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

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.
  1. Drain the cooling system. For additional information, refer to ENGINE COOLING - DIESEL ENGINE .
  2. Drain the secondary cooling system. For additional information, refer to ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  3. Remove 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 .
  4. Remove the upper intake manifold. For additional information, refer to ENGINE - 6.7L DIESEL .
  5. Disconnect the 3 coolant hoses from the EGR cooler assembly.
    • Detach the wiring harness and coolant hose retainer from the bypass.
  6. Disconnect the EGR valve and Engine Coolant Temperature (ECT) sensor - secondary cooling system ECT 2 electrical connectors.
    • Detach the wiring harness retainer.
  7. Disconnect the electrical connector and vacuum hose from the bypass valve solenoid.
  8. Remove the 2 RH upper sound shield retainers.
  9. Remove the 2 bolts for the wiring harness bracket from the front of the bypass.
  10. Remove the 2 bolts and the EGR valve inlet tube bracket.
    • Discard the 2 bolts.
      Fig 1: Locating EGR Valve Inlet Tube Bracket Bolts
      G07480920Courtesy of FORD MOTOR CO.
    11. NOTE: EGR cooler side shown in illustration, exhaust manifold side similar.
  11. Remove the 4 bolts and the EGR valve inlet tube.
    • Remove and discard the 2 EGR valve inlet tube gaskets.
      Fig 2: Locating EGR Valve Inlet Tube Bolts
      G07480921Courtesy of FORD MOTOR CO.
  12. Detach and disconnect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector.
  13. Remove the 4 bolts and the bypass outlet tube.
    • Discard the EGR valve outlet tube gaskets.
  14. Detach the 2 wiring harness retainers from the back of the EGR cooler.
  15. Remove the Exhaust Pressure (EP) sensor tube nut.
    16. NOTE: EGR cooler assembly must be lifted off the 2 alignment pins before removal.
    NOTE: While removing the EGR cooler it may be necessary to reposition the EP sensor tube.
  16. Remove the 7 bolts and the EGR cooler assembly.
    • Discard the 2 EGR cooler assembly gaskets.
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