REMOVAL AND INSTALLATION
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1 Engine Emission Control REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Cooler 6.4L Diesel, Vertical Cooler Item Part Number Description 1 Fuel cooler tube 2 W Power steering reservoir bolts (2 required) 3 3R700 Power steering reservoir Copyright 2007, Ford Motor Company Last updated: 7/9/2007
2 Engine Emission Control REMOVAL AND INSTALLATION 4 LH charge air cooler (CAC) tube-to-cac tube flex joint clamp 5 LH CAC tube flex joint 6 LH CAC tube flex joint-to-turbocharger clamp 7 Upper radiator hose quick connect coupling 8 Exhaust gas recirculation temperature (EGRT) sensor outlet electrical connector (part of 12B637) EGR valve coolant supply hose clamp 10 9F466 EGR valve coolant supply hose 11 W EGR cooler coolant hose position retainer nut
3 Engine Emission Control REMOVAL AND INSTALLATION 12 9L456 EGR cooler coolant hose 14 W EGR cooler upper stud position retainer 15 W EGR cooler upper bolt 13 W EGR cooler upper nut EGR cooler coolant inlet hose 18 W EGR cooler lower nut (2 clamp required) 17 9F466 EGR cooler coolant inlet hose 19 W EGR cooler lower stud (2 required)
4 Engine Emission Control REMOVAL AND INSTALLATION 20 9E933 EGR cooler outlet gasket 24 EGR cooler coolant outlet 21 9P456 EGR cooler (vertical) hose 22 9H454 EGR cooler inlet gasket EGR cooler coolant outlet hose clamp
5 Engine Emission Control REMOVAL AND INSTALLATION Item Part Number Description 12. Remove the EGR cooler lower 2 nuts, the 2 25 N Power steering tube position studs and the EGR cooler inlet gasket. retainer nut Discard the 2 studs and the EGR cooler 26 Power steering tube position retainer inlet gasket. 27 Power steering tube position 13. Remove the 3 nuts and separate the EGR cooler retainer support clamps. 28 W EGR cooler support bracket Before removing the nuts, mark the location upper bolt of the clamps on the support bracket. 29 W EGR cooler support bracket stud 14. Disconnect the EGR cooler coolant inlet hose 30 W EGR cooler support bracket and discard the clamp. lower bolt (2 required) 31 9F488 EGR cooler support clamps 15. Position aside the EGR cooler and disconnect (3 required) the EGR cooler coolant outlet hose. 32 9F465 EGR cooler support bracket Discard the coolant outlet hose clamp. Removal 16. Remove the EGR cooler and discard the outlet gasket. 1. Remove the degas bottle assembly. For additional information, refer to Section Remove the power steering tube position retainers nut and position the power steering 2. Remove the spring clip and disconnect the tubes aside. upper radiator hose quick connect coupling. 18. Remove the 2 EGR cooler support bracket 3. Disconnect the fuel cooler tube from the lower bolts and the stud bolt. retainer on the power steering reservoir. 19. Remove the EGR cooler support bracket upper 4. Remove the 2 bolts and position the power bolt and the EGR cooler support bracket. steering reservoir aside. Remove and discard the 3 EGR cooler 5. Loosen the charge air cooler (CAC) tube flex support clamps. joint-to-turbocharger clamp and position the Installation CAC tube aside. 6. Remove the cooling fan stator. For additional information, refer to Section Position 3 new EGR cooler support clamps on the EGR cooler bracket Position the EGR cooler bracket and install the Disconnect the exhaust gas recirculation 3 bolts and the stud bolt finger-tight. temperature (EGRT) sensor outlet electrical connector. 3. NOTE: Do not tighten the clamps for the EGR cooler at this time. 8. Disconnect the EGR valve coolant supply hose from the retainer and the EGR cooler. Position the EGR cooler and using a new clamp, connect the EGR cooler coolant outlet 9. Remove the EGR cooler coolant hose position hose and loosely install the EGR cooler clamp retainer nut and the coolant hose position nuts. retainer. 4. Using a new clamp, connect the EGR cooler 10. Remove the EGR cooler upper nut and bolt. coolant inlet hose and tighten the inlet and outlet hose clamps. 11. Remove the EGR cooler upper stud. Tighten to 4 Nm (35 lb-in).
6 Engine Emission Control REMOVAL AND INSTALLATION 5. Using a new EGR cooler outlet gasket, position 13. Tighten the EGR cooler upper nut and bolt. the gasket and install the EGR cooler upper stud. 6. Install the EGR cooler upper nut and bolt finger-tight. 7. Using a new EGR cooler inlet gasket, install the lower gasket and the EGR cooler lower 2 studs. 14. Tighten the 2 EGR cooler lower nuts. 15. Install the EGR valve coolant supply hose position retainer and the nut. Tighten to 12 Nm (9 lb-ft). 16. Using a new clamp, connect the EGR valve Tighten to 17 Nm (13 lb-ft). coolant supply hose. 8. Install the EGR cooler lower retaining nuts finger-tight. 9. NOTE: Make sure to locate the EGR cooler clamps at the marked locations on the support bracket. Tighten to 4 Nm (35 lb-in). 17. Connect the EGRT sensor electrical connector. 18. Install the cooling fan stator. For additional information, refer to Section Position the EGR cooler clamps and tighten the 19. Position back the CAC tube and tighten the 3 clamp nuts. clamp. Tighten to 9 Nm (80 lb-in). Tighten to 8 Nm (71 lb-in). Loosen the clamps 720 degrees. Tighten to 7 Nm (62 lb-in). 10. Tighten the EGR cooler support bracket lower 2 bolts. 11. Tighten the EGR cooler support bracket upper bolt and the lower stud bolt. 20. Position back the power steering reservoir and install the 2 bolts. Tighten to 8 Nm (71 lb-in). 21. Connect the fuel cooler tube to the retainer on the power steering reservoir. 22. Install the spring clip and connect the upper radiator hose quick connect coupling. 23. Install the degas bottle assembly. For additional 12. Position back the 2 power steering tube position information, refer to Section retainers and install the nut. Tighten to 25 Nm (18 lb-ft).
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