2.7L - Upper Tube

Fig 1: Identifying Inner EGR Tube Seal

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1 - INNER EGR TUBE SEAL

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.

Clean and inspect gasket sealing surfaces.
NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.
Install 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 2: Identifying EGR Flange, EGR Tube & Intake Manifold
Courtesy of CHRYSLER LLC

1 - EGR TUBE

2 - INTAKE MANIFOLD
Lubricate the EGR mounting tube hole in the intake manifold with Mopar® Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal.
Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seals, and verify that the seals are correctly positioned in the intake manifold.

Fig 3: EGR VALVE
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Install new gasket between the EGR valve and tube and install bolts (2). Tighten bolts to 15 N.m (11 ft. lbs.).

Fig 4: Identifying EGR Flange, EGR Tube & Intake Manifold
Courtesy of CHRYSLER LLC

1 - EGR TUBE

2 - INTAKE MANIFOLD

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 5: ELECTRICAL CONNECTOR - 3.5L
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Connect the electrical connector to EGR valve and lock.
Verify that no wiring harnesses or hoses are contacting the EGR tube.

Fig 6: PURGE SOLENOID INSTALLED
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Install purge solenoid to bracket.
Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).