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

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.

NOTE: If the bypass is replaced, all gaskets and seals must be replaced or damage to the EGR cooler may occur.

NOTE: Caution must be observed when removing the EGR cooler core as to avoid sealing flange scratches or damage to the sealing surfaces may occur.

NOTE: Do not attempt to remove the cooler core by prying between the header plate and housing or damage to the cooler core will occur.

NOTE: The bypass must be replaced with the EGR cooler assembly off the engine.

Disconnect the bypass valve solenoid-to-bypass actuator vacuum hose.
Remove the 2 bolts and the bypass valve solenoid.
Remove the 2 screws and the bypass actuator.
Remove the 4 bolts, 2 stud bolts and the EGR cooler end tank.
- Discard the EGR cooler end tank gasket.
  
  Fig 1: Locating EGR Cooler End Tank Bolts And Stud Bolts
  Courtesy of FORD MOTOR CO.
Remove the 13 bolts and the EGR valve.
- Discard the 13 bolts and EGR valve gasket.
  
  Fig 2: Locating EGR Valve Bolts
  Courtesy of FORD MOTOR CO.
Remove the 9 bolts and the bypass.
- Discard the 9 bolts and bypass gasket.
  
  Fig 3: Locating EGR Cooler Bolts
  Courtesy of FORD MOTOR CO.
Using 2 equal lengths of wood or 2 equal length hammer handles, insert them into the opening at the EGR cooler end tank until they touch the EGR cooler core.

Fig 4: Locating Hammer Handles On EGR Cooler Opening
Courtesy of FORD MOTOR CO.

NOTE: A snug fit of the wood will keep the wood from falling out of the EGR cooler and will aid in the removal of the EGR cooler core.

NOTE: The EGR cooler O-ring seals are very robust and will hold the cooler core very tight in the EGR cooler housing.

Holding the EGR cooler housing, strike the EGR cooler housing down on the wood forcing the EGR cooler core out of the housing.
- Discard the EGR cooler core gasket.
  
  Fig 5: Removing EGR Cooler Housing
  Courtesy of FORD MOTOR CO.
Remove the 4 EGR cooler core insulators.

Fig 6: Locating EGR Cooler Core Insulators
Courtesy of FORD MOTOR CO.
Remove and discard the 2 EGR cooler O-ring seals and clean O-ring seal seat on the EGR cooler housing.

Fig 7: Locating EGR Cooler O-Ring Seals
Courtesy of FORD MOTOR CO.

NOTE: Gaskets are sensitive to debris and surface defects, sealing surfaces must be thoroughly cleaned before new gaskets are installed.

NOTE: Scratches as shown in illustration may lead to leaks.

Fig 8: Locating Cooler Sealing Surfaces

Courtesy of FORD MOTOR CO.

Inspect all cooler sealing surfaces for defects that may lead to a leak path. If defects are found, replace the components as required.