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 (Static Fill) Cooling System Draining and Filling (Vac-N-Fill).
2. Remove the charger air outlet pipe.
3. Remove the air intake pipe.
4. Remove the intake manifold tube.
5. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler.
6. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way.




7. Remove the EGR valve cooler coolant hose clamp nut (2).
8. Reposition the EGR valve cooler coolant hose clamp (1).
9. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way.




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




12. Remove the front EGR valve cooler bolts (1).
13. Remove the EGR valve cooler and gasket. Discard the gasket.

Installation Procedure




1. Install a NEW EGR valve cooler gasket onto the cooler studs, and install the EGR cooler.

Notice: Refer to Fastener Notice.

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

Tighten the bolts to 50 N.m (37 lb ft).




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

Tighten the bolts to 25 N.m (18 lb ft).

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

Tighten the nuts to 53 N.m (39 lb ft).




5. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
6. Position the EGR valve cooler coolant hose clamp (1).
7. Install the EGR valve cooler coolant hose clamp nut (2).

Tighten the nut to 24 N.m (18 lb ft).




8. Position the heater inlet hose and install the hose to the EGR valve cooler.
9. Position the heater inlet hose clamp (1) at the EGR valve cooler.
10. Install the intake manifold tube.
11. Install the air intake pipe.
12. Install the charger air outlet pipe.
13. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill).