Upper Tube

Upper Tube

Removal






1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3).
2. Disconnect negative battery cable.






3. Remove purge solenoid from bracket.






4. Relocate the purge solenoid.
5. Unlock and disconnect the electrical connector from EGR valve.






6. Remove upper tube bolts to EGR valve (2).
7. Remove upper tube from intake manifold.

NOTE: Replace the EGR tube gasket and silicone rubber seals any time the EGR tube is removed from the intake manifold.

8. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum.
9. Clean mounting surface.

Installation

CAUTION: Do Not use metal scrapers when cleaning the mounting surface of the EGR valve. Damage from scratching the surface may cause an improper seal.

CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum.

1. Clean and inspect gasket sealing surfaces.

NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.






2. Install new silicone rubber seal (1) on the intake manifold end of the EGR tube. Position seal 17 mm (0.67 in.) from the tube flange.
3. Lubricate the EGR mounting tube hole in the intake manifold with Mopar Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal.






4. Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seals, and verify that the seals are correctly positioned in the intake manifold.






5. Install new gasket between the EGR valve and tube and install bolts (2). Tighten bolts to 15 Nm (11 ft. lbs.).






NOTE: The EGR tube flange (1) does not need to be flush with the intake manifold (2) to be sealed. The EGR tube flange can be up to 2 mm (0.08 in.) from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed.






6. Connect the electrical connector to EGR valve and lock.
7. Verify that no wiring harnesses or hoses are contacting the EGR tube.






8. Install purge solenoid to bracket.
9. Connect negative battery cable and tighten nut to 5 Nm (45 in. lbs.).