EGR Cooler

This procedure covers removal and replacement of the EGR cooler on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine, including coolant drainage, exhaust component removal, and cooler installation.

Warnings

Tools required

Parts

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

Fluids

• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands
4. Place coolant drain pan under radiator drain valve
5. Open radiator drain valve and drain coolant into pan until level is below EGR cooler (approximately 2 gallons)
6. Close radiator drain valve
7. Remove engine cover by pulling upward on perimeter clips

Procedure

1. 1

   Remove air intake components
   Disconnect air intake tube from throttle body. Loosen hose clamps and remove intake tube assembly to gain access to the EGR valve area. Set aside in a clean area.
2. 2

   Disconnect EGR valve electrical connector and vacuum lines
   Press the tab on the EGR valve electrical connector and disconnect. Identify and label any vacuum lines connected to the EGR valve, then disconnect them. Take photos for reference during reassembly.
3. 3

   Remove EGR valve from cooler
   Remove the mounting bolts securing the EGR valve to the EGR cooler. Carefully separate the valve from the cooler and remove the old gasket. Inspect the valve for carbon buildup and clean if reusing.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
4. 4

   Disconnect coolant lines from EGR cooler
   Working from above, locate the coolant inlet and outlet lines connected to the EGR cooler. Use a wrench to loosen the fittings and disconnect both coolant lines. Have a rag ready to catch residual coolant. Cap or plug the lines to prevent contamination.
   ⚠Residual coolant may still drain from lines even after draining radiator. Keep rags and drain pan nearby.
5. 5

   Remove heat shields
   Remove the heat shield bolts securing any heat shields around the EGR cooler and exhaust manifold area. Remove the heat shields and set aside. Note the orientation and location of each shield for reinstallation.
   Torque spec

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

   Disconnect upstream O2 sensor
   Working from below the vehicle, locate the upstream oxygen sensor on the exhaust pipe near the EGR cooler connection. Disconnect the electrical connector, then use an O2 sensor socket to remove the sensor. Apply anti-seize to threads during reinstallation.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
7. 7

   Remove exhaust pipe-to-EGR cooler connection
   Locate the exhaust flange bolts connecting the exhaust pipe to the EGR cooler outlet. Apply penetrating oil if needed and allow to soak for 5-10 minutes. Remove the exhaust flange bolts and separate the connection. Remove and discard the old gasket.
   ⚠These bolts are frequently seized due to heat cycling. Use caution to avoid breaking bolts in the flange.
   Torque spec

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

   Support exhaust system
   The exhaust pipe will drop slightly when disconnected. Support the exhaust system using a jack stand or wire hanger to prevent stress on downstream components and hangers.
9. 9

   Remove EGR cooler-to-exhaust manifold connection
   Working from above, remove the flange bolts connecting the EGR cooler inlet to the exhaust manifold. These are high-temperature fasteners. Remove all bolts and separate the EGR cooler from the manifold. Remove and discard the old gasket.
   ⚠Support the EGR cooler as you remove the final bolts to prevent it from falling and causing injury or damage.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Remove EGR cooler assembly
    With all connections removed, carefully maneuver the EGR cooler out of the engine bay. It may be necessary to work it at an angle due to surrounding components. Inspect the removed cooler for internal blockage or external damage.
11. 11

    Clean all mating surfaces
    Use a gasket scraper and wire brush to thoroughly clean all mating surfaces on the exhaust manifold flange, exhaust pipe flange, and EGR valve mounting surface. Remove all old gasket material and carbon buildup. Wipe clean with a lint-free cloth.
12. 12

    Install new EGR cooler
    Install new gaskets on both the exhaust manifold connection and the exhaust pipe connection. Apply anti-seize to the flange bolt threads. Position the new EGR cooler in place and start all flange bolts by hand. Install and torque the exhaust manifold flange bolts first, then the exhaust pipe flange bolts. Follow proper torque sequence if specified in service manual.
    Torque spec

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

    Reconnect coolant lines
    Remove caps or plugs from coolant lines. Reconnect the coolant inlet and outlet lines to the new EGR cooler. Tighten fittings securely using appropriate wrench. Ensure lines are not kinked or under tension.
14. 14

    Install EGR valve
    Install a new EGR valve gasket on the EGR cooler. Position the EGR valve and install the mounting bolts. Torque to specification. Reconnect the electrical connector and any vacuum lines removed earlier.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
15. 15

    Reinstall remaining components
    Reinstall the O2 sensor with anti-seize on threads and torque to specification. Reinstall heat shields and torque bolts to specification. Remove exhaust support. Reinstall air intake components. Reconnect negative battery cable.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)
16. 16

    Refill and bleed cooling system
    Refill the cooling system with the appropriate Motorcraft Orange Coolant to the proper level. Start the engine and allow it to reach operating temperature with the radiator cap off. Add coolant as needed to maintain proper level. Install radiator cap and check for leaks at all EGR cooler coolant connections.
    ⚠Monitor coolant temperature during bleeding process. Do not allow engine to overheat.

Reassembly

1. Double-check all coolant line connections for tightness before starting engine
2. Verify all electrical connectors are fully seated and locked
3. Ensure exhaust connections are properly sealed with new gaskets
4. Check that heat shields are properly installed to prevent heat damage to surrounding components

Verification

• Start engine and check for exhaust leaks at all EGR cooler connections (listen for hissing sounds)
• Inspect all coolant connections for leaks with engine at operating temperature
• Verify no check engine lights or EGR-related codes are present using scan tool
• Check coolant level after test drive and top off if necessary
• Monitor coolant level over the next few days to ensure system is properly sealed

More procedures for this vehicle