Exhaust Gas Recirculation Valve Cooler Replacement (Rear)

Exhaust Gas Recirculation Valve Cooler Replacement (LML-Rear)

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 Gasoline) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac-N-Fill Diesel) Cooling System Draining and Filling (Vac-N-Fill).

3. Remove the right exhaust manifold outlet pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LML) Exhaust Manifold Outlet Pipe Replacement - Right Side.





4. Remove the bolts (1) to the rear EGR bracket (2).

5. Lower the vehicle.

6. Remove the generator. Refer to Generator Replacement (Diesel) Generator ReplacementGenerator Replacement (V6) Generator ReplacementGenerator Replacement (V8) Generator Replacement.

7. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement Intake Manifold Tube Replacement.





8. Remove the EGR bypass pipe bolts (1) and the rear EGR bypass pipe bolts (3).

9. Remove the EGR bypass pipe center mounting bolt (5) and remove the EGR bypass pipe (6).

10. Remove the turbocharger air inlet adapter. Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.





11. Remove the rear EGR cooler to front EGR cooler bolts (1).





12. Remove the following hoses:

* Cooling Feed Hose (1)

* Cooling Feed Hose (2)

* Heater Water Bypass Hose (3)

* Heater Inlet Hose (4)





13. Remove the rear EGR mounting bolts (1) and let the bracket fall to the floor.

14. Disconnect the EGR bypass valve electrical connector.





15. Remove the rear EGR cooler (2) and discard the gasket (1).

Note:
There is engine coolant inside the EGR coolers.

16. Transfer the EGR bypass valve to the rear EGR cooler.

Installation Procedure





1. Loosely install the rear EGR mounting bolt (1) to the EGR bracket (2) as shown.





2. Position the rear EGR cooler (1) and the NEW gasket (2), on top of the engine.





3. Rotate the EGR bracket into place and loosely tighten the rear EGR mounting bolts (1).

4. Raise the vehicle.





Caution:
Refer to Fastener Caution Fastener Caution.

5. Install the rear EGR bracket bolts (1) and tighten to 25 Nm (18 lb ft).

6. Lower the vehicle.





7. Tighten the rear EGR mounting bolts (1) to 53 Nm (39 lb ft).





8. Install the front EGR cooler bolts to the rear EGR cooler and tighten the bolts (1) to 25 Nm (18 lb ft).

Note:
Make sure the turbocharger air inlet adapter is seated properly along the clamp.

9. Install the turbocharger air inlet adapter to the turbocharger. Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.





10. Install the following hoses:

* EGR Cooling Feed Hose (1)

* EGR Cooling Feed Hose (2)

* Heater Water Bypass Hose (3)

* Heater Inlet Hose (4)

11. Connect the EGR bypass valve electrical connector.





12. Install the EGR bypass pipe center mounting bolt (5) and tighten to 10 Nm (89 lb in).

13. Install the EGR bypass pipe bolts (1) and the rear EGR bypass pipe bolts (3). Tighten to 25 Nm (18 lb ft).

14. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement Intake Manifold Tube Replacement.

15. Install the right exhaust manifold outlet pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LML) Exhaust Manifold Outlet Pipe Replacement - Right Side.

16. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac-N-Fill Diesel) Cooling System Draining and Filling (Vac-N-Fill).