This procedure covers removal and replacement of the EGR valve on the 3.5L EcoBoost V6 engine, including disconnecting electrical connections, removing the EGR tube, and installing a new valve with proper torque specifications.

Warnings

Tools required

Parts

• EGR valve assembly × 1 — Use OEM specification
• EGR valve gasket × 1 — Included with valve or separate OEM gasket
• EGR tube gasket × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after last operation)
2. Disconnect negative battery cable and wait 2 minutes for systems to power down
3. Remove engine cover by pulling upward on the front edge to release clips
4. If additional access is needed, remove air intake duct from throttle body to turbo outlet

Procedure

1. 1

   Disconnect EGR valve electrical connector
   Locate the EGR valve electrical connector on the driver side of the engine. Press the locking tab and carefully disconnect the wiring harness from the EGR valve. Move the harness aside to prevent damage during removal.
2. 2

   Remove EGR tube fitting
   Locate the EGR tube connection at the EGR valve. Using a 13mm socket, loosen and remove the EGR tube fitting nut. The tube connects the EGR valve to the exhaust manifold. Carefully work the tube free from the valve, being mindful not to bend or kink the tube.
   ⚠The EGR tube may be carbon-fouled at the connection point. Do not force the tube; use penetrating oil if needed and allow time to soak.
   Torque spec

   EGR Tube Fitting35 Nm (26 lb-ft)
3. 3

   Inspect and remove EGR tube gasket
   Once the tube is separated, inspect the gasket at the EGR tube connection. Remove the old gasket and clean the sealing surface with a shop towel. Note the condition of carbon buildup for reference when installing the new valve.
4. 4

   Remove EGR valve mounting bolts
   Using a 10mm socket, remove the two EGR valve mounting bolts securing the valve to the intake manifold. Support the valve with one hand while removing the final bolt to prevent it from falling. The valve may be stuck due to carbon deposits; gently work it free if needed.
   Torque spec

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

   Remove EGR valve and gasket
   Carefully remove the EGR valve from the intake manifold. Remove and discard the old gasket from the mounting surface. Do not allow any gasket material or debris to fall into the intake manifold opening.
   ⚠Cover the intake manifold opening with a clean shop towel to prevent debris from entering the intake system.
6. 6

   Clean mounting surfaces
   Thoroughly clean the EGR valve mounting surface on the intake manifold using a wire brush and shop towels. Remove all carbon deposits and old gasket material. Ensure the surface is completely clean and flat for proper sealing. Wipe clean with a final towel and inspect for damage.
7. 7

   Install new EGR valve gasket
   Position the new EGR valve gasket onto the intake manifold mounting surface. Ensure the gasket is properly aligned with the bolt holes and intake port opening. The gasket should lay flat without any wrinkles or gaps.
8. 8

   Install new EGR valve
   Position the new EGR valve onto the gasket, aligning the mounting holes. Insert both mounting bolts by hand and thread them several turns to ensure proper alignment. Do not tighten at this stage.
9. 9

   Torque EGR valve bolts
   Using a torque wrench, tighten the EGR valve mounting bolts in an alternating pattern to 25.0 Nm (18 lb-ft). Start with the upper bolt, then the lower bolt, and repeat the pattern to ensure even clamping force on the gasket.
   Torque spec

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

    Install new EGR tube gasket
    Position the new EGR tube gasket onto the EGR valve connection point. Ensure it is properly seated in the groove or against the sealing surface.
11. 11

    Connect and torque EGR tube
    Carefully align the EGR tube to the EGR valve connection, ensuring the gasket remains in position. Thread the fitting nut by hand to avoid cross-threading. Using a torque wrench with 13mm socket, tighten the EGR tube fitting to 35.0 Nm (26 lb-ft).
    Torque spec

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

    Reconnect electrical connector
    Reconnect the EGR valve electrical connector to the new valve. Ensure the connector locks fully into place with an audible click. Gently tug on the connector to verify it is secure.

Reassembly

1. Reinstall the air intake duct if it was removed, ensuring all clamps are tight
2. Reinstall the engine cover by aligning the clips and pressing firmly until seated
3. Reconnect the negative battery cable and tighten securely

Verification

• Start the engine and allow it to reach operating temperature while monitoring for any exhaust leaks at the EGR valve or tube connections
• Use a scan tool to verify no EGR-related diagnostic trouble codes are present
• Perform a test drive and verify smooth operation with no rough idle or hesitation
• After the engine cools, recheck the EGR tube fitting and valve mounting bolts for proper tightness
• Monitor the vehicle over the next few drive cycles to ensure the EGR system is functioning properly without fault codes

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