EGR Cooler Explanation

EGR COOLER REMOVAL
1. Disconnect the negative battery cable.
2. Center and lock the steering wheel.
3. Remove the pinch bolt (Fig 1) #2 at the upper intermediate shaft #1.
4. Separate the upper coupler on the lower shaft (Fig 1) #3 from the upper intermediate shaft #1 and position aside.
5. Remove four nuts and the engine cover.
6. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE
7. Remove the front lower splash shield.
8. Drain the engine coolant. Refer to STANDARD PROCEDURE
9. Remove the left wheel-house splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, REMOVAL
10. Disconnect the IAT/BPS sensor harness connector.
11. Disconnect the Charge Air Cooler (CAC) outlet hose from the EGR air flow control valve.
12. Remove the air cleaner body. Refer BODY, AIR CLEANER, REMOVAL for 3.6L.
13. Remove generator. Refer to GENERATOR, REMOVAL
14. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL
15. Remove the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), REMOVAL
16. Disconnect the EGR valve harness connector.
17. Remove the lower intermediate shaft-to-upper intermediate shaft pinch bolt and disconnect the intermediate shaft.
18. Remove the upper radiator hose to thermostat housing.
19. Remove the two lower coolant hoses (Fig 2) #1 and #3 from EGR cooler.
20. Disconnect the heater hose at the water pump inlet tube.
21. Disconnect the heater hose at the thermostat housing.
22. Disconnect the EGR bypass vacuum line (Fig 2) #2 from vacuum solenoid.
23. Remove the lower EGR cooler support bracket bolt (Fig 3) #1.
24. Remove the two lower EGR manifold bolts (Fig 4) #1.
25. Remove the two nuts (Fig 5) #3 securing the upper intermediate shaft to the cowl and remove the shaft #1 from the studs #2.
26. Disconnect the heater tubes (Fig 6) #1 from clips #2 and position the aside
27. Remove the left side EGR cooler support bracket bolt (Fig 7) #1.
28. Remove the two upper EGR manifold bolts (Fig 8) #1.
29. Disconnect the upper coolant hose (Fig 9) #1 from EGR cooler #2.
30. Remove bolts and separate the EGR cooler from manifold

EGR COOLER INSTALLATION
1. Clean the gasket mating surfaces.
2. Position a new gasket (Fig 10) #2 onto the EGR cooler manifold (Fig 10) #1.
3. Install the EGR cooler. Tighten bolts to 15 N.m (11 ft lbs.).
4. Connect the upper coolant hose (Fig 9) #1 from EGR cooler #2.
5. Install the EGR cooler and manifold assembly and tighten the upper bolts (Fig 4) #1 finger tight.
6. Install the left side EGR cooler support bracket bolt (Fig 7) #1 and tighten to 25 N.m (18 ft. lbs.).
7. Position the heater tubes (Fig 6) #1 back into clips #2.
8. Install the intermediate shaft (Fig 5) #1 to studs #2 at cowl. Tighten nuts (3) to 13 N.m (10 ft. lbs.).
9. Install the two lower EGR manifold bolts (Fig 4) #1. Tighten the four bolts (1) to 25 N.m (18 ft. lbs.).
10. Install the lower EGR cooler support bracket bolt (Fig 3) #1. Tighten bolt (1) to 45 N.m (33 ft. lbs.).
11. Connect the EGR bypass vacuum line (Fig 2) #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 (Fig 2) #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 pinch bolt to 49 N.m
(36 ft. lbs.).
17. Connect the EGR valve 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 for 2.8L Diesel, BODY, AIR CLEANER, INSTALLATION for 3.0L or BODY, AIR CLEANER, INSTALLATION for
3.6L.
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 STANDARD PROCEDURE .
26. Install the front lower splash shield.
27. Install the engine cover and securely tighten nuts.
28. Install the lower intermediate shaft coupler (Fig 1) #3 to upper intermediate shaft #1.
29. Install the pinch bolt (Fig 1) #2. Tighten to 49 N.m (36 ft. lbs.).
30. Remove the steering wheel lock.
31. Connect the negative battery cable.