Prior to installing the EGR connection tube V-band clamps, coat the clamp surfaces with high-temperature anti-seize compound. Install the EGR connection tube. Use new gaskets. Tighten the V-band clamps. Torque Value: 11 N•m [ 97 in-lb ] Install the capscrews holding the EGR connection tube to the EGR cooler brace. Torque Value: 24 N•m [… Read More »
Scrape the gasket surfaces of the EGR connection tube, as well as the EGR valve and the EGR cooler, free of gasket material. Take caution not to drop any foreign material in the EGR cooler and EGR valve. NOTE: It is common for the EGR components to have a buildup of carbon on their inside… Read More »
Remove the capscrews from the support flange of the EGR connection tube. NOTE: Use caution to keep debris from falling in the EGR cooler and the EGR valve when removing the EGR connection tube. Remove the EGR connection tube by loosening the V- band clamps from both ends of the EGR connection tube. Cover all… Read More »
NOTE: Make sure to install any previously removed spacers between the EGR valve and air intake connection. The spacers will require an additional set of EGR valve mounting gaskets. Install the EGR valve, with new mounting gaskets, onto the air intake connection. Install the four capscrews holding the EGR valve to the air intake connection… Read More »
Clean the EGR valve and air intake connection mounting surfaces of gasket material. Take care to keep any debris out of the air intake system. NOTE: A light coating of carbon is common on the inside of the EGR valve, and does not need to be removed. NOTE: The EGR valve can have a corrosion… Read More »
Clean the area around the EGR valve with a clean cloth to help prevent debris from entering the air intake system when the EGR valve is removed. Remove the four capscrews holding the EGR valve to the air intake connection. Remove the EGR valve and mounting gasket(s). Discard the gasket(s). Use heavy tape or protective… Read More »
Install the EGR cooler assembly with a new gasket between the EGR cooler and exhaust manifold. Install the capscrews and spacers that connect the EGR cooler to the exhaust manifold hand-tight only. Install the EGR cooler to mounting bracket capscrews, hand-tight only. Tighten the exhaust manifold capscrews (1) first. Torque Value: 43 N•m [ 32… Read More »
Lubricate the sealing a-ring on the EGR cooler coolant inlet line with assembly lubricant, Part Number 3163086, for ease of installation to the EGR cooler coolant connection. Insert the EGR cooler coolant inlet line into the EGR cooler. Attach the EGR cooler coolant inlet support bracket assembly by wrapping it around EGR cooler body, as… Read More »
Use safety solvent to clean the soot from the inside of the EGR cooler. Use compressed air to dry the inside of the EGR cooler. If any solvents or cleaners entered the coolant side of the EGR cooler, use clean water to flush the coolant side of the cooler to prevent these solvents or cleaners… Read More »
NOTE: This procedure applies to Rear Gear Train engines only. For Front Gear Train engines, refer to the vehicle manufacturer’s service information. In order to pressure test the EGR cooler for leaks, a test fitting must be fabricated to connect compressed air to the EGR cooler coolant inlet. Obtain a straight thread plug, Part Number… Read More »