Exhaust Gas Recirculation (EGR) Valve

Exhaust Gas Recirculation (EGR) Valve - 6.7L Diesel





Removal

NOTE: Only replace the EGR valve on-vehicle if directed to do so to by the Computers and Control Systems Information due to an electrical concern.

NOTE: The EGR valve cannot be replaced on-vehicle for a coolant leak. For additional information, refer to Exhaust Gas Recirculation (EGR) Cooler Leak Test Procedures.

1. Drain the cooling system. For additional information, refer to Engine Cooling - Diesel Engine Cooling System Draining, Filling and Bleeding.

2. Remove the Air Cleaner (ACL) assembly and ACL outlet pipe. For additional information, refer to the Intake Air System Components - Exploded View, 6.7L Diesel in Intake Air Distribution and Filtering Diagrams.

3. Disconnect the EGR valve coolant vent hose from the EGR valve.

4. Detach the coolant hose retainer from the EGR valve.

5. Disconnect the EGR valve electrical connector.

6. Remove the 2 bolts and the EGR valve inlet tube bracket.
- Discard the 2 bolts.





7. NOTE: EGR cooler side shown, exhaust manifold side similar.

Remove the 4 bolts and the EGR valve inlet tube.

- Remove and discard the 2 EGR valve inlet tube gaskets.





8. Remove the 13 bolts and the EGR valve.
- Discard the 13 bolts and the EGR valve gasket.

Installation

1. Using a new EGR valve gasket and 13 new bolts, install the EGR valve and tighten the bolts in the sequence shown in 4 stages:
- Stage 1: Tighten bolts 1 thru 12 to 12 Nm (106 lb-in).

- Stage 2: Tighten bolts 1 thru 12 to 16 Nm (142 lb-in).

- Stage 3: Tighten bolts 1 thru 4 to 16 Nm (142 lb-in).

- Stage 4: Tighten bolt 13 to 12 Nm (106 lb-in) and then an additional 90 degrees.





2. NOTE: EGR cooler side shown, exhaust manifold side similar.

Using 2 new EGR valve inlet tube gaskets, install the EGR valve inlet tube and the 4 bolts. Tighten the bolts in the following sequence.

- Tighten the bolts at the exhaust manifold to 10 Nm (89 lb-in).

- Tighten the bolts at the EGR cooler to 10 Nm (89 lb-in).





3. NOTE: Apply threadlock to the EGR cooler side bolt threads prior to installation.

Install the EGR valve inlet tube bracket and the 2 new bolts. Tighten in 4 stages:

- Stage 1: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler to 10 Nm (89 lb-in).

- Stage 2: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler an additional 45 degrees.

- Stage 3: Tighten the EGR valve inlet tube bracket bolt to 10 Nm (89 lb-in).

- Stage 4: Tighten the EGR valve inlet tube bracket bolt an additional 45 degrees.





4. Connect the EGR valve electrical connector.

5. Attach the coolant hose retainer to the EGR valve.

6. Connect the EGR valve coolant vent hose to the EGR valve.

7. Install the Air Cleaner (ACL) assembly and ACL outlet pipe. For additional information, refer to the Intake Air System Components - Exploded View, 6.7L Diesel in Intake Air Distribution and Filtering Diagrams.

8. NOTICE: Evaluate the cooling system condition before filling the engine cooling system. Failure to follow these instructions can result in damage to the engine.

Evaluate the cooling system condition. For additional information, refer to Cooling System Condition Evaluation in Engine Cooling - Diesel Engine Cooling System Condition Evaluation.

9. Initiate EGR valve learning cycle after EGR replacement in the following sequence.

1. Turn the ignition key to the Key ON Engine OFF (KOEO) for 10 seconds.

2. Turn the ignition key to the OFF position for 30 seconds.