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

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: Make sure the EP sensor tube is aligned on the stud bolt on the back of the EGR cooler.

Using 2 new EGR cooler assembly gaskets, install the EGR cooler assembly on the alignment pins and install the 7 bolts.
- Tighten to 10 Nm (89 lb-in) in sequence shown in illustration.
  
  Fig 1: EGR Cooler Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the EP sensor nut.
- Tighten to 10 Nm (89 lb-in).
Attach the 2 wiring harness retainers to the back of the EGR cooler.
Using new gaskets, install the bypass outlet tube and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
Connect and attach the EGRT electrical connector.

NOTE: EGR cooler side shown in illustration, exhaust manifold side similar.

Using 2 new EGR valve inlet tube gaskets, install the EGR valve inlet tube and the 4 bolts. Tighten the bolts in the following sequence.
- Tighten the bolts at the exhaust manifold to 10 Nm (89 lb-in).
- Tighten the bolts at the EGR cooler to 10 Nm (89 lb-in).
  
  Fig 2: Locating EGR Valve Inlet Tube Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Apply threadlock to the EGR cooler side bolt threads prior to installation.

Install the EGR valve inlet tube bracket and the 2 new bolts. Tighten in 4 stages:
- Stage 1: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler to 10 Nm (89 lb-in).
- Stage 2: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler an additional 45 degrees.
- Stage 3: Tighten the EGR valve inlet tube bracket bolt to 10 Nm (89 lb-in).
- Stage 4: Tighten the EGR valve inlet tube bracket bolt an additional 45 degrees.
  
  Fig 3: Locating EGR Valve Inlet Tube Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the wiring harness bracket to the front of the bypass.
- Tighten to 10 Nm (89 lb-in).
Install the 2 RH upper sound shield retainers.
Connect the electrical connector and vacuum line to the bypass valve solenoid.
Connect the EGR valve and ECT sensor - secondary cooling system ECT 2 electrical connectors.
- Attach the wiring harness retainer.
Connect the 3 coolant hoses to the EGR valve cooler assembly.
- Attach the coolant hose retainer to the bypass.
Install the upper intake manifold. For additional information, refer to ENGINE - 6.7L DIESEL .
Install the Air Cleaner (ACL) assembly and ACL outlet pipe. For additional information, refer to the Intake Air System Components - Exploded View, 6.7L Diesel in INTAKE AIR DISTRIBUTION & FILTERING .

NOTE: Evaluate the cooling system condition before filling the engine and the secondary cooling systems. Failure to follow these instructions can result in damage to the engine or the secondary cooling system.

Evaluate the engine and the secondary cooling systems condition. For additional information, refer to Cooling System Condition Evaluation in ENGINE COOLING - DIESEL ENGINE or ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .