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Cooler, EGR: Installation

GC0145368Courtesy of CHRYSLER GROUP, LLC
  1. Clean the gasket mating surfaces.
  2. Position a NEW  gasket (2) onto the EGR cooler manifold (1).
    GC0145373Courtesy of CHRYSLER GROUP, LLC
  3. Install the EGR cooler. Tighten the bolts to 15 N.m (11 ft. lbs.).
  4. Connect the upper coolant hose (1) from EGR cooler (2).
    GC0145363Courtesy of CHRYSLER GROUP, LLC
  5. Install the EGR cooler and manifold assembly and tighten the upper bolts (1) finger tight.
    GC0145362Courtesy of CHRYSLER GROUP, LLC
  6. Install the left side EGR cooler support bracket bolt and tighten to 25 N.m (18 ft. lbs.).
    GC0148214Courtesy of CHRYSLER GROUP, LLC
  7. Position the heater tubes (1) back into clips (2).
    GC0085671Courtesy of CHRYSLER GROUP, LLC
  8. Install the intermediate shaft (1) to studs (2) at the cowl. Tighten the nuts (3) to 13 N.m (10 ft. lbs.).
    GC0145363Courtesy of CHRYSLER GROUP, LLC
  9. Install the two lower EGR manifold bolts (1). Tighten the four bolts (1) to 25 N.m (18 ft. lbs.).
    GC0145367Courtesy of CHRYSLER GROUP, LLC
  10. Install the lower EGR cooler support bracket bolt (1). Tighten the bolt (1) to 45 N.m (33 ft. lbs.).
    GC0145361Courtesy of CHRYSLER GROUP, LLC
  11. Connect the EGR bypass vacuum line (2) to vacuum solenoid.
  12. Connect the heater hose at the thermostat housing.
  13. Connect the heater hose at the water pump inlet tube.
  14. Install the two lower coolant hoses (1 and 3) to EGR cooler.
  15. Install the upper radiator hose to thermostat housing.
  16. Connect the upper intermediate shaft-to-lower intermediate shaft. Tighten the pinch bolt to 49 N.m (36 ft. lbs.).
  17. Connect the EGR valve wire harness connector.
  18. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
  19. Install the A/C Compressor. Tighten the bolts to 28 N.m (21 ft. lbs.).
  20. Install the generator. Refer to GENERATOR, INSTALLATION .
  21. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  22. Connect the Charge Air Cooler (CAC) outlet hose to the EGR air flow control valve.
  23. Install the left wheel house splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, INSTALLATION .
  24. Evacuate and charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  25. Fill the cooling system. Refer to COOLANT FILL VOLUMES .
  26. Install the front lower splash shield.
  27. Install the engine cover and securely tighten the nuts.
    GC0085670Courtesy of CHRYSLER GROUP, LLC
  28. Install the lower intermediate shaft coupler (3) to upper intermediate shaft (1).
  29. Install the pinch bolt (2) and tighten to 49 N.m (36 ft. lbs.).
  30. Remove the steering wheel lock.
  31. Connect the negative battery cable.
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