Exhaust Gas Recirculation (EGR) Cooler: Installation

WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 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.

Courtesy of FORD MOTOR COMPANY
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 Tightening Sequence
Courtesy of FORD MOTOR COMPANY
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)

Courtesy of FORD MOTOR COMPANY
Install the new EGR outlet pipe gaskets.

Courtesy of FORD MOTOR COMPANY
Install the EGR cooler outlet pipe and the EGR cooler outlet pipe bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Attach the EGRT (exhaust gas recirculation temperature) electrical connector retainer and the wiring harness retainer.

Courtesy of FORD MOTOR COMPANY
Connect the EGRT (exhaust gas recirculation temperature) sensor electrical connector.

Courtesy of FORD MOTOR COMPANY
Install the new EGR valve inlet tube gaskets.

Courtesy of FORD MOTOR COMPANY
- 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)
Courtesy of FORD MOTOR COMPANY
Install the engine wire harness, then install and tighten the engine wire harness bolts.
Torque: 80 lb.in (9 Nm)

Courtesy of FORD MOTOR COMPANY
Attach the wire harness retainer.

Courtesy of FORD MOTOR COMPANY
Install the RH upper sound shield and then install the RH upper sound shield retainers.

Courtesy of FORD MOTOR COMPANY
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 °

Bolt 2

Stage 3: 89 lb.in (10 Nm)

Stage 4: 45 °

Bolt 3

Stage 5: 89 lb.in (10 Nm)

Stage 6: 45 °

Courtesy of FORD MOTOR COMPANY
Connect the electrical connector and the vacuum tubes to the EGR bypass valve solenoid. Attach the wiring harness retainers.

Courtesy of FORD MOTOR COMPANY
Connect the EGR valve electrical connector.

Courtesy of FORD MOTOR COMPANY
Connect the EGR valve coolant vent hose to the EGR valve. Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY
Connect the coolant hose. Refer to: Quick Release Coupling .

Courtesy of FORD MOTOR COMPANY
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: Cooling System Condition Evaluation .