Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel: Assembly

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Using 2 new O-ring seals, install the O-ring seals in the EGR cooler housing and lube the O-ring seals with clean engine coolant to ease installation.

Fig 1: Locating EGR Cooler O-Ring Seals
Courtesy of FORD MOTOR CO.

NOTE: Inspect the new EGR cooler core gasket for correct location, it is marked COOLER SIDE on the upper left hand corner. Incorrect installation of this gasket could result in an internal coolant leak to the exhaust and severe engine damage.

Fig 2: Installing EGR Cooler Gasket On Cooler Core

Courtesy of FORD MOTOR CO.

Using a new EGR cooler core gasket, marked "cooler side", install the EGR cooler gasket on the cooler core as shown in illustration.
Install the 4 EGR cooler core insulators.

Fig 3: Locating EGR Cooler Core Insulators
Courtesy of FORD MOTOR CO.

NOTE: Handle the EGR cooler core and housing assembly carefully as the EGR cooler core could slide out of the housing and damage to the EGR cooler core may occur.

Fig 4: Installing EGR Cooler Core Into EGR Cooler Housing

Courtesy of FORD MOTOR CO.

Install the EGR cooler core into the EGR cooler housing, using even pressure to seat on the O-ring seals.

NOTE: Inspect the new bypass gasket for correct location, it is marked BYPASS SIDE on the upper right hand corner. Incorrect installation of this gasket could result in an internal coolant leak to the exhaust and severe engine damage.

Install the bypass gasket as shown in illustration.
- If replacing the EGR valve and bypass as an assembly, go to step 6. If replacing the bypass only, go to step 7.
  
  Fig 5: Identifying Assembly Of EGR Valve And Bypass Assembly
  Courtesy of FORD MOTOR CO.
Using 9 new bolts and 1 new EGR valve long center bolt, install the EGR valve and bypass assembly and the 10 bolts and tighten in the sequence shown in illustration in 3 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 12 Nm (106 lb-in).
- Stage 3: Tighten to 12 Nm (106 lb-in) and then an additional 90 degrees.
  
  Fig 6: EGR Valve And Bypass Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using 9 new bolts, install the bypass and the 9 bolts and tighten in the sequence shown in illustration in 3 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 12 Nm (106 lb-in).
- Stage 3: Tighten to 12 Nm (106 lb-in) and then an additional 90 degrees.
  
  Fig 7: Bypass Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using a new EGR valve gasket and 13 new bolts, install the EGR valve and the bolts and tighten in the sequence shown in illustration in 4 stages:
- Stage 1: Tighten bolts 1 thru 12 to 12 Nm (106 lb-in).
- Stage 2: Tighten bolts 1 thru 12 to 16 Nm (142 lb-in).
- Stage 3: Tighten bolts 1 thru 4 to 16 Nm (142 lb-in).
- Stage 4: Tighten bolt 13 to 12 Nm (106 lb-in) and then an additional 90 degrees.
  
  Fig 8: EGR Valve Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using a new EGR cooler end tank gasket, install the EGR cooler end tank, 4 bolts and 2 stud bolts and tighten in the sequence shown in illustration in 2 stages:
- Stage 1: Tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
  
  Fig 9: EGR Cooler End Tank Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the bypass actuator and the 2 screws.
Install the bypass valve solenoid and the 2 bolts.

NOTE: Ensure all EGR cooler assembly gaskets, O-rings and fasteners have been replaced.

Connect the bypass valve solenoid-to-bypass actuator vacuum hose.