EGR Cooler: Service and Repair

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 (Static Fill)Cooling System Draining and Filling (Vac N Fill) Cooling System Draining and Filling (Vac N Fill)Cooling System Draining and Filling (Static Fill Diesel) Cooling System Draining and Filling (Static Fill Diesel).

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

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

4. Remove the exhaust gas recirculation valve temperature sensor - 1. Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 .

5. Disconnect both exhaust gas recirculation coolant hoses from the exhaust gas recirculation valve cooler.




6. If equipped, remove the exhaust outlet pipe heat shield bolts (3) and remove the exhaust outlet pipe heat shield (4).

7. Remove the exhaust outlet pipe to exhaust gas recirculation valve cooler fasteners (1).




8. Remove the rear exhaust gas recirculation valve cooler bolts (3).

9. Remove the front exhaust gas recirculation valve cooler bolt (1).

10. Disconnect the exhaust gas recirculation valve electrical connector (2).




11. Carefully remove the exhaust gas recirculation valve assembly (1) from the engine.




12. Remove the exhaust gas recirculation valve to exhaust gas recirculation valve cooler bolts (3).

13. Separate the exhaust gas recirculation valve cooler (1) from the exhaust gas recirculation valve (2).

14. Discard the gasket.

Installation Procedure




1. Connect the exhaust gas recirculation valve cooler (1) to the exhaust gas recirculation valve (2) using a NEW gasket.

Caution: Refer to Exterior Trim Emblem Removal Caution Service Precautions.

2. Install the exhaust gas recirculation valve to exhaust gas recirculation valve cooler bolts (3) and tighten to 25 Nm (18 lb ft).




3. Carefully Install the exhaust gas recirculation valve assembly (1) to the engine.




4. Connect the exhaust gas recirculation valve electrical connector (2).

5. Install the front exhaust gas recirculation valve cooler bolt (1) and tighten to 25 Nm (18 lb ft).

6. Install the rear exhaust gas recirculation valve cooler bolts (3) and tighten to 50 Nm (37 lb ft).




7. Install the exhaust outlet pipe to exhaust gas recirculation valve cooler fasteners (1) and tighten to 53 Nm (39 lb ft).

8. If equipped, Install the exhaust outlet pipe heat shield (4), washers (2) and tighten the bolts to 10 Nm (89 lb in).

9. Connect both exhaust gas recirculation coolant hoses from the exhaust gas recirculation valve cooler.

10. Install the exhaust gas recirculation valve temperature sensor - 1. Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 .

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

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

13. Refill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac N Fill) Cooling System Draining and Filling (Vac N Fill)Cooling System Draining and Filling (Static Fill Diesel) Cooling System Draining and Filling (Static Fill Diesel).