VALVE, Exhaust Gas Recirculation (EGR): Installation: 3.5L

CAUTION: Do Not use metal scrapers when cleaning the mounting surface of the EGR valve. Damage from scratching the surface may cause an improper seal.

CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum.

Fig 1: EGR Valve Mounting Bolts - 3.5L

Courtesy of CHRYSLER LLC

1. Clean and inspect the gasket sealing surfaces.
2. Install the EGR valve, gasket and mounting bolts (2). Tighten the bolts to 30 N.m (22 ft. lbs.).
   Fig 2: Identifying Inner EGR Tube Seal

   Courtesy of CHRYSLER LLC
   NOTE: Install a new rubber silicone seal on the intake manifold end of EGR tube any time it is removed from the intake manifold.
3. Install a new silicone rubber seal (1) on the intake manifold end of the EGR tube. Position seal 17 mm (0.67 in.) from the tube flange.
   Fig 3: Identifying EGR Flange, EGR Tube & Intake Manifold

   Courtesy of CHRYSLER LLC
4. Lubricate the EGR mounting tube hole in the intake manifold with Mopar® Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal.
5. Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seal, and verify that the seal is correctly positioned in the intake manifold.
   Fig 4: EGR Valve Mounting Bolts - 3.5L

   Courtesy of CHRYSLER LLC
6. Install a new gasket between the EGR valve (3) and the EGR tube. Install the bolts (1) and tighten to 15 N.m (11 ft. lbs.).
   Fig 5: Identifying EGR Flange, EGR Tube & Intake Manifold

   Courtesy of CHRYSLER LLC
   NOTE: The EGR tube flange (1) does not need to be flush with the intake manifold (2) to be sealed. The EGR tube flange can be up to 2 mm (0.08 in.) from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed.
   Fig 6: ELECTRICAL CONNECTOR - 3.5L

   Courtesy of CHRYSLER LLC
7. Connect and lock the electrical connector to EGR valve.
8. Verify that no wiring harnesses or hoses are contacting the EGR tube.
   Fig 7: PURGE SOLENOID INSTALLED

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9. Install the purge solenoid to its mounting bracket.
   Fig 8: Removing/Installing Cowl Panel

   Courtesy of CHRYSLER LLC
10. Install the strut tower support (6) with four bolts. Tighten the bolts to 20 N.m (15 ft. lbs.).
11. Install the wiper module and cowl panel (1). Refer to Electrical/Wipers/Washers/LINKAGE, Wiper Arm - Installation .
12. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
13. Using a scan tool, erase any previously recorded Diagnostic Trouble Codes (DTCs).