Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement

EXHAUST GAS RECIRCULATION (EGR) VALVE COOLER TUBE REPLACEMENT

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. Drain the cooling system. Refer to Draining and Filling Cooling System.
6. Remove the positive crankcase ventilation (PCV) hose/pipe.




7. Remove the electrical harness bolts.




8. Remove the engine harness power lead nut (2) from the intake air heater stud.
9. Remove the engine harness power lead (1) from the intake air heater stud.




10. Disconnect the intake air heater (IAH) electrical connector (1).
11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
12. Remove the engine harness clip from the side of the air inlet tube.




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




14. Remove the air inlet tube nuts.
15. Remove the air inlet tube.




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




17. Disconnect the EGR cooler tube heater hose.
18. Remove the EGR coolant pipe bolts.
19. Remove the EGR coolant pipe.




20. Remove the rear EGR cooler tube bolts.




21. Remove the EGR cooler tube bolts.




22. 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.

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. Install the engine harness clip to the side of the air inlet tube.
12. Connect the MAP sensor electrical connector (2).
13. Connect the IAH electrical connector (1).




14. Install the engine harness power lead (1) to the intake air heater stud.
15. Install the engine harness power lead nut (2) to the intake air heater stud.

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




16. Install a electrical harness bolts.

Tighten the bolts to 4 N.m (35 lb in).

17. Install the PCV hose/pipe.




18. Install a NEW quick connect fitting clip to the charged air cooler duct.
19. Install the charged air cooler outlet duct to the intake.
20. Install the intake manifold cover.
21. Fill the cooling system. Refer to Draining and Filling Cooling System.