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Cooler, EGR: Installation: Installation

Fig 1: New Gasket & EGR Cooler Manifold
GC0145368Courtesy of CHRYSLER GROUP, LLC
  1. Clean the gasket mating surfaces.
  2. Position a new gasket (2) onto the EGR cooler manifold (1).
    Fig 2: Upper Coolant Hose & EGR Cooler
    GC0145373Courtesy of CHRYSLER GROUP, LLC
  3. Install the EGR cooler. Tighten bolts to 15 N.m (133 in lbs.).
  4. Connect the upper coolant hose (1) from EGR cooler (2).
    Fig 3: EGR Manifold Nuts
    GC0145363Courtesy of CHRYSLER GROUP, LLC
  5. Install the EGR cooler and manifold assembly and tighten the upper nuts finger tight.
    Fig 4: EGR Cooler Support Bracket Bolt
    GC0145362Courtesy of CHRYSLER GROUP, LLC
  6. Install the left side EGR cooler support bracket bolt and tighten to 25 N.m (18 ft. lbs.).
    Fig 5: Heater Tubes & Clips
    GC0148214Courtesy of CHRYSLER GROUP, LLC
  7. Position the heater tubes (1) back into clips (2).
    Fig 6: Upper Intermediate Shaft, Studs & Nuts
    GC0085671Courtesy of CHRYSLER GROUP, LLC
  8. Install the intermediate shaft (1) to studs (2) at cowl.
  9. Install the mounting nuts (3). Tighten to 13 N.m (115 in. lbs.).
    Fig 7: EGR Manifold Nuts
    GC0145363Courtesy of CHRYSLER GROUP, LLC
  10. Install the two upper EGR manifold nuts (1). Tighten the four nuts (1) to 25 N.m (18 ft. lbs.).
    Fig 8: EGR Cooler Support Bracket Bolt
    GC0145367Courtesy of CHRYSLER GROUP, LLC
  11. Install the lower EGR cooler support bracket bolt (1). Tighten bolt (1) to 45 N.m (33 ft. lbs.).
    Fig 9: Two Lower Coolant Hoses & Vacuum Line
    GC0145361Courtesy of CHRYSLER GROUP, LLC
  12. Connect the EGR bypass vacuum line (2) to vacuum solenoid.
  13. Connect the heater hose at the thermostat housing.
  14. Connect the heater hose at the water pump inlet tube.
  15. Install the two lower coolant hoses (1 and 3) to EGR cooler.
  16. Install the upper radiator hose to thermostat housing.
  17. Connect the upper intermediate shaft-to-lower intermediate shaft. Tighten pinch bolt to 49 N.m (36 ft. lbs.).
  18. Connect the EGR valve harness connector.
  19. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
  20. Install the A/C Compressor. Tighten the bolts to 28 N.m (21 ft. lbs.).
  21. Install the generator. Refer to GENERATOR, INSTALLATION .
  22. Install the serpentine belt.
  23. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION
  24. Connect the Charge Air Cooler (CAC) outlet hose to the EGR air flow control valve.
  25. Install the left wheel house splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, INSTALLATION .
  26. Evacuate and charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  27. Fill cooling system. Refer to STANDARD PROCEDURE .
  28. Install the front lower splash shield.
  29. Install the engine cover and securely tighten nuts.
  30. Install the lower intermediate shaft coupler (3) to upper intermediate shaft (1).
  31. Install the pinch bolt (2). Tighten to 49 N.m (36 ft. lbs.).
  32. Remove the steering wheel lock.
  33. Connect the negative battery cable.
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