EGR Valve

This procedure covers the removal and replacement of the EGR valve on the 5.0L Coyote V8 engine, including disconnection of electrical connectors, coolant lines, and exhaust gas recirculation tube.

Warnings

Tools required

Parts

• EGR valve assembly × 1 — Motorcraft CX-2624 or equivalent
• EGR valve gasket × 1 — Use OEM specification
• EGR tube gasket × 1 — Use OEM specification
• Coolant hose clamps × 2 — Replace if damaged

Fluids

• Motorcraft Orange Coolant — 1 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and wait 2 minutes
3. Place drain pan under engine to catch coolant spillage
4. Remove engine cover by pulling upward on all four corners to disengage snap fittings
5. Locate the EGR valve on the passenger side of the engine near the throttle body

Procedure

1. 1

   Disconnect EGR valve electrical connector
   Press the tab on the EGR valve electrical connector and pull straight away from the valve. If connector is stubborn, gently work it side to side while pulling to avoid damaging the pins.
2. 2

   Disconnect EGR coolant hoses
   Using a flat blade screwdriver or hose clamp pliers, reposition the two spring clamps on the coolant hoses connected to the EGR valve. Slide clamps back approximately 2 inches from the valve. Twist and pull the hoses off the valve nipples. Some coolant will drain from these hoses.
3. 3

   Remove EGR tube connection
   Locate the EGR tube fitting that connects the EGR valve to the exhaust manifold. Using a 13mm socket, loosen and remove the EGR tube fitting nut. Pull the tube away from the valve and support it to prevent stress on the exhaust manifold connection. Remove and discard the gasket.
   Torque spec

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

   Remove EGR valve mounting bolts
   Using a 10mm socket, remove the two bolts securing the EGR valve to its mounting bracket on the intake manifold. Keep track of any washers or spacers.
   Torque spec

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

   Remove EGR valve assembly
   Carefully pull the EGR valve assembly away from the mounting bracket. Angle the valve to clear any nearby components. Allow any remaining coolant to drain into the pan. Remove and discard the old gasket from the mounting surface.
6. 6

   Clean mounting surfaces
   Use a wire brush and scraper to thoroughly clean the EGR valve mounting surface on the intake manifold and the EGR tube mating surface. Remove all old gasket material and carbon deposits. Wipe clean with a shop towel. Inspect surfaces for damage or warping.
7. 7

   Install new EGR valve
   Position the new gasket on the mounting bracket. Install the new EGR valve onto the bracket, ensuring the gasket remains properly aligned. Thread in both mounting bolts by hand to prevent cross-threading.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
8. 8

   Torque EGR valve bolts
   Using a torque wrench, tighten the EGR valve mounting bolts to 25.0 Nm (18.0 lb-ft) in an alternating pattern to ensure even seating of the gasket.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
9. 9

   Reconnect EGR tube
   Install a new EGR tube gasket onto the fitting. Align the EGR tube with the valve port and hand-thread the fitting nut. Torque the EGR tube fitting to 35.0 Nm (26.0 lb-ft).
   Torque spec

   EGR Tube Fitting35 Nm (26 lb-ft)
10. 10

    Reconnect coolant hoses
    Push the coolant hoses firmly onto the EGR valve nipples until they are fully seated. Slide the spring clamps back into their original positions approximately 1/4 inch from the end of each nipple. Verify clamps are properly engaged.
11. 11

    Reconnect electrical connector
    Align the EGR valve electrical connector with the valve pins and push firmly until you hear and feel a positive click, indicating the locking tab has engaged.
12. 12

    Refill coolant and bleed system
    Check coolant level in the degas bottle and add Motorcraft Orange Coolant as needed to bring level to the COLD FILL mark. Start the engine and allow it to reach operating temperature with the degas bottle cap off. Add coolant as needed during warm-up. Once the thermostat opens and coolant circulates, top off to the HOT FILL mark and install the cap.

Reassembly

1. Reinstall engine cover by aligning all four grommets and pressing down firmly until snapped into place
2. Reconnect negative battery cable
3. Clear any diagnostic trouble codes stored during the repair using a scan tool

Verification

• Start the engine and verify no coolant leaks from EGR valve hose connections
• Check for exhaust leaks at the EGR tube connection while engine is running
• Allow engine to reach operating temperature and verify EGR valve operation with a scan tool showing EGR flow commands
• Verify no diagnostic trouble codes related to EGR system (P0401, P0402, P0403, P0404)
• Check coolant level after engine cools and top off if necessary

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