EGR Tube

This procedure covers removal and replacement of the EGR (Exhaust Gas Recirculation) tube on the 2015-2020 Ford F-150 with 5.0L Coyote V8 engine, including proper sealing and torque specifications.

Warnings

Tools required

Parts

• EGR tube assembly × 1 — Use OEM specification
• EGR tube gasket (exhaust manifold side) × 1 — Use OEM specification
• EGR tube gasket (EGR valve side) × 1 — Use OEM specification

Preparation

1. Ensure engine has been off for at least 2 hours and exhaust system is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal to prevent accidental engine start
4. Spray all EGR tube flange bolts with penetrating oil and allow to soak for 15-20 minutes
5. Remove engine cover by pulling upward on retaining clips

Procedure

1. 1

   Access EGR tube area
   The EGR tube is located on the passenger side of the engine between the exhaust manifold and EGR valve. Remove any heat shields or covers obstructing access to the EGR tube connections. Use 10mm socket to remove heat shield bolts if present.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect EGR valve electrical connector
   Locate the EGR valve electrical connector on top of the EGR valve assembly. Press the locking tab and disconnect the electrical connector. Move the wiring harness aside to provide clearance.
3. 3

   Remove EGR valve mounting bolts
   Using a 10mm socket, remove the two bolts securing the EGR valve to its mounting bracket. Note the position of any brackets or tabs for reassembly. You may need to loosen but not fully remove the EGR valve to access the tube connection.
   Torque spec

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

   Disconnect EGR tube from EGR valve
   Using a 15mm socket, remove the two flange bolts connecting the EGR tube to the EGR valve. Support the tube to prevent it from falling. Remove and discard the old gasket from the connection point.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Disconnect EGR tube from exhaust manifold
   Using a 13mm socket with extension, remove the two flange bolts connecting the EGR tube to the exhaust manifold. The bolts may be difficult to access and may require a universal joint. Carefully maneuver the EGR tube out of the engine bay. Remove and discard the old gasket.
   ⚠Exhaust manifold bolts are highly susceptible to breakage. If a bolt breaks, extraction may require drilling and tapping, significantly extending repair time.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Clean mating surfaces
   Using a wire brush and shop towels, thoroughly clean all gasket mating surfaces on both the EGR valve and exhaust manifold flanges. Remove all carbon deposits, old gasket material, and corrosion. Inspect mating surfaces for warping, cracks, or damage. Replace components if surfaces are not flat or show signs of warping.
7. 7

   Install new EGR tube
   Position new gaskets on both the exhaust manifold and EGR valve flanges. Apply a thin coat of anti-seize compound to the threads of all EGR tube flange bolts (avoid getting anti-seize on gasket surfaces). Position the new EGR tube into place, aligning the flanges with both connection points.
8. 8

   Connect EGR tube to exhaust manifold
   Install the exhaust manifold flange bolts finger-tight, ensuring the gasket remains properly seated. Using a torque wrench and 13mm socket, tighten the bolts in a cross pattern to specification. Verify the tube flange is seated evenly against the manifold.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
9. 9

   Connect EGR tube to EGR valve
   Align the EGR tube flange with the EGR valve connection point. Install the flange bolts finger-tight, ensuring the gasket is properly positioned. Using a torque wrench and 15mm socket, tighten the bolts in a cross pattern to specification.
   Torque spec

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

    Reinstall EGR valve and components
    If the EGR valve was loosened or removed, reinstall it to the mounting bracket using the 10mm bolts. Torque the mounting bolts to specification. Reconnect the EGR valve electrical connector until it clicks into place. Reinstall any heat shields removed during disassembly.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reinstall engine cover by pressing down firmly on all mounting points until clips engage
2. Reconnect negative battery terminal and tighten securely
3. Double-check all electrical connections are properly seated and locked
4. Verify all tools and materials have been removed from engine bay

Verification

• Start engine and allow to idle. Listen for any exhaust leaks at EGR tube connections (hissing or ticking sounds indicate leak)
• With engine at idle, visually inspect both EGR tube flange connections for signs of exhaust gas leakage
• Allow engine to reach operating temperature and verify no exhaust leaks develop under heat
• Use a scan tool to verify no EGR-related diagnostic trouble codes are present
• Test drive vehicle and confirm smooth operation with no Check Engine Light illumination
• After test drive, recheck all EGR tube connections for tightness and signs of leakage 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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