Exhaust Gas Recirculation (EGR) Cooler: Installation

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Make sure that the mating surfaces are clean and free of foreign material.

Clean the mating surfaces. Install the new EGR cooler gaskets.

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Install the EGR cooler assembly and then install and tighten the EGR cooler bolts in the sequence shown.
Torque: 89 lb.in (10 Nm)

Fig 1: EGR Cooler Assembly Component Locations W/ Bolt Tightening Sequence
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Install the exhaust pressure sensor tube assembly and exhaust pressure sensor assembly bracket nut. Hand tighten the exhaust pressure sensor tube assembly flare nut and bracket nut.
Torque: Exhaust pressure sensor tube assembly flare nut : 133 lb.in (15 Nm) Exhaust pressure sensor tube assembly bracket nut : 89 lb.in (10 Nm) Exhaust pressure sensor tube assembly flare nut : 177 lb.in (20 Nm)

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Install the new EGR outlet pipe gaskets.

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Install the EGR cooler outlet pipe and the EGR cooler outlet pipe bolts.
Torque: 89 lb.in (10 Nm)

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Attach the EGRT (exhaust gas recirculation temperature) electrical connector retainer and the wiring harness retainer.

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Connect the EGRT (exhaust gas recirculation temperature) sensor electrical connector.

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Install the new EGR valve inlet tube gaskets.

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- Install the EGR valve inlet tube and the bolts.
  Torque: Tighten the bolts at the exhaust manifold. : 89 lb.in (10 Nm) Tighten the bolts at the EGR cooler. : 89 lb.in (10 Nm)
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Install the engine wire harness, then install and tighten the engine wire harness bolts.
Torque: 80 lb.in (9 Nm)

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Attach the wire harness retainer.

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Install the RH upper sound shield and then install the RH upper sound shield retainers.

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Install the EGR cooler inlet tube bracket and hand start the bolts.
Torque: Bolt 1: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg. Bolt 2: Stage 3: 89 lb.in (10 Nm) | Stage 4: 45 deg. Bolt 3: Stage 5: 89 lb.in (10 Nm) | Stage 6: 45 deg.

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Connect the electrical connector and the vacuum tubes to the EGR bypass valve solenoid. Attach the wiring harness retainers.

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Connect the EGR valve electrical connector.

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Connect the EGR valve coolant vent hose to the EGR valve. Use the General Equipment: Hose Clamp Remover/Installer

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Connect the coolant hose. Refer to: Quick Release Coupling .

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Install the upper intake manifold. Refer to: Upper Intake Manifold .
Install the air cleaner outlet pipe and the air cleaner. Refer to: Air Cleaner Outlet Pipe . Refer to: Air Cleaner .
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. Refer to: Engine Cooling System Condition Evaluation .