EGR Tube: Service and Repair

Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine)
Removal Procedure





1. Remove the intake manifold cover.
2. Remove the air cleaner outlet duct.
3. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
4. Remove the charged air cooler outlet duct from the intake.





5. Remove the electrical harness bolts.
6. Reposition the engine harness from the air inlet tube.





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





8. Disconnect the air intake heater electrical connector.
9. Disconnect manifold absolute pressure (MAP) sensor electrical connector.
10. Remove the engine harness clip from the air inlet tube.
11. Remove the air inlet tube nuts.
12. Remove the air inlet tube.





13. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
14. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp.
15. Remove the EGR coolant pipe hose.





16. Remove the EGR coolant pipe bolts.
17. Remove the EGR coolant pipe.
18. Remove and discard the coolant pipe O-ring seal.

Installation Procedure





1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant.
2. Install the EGR coolant pipe.

3. Notice: Refer to Fastener Notice in Service Precautions .

Install the EGR coolant pipe bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





4. Install the EGR coolant pipe hose.
5. Position the EGR coolant pipe hose clamp.
6. Connect the ECT sensor electrical connector.





7. Install the air inlet tube.
8. Install the air inlet tube nuts.
^ Tighten the nuts to 25 Nm (18 ft. lbs.).
9. Connect the air intake heater electrical connector.
10. Connect MAP sensor electrical connector.
11. Install the engine harness clip to the air inlet tube.





12. Install the air inlet tube to intake manifold tube bolt and nut.
^ Tighten the bolt/nut to 10 Nm (89 inch lbs.).





13. Position the engine harness to the air inlet tube.
14. Install the engine harness bolts.
^ Tighten the bolts to 4 Nm (35 inch lbs.).





15. Install a NEW quick connect fitting clip to the charged air cooler duct.
16. Install the charged air cooler outlet duct to the intake.
17. Install the air cleaner outlet duct.
18. Install the intake manifold cover.