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.
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.

NOTE: Refer to Fastener Notice in Service Precautions.




2. Install the EGR cooler tube bolts.

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




3. Install the rear EGR cooler tube bolts.

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




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

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




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

Tighten
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.

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




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

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

15. Install the intake manifold cover.
16. Fill the cooling system.