EGR Tube: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE COOLER TUBE REPLACEMENT

REMOVAL PROCEDURE




1. Remove the intake manifold cover.
2. Remove the air cleaner outlet duct.
3. Loosen the charged air cooler outlet duct to intake hose clamp.

IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

4. Remove the charged air cooler outlet duct from the intake.
5. Drain the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System.
6. Remove the positive crankcase ventilation (PCV) hose/pipe.




7. If necessary, remove the tie strap from the electrical harness.




8. Remove the air inlet tube to intake manifold tube bolt and nut.




9. Remove the air inlet tube nuts.
10. Remove the air inlet tube.




11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.




12. Disconnect the EGR cooler tube heater hose.
13. Remove the EGR coolant pipe bolts.
14. Remove the EGR coolant pipe.




15. Remove the rear EGR cooler tube bolts.




16. Remove the EGR cooler tube bolts.




17. Remove the EGR cooler tube.

INSTALLATION PROCEDURE




1. Install the EGR cooler tube.




2. Install the EGR cooler tube bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the bolts to 50 N.m (37 lb ft).




3. Install the rear EGR cooler tube bolts.

Tighten the bolts to 20 N.m (15 lb ft).




4. Install the EGR coolant pipe.
5. Install the EGR coolant pipe bolts.

Tighten the bolts to 25 N.m (18 lb ft).
6. Connect the EGR cooler tube heater hose.




7. Connect the EGR valve electrical connector.




8. Install the air inlet tube.
9. Install the air inlet tube nuts.

Tighten the nuts to 25 N.m (18 lb ft).




10. Install the air inlet tube to intake manifold tube bolt and nut.

Tighten the bolt/nut to 10 N.m (89 lb in).




11. If necessary, install a tie strap to the electrical harness.
12. Install the PCV hose/pipe.




13. Install the charged air cooler outlet duct to the intake.

IMPORTANT: Lubricate the end of the duct prior to installation.

14. Tighten the charged air cooler outlet duct to intake hose clamp.

Tighten the clamp to 6 N.m (53 lb in).

15. Install the intake manifold cover.
16. Fill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System.