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Home >> Jeep >> 2011 >> Wrangler V6-3.8L >> Repair and Diagnosis >> Powertrain Management >> Emission Control Systems >> Exhaust Gas Recirculation >> EGR Cooler >> Service and Repair >> EGR Cooler - Installation
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EGR Cooler - Installation






INSTALLATION - EGR COOLER





1. Clean the gasket mating surfaces.
2. Position a new gasket (2) onto the EGR cooler manifold (1).





3. Install the EGR cooler. Tighten bolts to 15 Nm (133 in lbs.).
4. Connect the upper coolant hose (1) from EGR cooler (2).





5. Install the EGR cooler and manifold assembly and tighten the upper nuts finger tight.





6. Install the left side EGR cooler support bracket bolt and tighten to 25 Nm (18 ft. lbs.).





7. Position the heater tubes (1) back into clips (2).





8. Install the intermediate shaft (1) to studs (2) at cowl.
9. Install the mounting nuts (3). Tighten to 13 Nm (115 in. lbs.).





10. Install the two upper EGR manifold nuts (1). Tighten the four nuts (1) to 25 Nm (18 ft. lbs.).





11. Install the lower EGR cooler support bracket bolt (1). Tighten bolt (1) to 45 Nm (33 ft. lbs.).





12. Connect the EGR bypass vacuum line (2) to vacuum solenoid.
13. Connect the heater hose at the thermostat housing.
14. Connect the heater hose at the water pump inlet tube.
15. Install the two lower coolant hoses (1 and 3) to EGR cooler.
16. Install the upper radiator hose to thermostat housing.
17. Connect the upper intermediate shaft-to-lower intermediate shaft. Tighten pinch bolt to 49 Nm (36 ft. lbs.).
18. Connect the EGR valve harness connector.
19. Install the EGR tube Exhaust Gas Recirculation (EGR) Tube - Installation.
20. Install the A/C Compressor. Tighten the bolts to 28 Nm (21 ft. lbs.).
21. Install the generator Generator - Installation
22. Install the serpentine belt.
23. Install the air cleaner body Air Cleaner Body - Installation.
24. Connect the Charge Air Cooler (CAC) outlet hose to the EGR air flow control valve.
25. Install the left wheel house splash shield Splash Shield - Installation.
26. Evacuate and charge the A/C system Refrigerant System Charge.
27. Fill cooling system Cooling System.
28. Install the front lower splash shield.
29. Install the engine cover and securely tighten nuts.
30. Install the lower intermediate shaft coupler (3) to upper intermediate shaft (1).
31. Install the pinch bolt (2). Tighten to 49 Nm (36 ft. lbs.).
32. Remove the steering wheel lock.
33. Connect the negative battery cable.

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