Exhaust Gas Recirculation Valve Cooler Replacement (Front)

Exhaust Gas Recirculation Valve Cooler Replacement (LML-Front)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill LGH, LML) (Service and Repair).
3. Remove the generator. Refer to Generator Replacement (V6) (Service and Repair)Generator Replacement (V8) (Service and Repair)Generator Replacement (Diesel) (Service and Repair).
4. Reposition the A/C compressor without discharging the refrigerant. Refer to Air Conditioning Compressor Replacement (LU3) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LGH, LML) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (HP2) (Air Conditioning Compressor Replacement).
5. Remove the turbocharger coolant feed hose. Refer toTurbocharger Coolant Hoses/Pipes Replacement (Feed-LGH/LML) (Turbocharger Coolant Hoses/Pipes Replacement (Feed-LGH/LML))Turbocharger Coolant Hoses/Pipes Replacement (Return to Turbocharger-LGH/LML) (Turbocharger Coolant Hoses/Pipes Replacement (Return to Turbocharger-LGH/LML))Turbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe-LGH/LML) (Turbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe-LGH/LML)).
6. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (Service and Repair).




7. Remove the EGR bypass pipe bolts (1) and the rear EGR bypass pipe bolts (3).
8. Remove the EGR bypass pipe center mounting bolt (5) and remove the EGR bypass pipe (6).




9. Remove the EGR valve bolts (1) and disconnect the EGR valve electrical connector.




10. Remove the EGR manifold cooling return hose (2) and the front EGR cooler mounting bolt (1).




11. Remove the rear EGR cooler to front EGR cooler bolts (1).
Note: There is engine coolant inside the EGR coolers.




12. Remove the front EGR cooler mounting bolts (1).




13. Remove the front EGR cooler (2) and discard the gasket (1).

Installation Procedure




1. Position the front EGR cooler (2), with a NEW gasket, to the rear EGR cooler.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the front EGR cooler to the rear EGR cooler. Tighten the bolts (1) to 25 Nm (18 lb ft).




3. Install the front EGR mounting bolts (1) and tighten to 25 Nm (18 lb ft).




4. Install the EGR manifold cooling return hose (2) and the mounting bolt (1). Tighten to 25 Nm (18 lb ft).




5. Install NEW gaskets to the EGR valve;intake manifold and the front EGR cooler. Tighten the EGR valve bolts (1) to 25 Nm (18 lb ft).
6. Connect the EGR valve electrical connector.




7. Install the EGR bypass pipe center mounting bolt (5) and tighten to 10 Nm (89 lb in).
8. Install NEW gaskets (2,4) and tighten the EGR bypass bolts (3) to 25 Nm (18 lb ft).
9. Install the EGR bypass valve to the EGR valve bolts (1). Tighten to 10 Nm (89 lb in).
10. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (Service and Repair).
11. Install the generator. Refer to Generator Replacement (V6) (Service and Repair)Generator Replacement (V8) (Service and Repair)Generator Replacement (Diesel) (Service and Repair).
12. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LU3) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LGH, LML) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (HP2) (Air Conditioning Compressor Replacement).
13. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill LGH, LML) (Service and Repair).