Exhaust Gas Recirculation Valve Cooler Replacement

Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure




1. 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).
2. Remove the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement).
3. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (Air Intake Pipe Replacement).




4. Open the intake air heater (IAH) harness lead cover (2).
5. Remove the engine wiring harness lead nut (1) from the IAH stud.
6. Remove the engine wiring harness lead (3) from the IAH stud.




7. Remove the electrical harness bolts (1).
8. Reposition the harness clip from the intake manifold tube, as needed.




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




10. Disconnect the intake air heater electrical connector.
11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
12. Remove the engine harness clip from the air inlet tube.
13. Remove the air inlet tube nuts and bolt.
14. Remove the air inlet tube.
15. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler.
16. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way.




17. Remove the EGR valve cooler coolant hose clamp nut (2).
18. Reposition the EGR valve cooler coolant hose clamp (1).
19. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way.




20. Remove the right exhaust pipe to EGR valve cooler nuts (2).
21. Remove the rear EGR valve cooler bolts (1).




22. Remove the outside bolt (2) of the EGR cooler heat shield.
23. Loosen the inside EGR cooler heat shield bolt (1) and rotate the heat shield counter-clockwise.




24. Remove the front EGR valve cooler bolts (1).




25. Remove the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 (Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1) or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 (Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2).
26. Remove the EGR valve cooler (2) and gasket (1). Discard the gasket.




27. If necessary, perform the following steps in order to remove the EGR brackets:

1. Remove the fuel injection fuel feed manifold bolt (3).
2. Remove the fuel feed pipe nut (1) and reposition the clip.
3. Remove the EGR bracket bolt (2).
4. Remove the EGR brackets (4).




28. If replacing the EGR valve cooler, perform the following steps:

1. Reposition the EGR valve cooler hose clamp and remove the hose (4).
2. Remove the EGR valve bolts (2).
3. Remove the EGR valve (3).
4. Remove and discard the EGR valve gaskets (1).

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution).

1. If the EGR valve cooler was replaced, perform the following steps:

1. Position the EGR valve (3) to the cooler.
2. Install the EGR valve bolts (2).

Tighten the bolts to 20 Nm (15 lb ft).

3. Install the EGR valve cooler hose (4) and position the hose clamp.
4. Install NEW EGR valve gaskets (1).




2. If necessary, perform the following steps in order to install the EGR brackets:

1. Position the EGR brackets (4).
2. Install the EGR bracket bolt (2).

Tighten the bolt to 25 Nm (18 lb ft).

3. Position the clip and install the fuel feed pipe nut (1).

Tighten the nut to 25 Nm (18 lb ft).

4. Install the fuel injection fuel feed manifold bolt (3).

Tighten the bolt to 25 Nm (18 lb ft).




3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine.
4. Install the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 (Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1) or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 (Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2).




5. Install the front EGR valve cooler bolts (1).

Tighten the bolts to 50 Nm (37 lb ft).




6. Rotate the EGR cooler heat shield clock-wise and align the outside bolt hole.
7. Tighten the inside EGR cooler heat shield bolt (1) to 25 Nm (18 lb ft).
8. Connect the electrical connector to the fuel rail pressure sensor and tighten the outside bolt (2) to 25 Nm (18 lb ft).




9. Install the rear EGR valve cooler bolts (1).

Tighten the bolts to 25 Nm (18 lb ft).

10. Install the right exhaust pipe to EGR valve cooler nuts (2).

Tighten the nuts to 53 Nm (39 lb ft).




11. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
12. Position the EGR valve cooler coolant hose clamp (1).
13. Install the EGR valve cooler coolant hose clamp nut (2).

Tighten the nut to 24 Nm (18 lb ft).




14. Position the heater inlet hose and install the hose to the EGR valve cooler.
15. Position the heater inlet hose clamp (1) at the EGR valve cooler.




16. Install the air inlet tube and NEW gaskets.
Caution: Refer to Fastener Caution (Fastener Caution)

17. Install the air inlet tube nuts and bolt.

Tighten the nuts to 25 Nm (18 lb ft).

18. Connect the intake air heater electrical connector.
19. Connect the MAP sensor electrical connector.
20. Install the engine harness clip to the air inlet tube.




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

Tighten the bolt/nut to 10 Nm (89 lb in).




22. Install the electrical harness bolts (1).

Tighten the bolts to 4 Nm (35 lb in).




23. Install the engine wiring harness lead (3) to the IAH stud.
24. Install the engine wiring harness lead nut (1) to the IAH stud.

Tighten the nut to 10 Nm (89 lb in).

25. Close the IAH harness lead cover (2).
26. Install the air intake pipe. Refer to Air Intake Pipe Replacement (Air Intake Pipe Replacement).
27. Install the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement).
28. 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).