a test drive and verify smooth operation with no check engine light illumination
• If available, use scan tool to command EGR valve operation and verify proper response

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