Exhaust Gas Recirculation (EGR) Valve - 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.

Using a new EGR valve gasket and 13 new bolts, install the EGR valve and tighten the bolts 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 1: EGR Valve Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

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.
Connect the EGR valve electrical connector.
Attach the coolant hose retainer to the EGR valve.
Connect the EGR valve coolant vent hose to the EGR valve.
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 cooling system. Failure to follow these instructions can result in damage to the engine.

Evaluate the cooling system condition. For additional information, refer to Cooling System Condition Evaluation in ENGINE COOLING - DIESEL ENGINE .
Initiate EGR valve learning cycle after EGR replacement in the following sequence.
1. Turn the ignition key to the Key ON Engine OFF (KOEO) for 10 seconds.
2. Turn the ignition key to the OFF position for 30 seconds.