Cooler, EGR: Installation: 6.4L

WARNING: This page is about a different car, the 2015 RAM 3500 HD and 2015 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Cooler & Studs

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If bolts were removed from the inlet side of the exhaust tube. Install new studs (2) onto the inlet exhaust side of the EGR cooler (1). Tighten the studs to 15 N.m (10 ft. lbs.).
Install a new Intake tube to EGR cooler gasket.
Align the EGR cooler to the intake tube.
Install a new nut to the upper stud and tighten to 23 N.m (17 ft. lbs.).

Fig 2: Remove/Install EGR Heat Shield
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Install the EGR heat shield (2). Tighten the bolts to 6 N.m (53 in. lbs.).

Fig 3: Remove/Install EGR Cooler
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Mount the EGR cooler (2) to the engine block. Tighten the bolts to 28 N.m (21 ft. lbs.).
Install the supply hose (5) and return hose (4) to the cooler.
Raise the vehicle.

Fig 4: Remove/Install Inlet Tube
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If the intake tube was removed, using a new gasket (3), position the EGR exhaust intake tube onto the exhaust manifold flange. Tighten the new flange nuts (1) to 23 N.m (17 ft. lbs.).

Fig 5: EGR Cooler Stud Nut
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Install a new nut (2) to the EGR cooler Stud.
Lower the vehicle.

Fig 6: Outlet Tube & Bolts
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Using a new gasket, install the exhaust outlet tube (1) to the EGR cooler. Tighten flange bolts (1) to 28 N.m (21 ft. lbs.).

Fig 7: Remove/Install EGR Valve
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Install the EGR control valve (2). Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .

Fig 8: Intake Manifold Removal/Installation Sequence
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Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION, 6.4L GAS .

Fig 9: Clamp, Air Intake Tube & Breather Hose
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Install the breather tube (3) to the air intake hose.

Fig 10: Installing Air Intake Hose To Throttle Body & Air Cleaner Housing
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Install the air intake hose to the throttle body and the air cleaner housing.

Fig 11: Temperature Sensors
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Connect the temperature (2) sensor.
Install the engine cover.
Connect the negative battery cable.
CAUTION:
All air must be purged from the 6.4L engine when refilling the cooling system. Failure to do so can cause EGR Cooler cracking which can lead to catastrophic engine and exhaust system damage.
Fill the engine cooling system. Refer to STANDARD PROCEDURE .
Start engine and check for coolant or exhaust leaks.
Take vehicle for test drive to operating temperature.
Allow the engine to cool down. Check and fill the cooling system to the proper level.