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

4. Reposition the A/C compressor without discharging the refrigerant. Refer to Air Conditioning Compressor Replacement (LU3) Removal and ReplacementAir Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) Removal and ReplacementAir Conditioning Compressor Replacement (LGH, LML) Removal and Replacement.

5. Remove the turbocharger coolant feed hose. Refer to Turbocharger Coolant Hoses/Pipes Replacement (Return to Turbocharger-LML) Turbocharger Coolant Hoses/Pipes Replacement (Return to Turbocharger)Turbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe-LML) Turbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe).

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





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).





Note:
There is engine coolant inside the EGR coolers.

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





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 25 Nm (18 lb ft).

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 25 Nm (18 lb ft).

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

11. Install the generator. Refer to Generator Replacement (Diesel) Generator ReplacementGenerator Replacement (V6) Generator ReplacementGenerator Replacement (V8) Generator Replacement.

12. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LU3) Removal and ReplacementAir Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) Removal and ReplacementAir Conditioning Compressor Replacement (LGH, LML) Removal and Replacement.

13. 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).