Cooler, EGR: Installation: Pickup

WARNING: This page is about a different car, the 2011 RAM Pickup and 2011 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: EGR Cooler Inlet Flange Nuts

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Install EGR cooler support bracket, if removed and tighten mounting bolts finger tight. If the EGR cooler support bracket was already installed, loosen the bolts to finger tight.
Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts (1) to finger tight.

Fig 2: EGR Cooler, Clamp, Exhaust Transfer Manifold & Nuts
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Using a new gasket, install the exhaust transfer manifold (3) Tighten nuts (4) to finger tight.
Using a new gasket, install the clamp (2) securing the EGR cooler (1) to exhaust transfer manifold (3), make sure that the bellows pilot is centered in the EGR cooler outlet. Tighten clamp finger tight.

Fig 3: Tightening EGR Cooler Mounting Bolts
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NOTE:
Lubricate the new O-rings with a soapy water solution.
Install EGR Cooler mounting bolts (3) finger tight.
Using new O-rings, install the rear coolant tube to connection (4) then (1) and install the bolt (2) finger tight.

Fig 4: Transmission Fill Tube Retaining Nut
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If equipped, position back the transmission fill tube (2) to the EGR cooler (1) finger tight.

Fig 5: EGR Cooler Inlet Flange Nuts
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Tighten nuts (1) on the EGR cooler inlet flange to the exhaust manifold to 60 N.m (44 ft. lbs.).

Fig 6: Tightening EGR Cooler Mounting Bolts
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Using a crisscross pattern, tighten bolt (2) and (3) to 24 N.m 18 ft. lbs.) to secure the EGR cooler onto the EGR cooler mounting bracket.

Fig 7: EGR Cooler Mounting Bracket-to-Cylinder Head Bolts
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Tighten the EGR cooler mounting bracket to cylinder head bolts to 36 N.m (27 ft. lbs.).

Fig 8: Installing EGR Cooler, O-ring & Forward Coolant Tube
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NOTE:
Lubricate the new O-rings with a soapy water solution.
Using a new O-ring (2), install the forward coolant tube (3) onto EGR cooler (1).

Fig 9: EGR Cooler, Clamp, Exhaust Transfer Manifold & Nuts
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Tighten nuts (4) on the exhaust transfer manifold (3) to 43 N.m (18 ft. lbs.).
Tighten clamp (2) to 10 N.m (89 in. lbs.).

Fig 10: Transmission Fill Tube Retaining Nut
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If equipped, tighten the nut (1) on the transmission fill tube (2) 10 N.m (89 in. lbs.).

Fig 11: Breather Hose, Breather Tube & Bolt
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Install the breather tube (2) and connect breather hose (1), Tighten the bolt (3) 24 N.m (18 ft. lbs.).

Fig 12: EGR Cooler Bypass Valve Assembly
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Install the EGR cooler bypass valve. Refer to VALVE, Exhaust Gas Recirculation (EGR) Cooler Bypass, Installation .

Fig 13: Diesel Generator Connectors

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1 - B + CONNECTOR

2 - GENERATOR

3 - FIELD WIRE CONNECTOR

Install the generator. Refer to GENERATOR, Installation .

Fig 14: Identifying Clamp, Outlet Tube & Breather Hose
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Install the outlet tube (2) to the turbocharger and tighten the clamp (1) 11 N.m (95 in. lbs.).
Connect the breather hose (3).

Fig 15: Air Cleaner Housing
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Install the air cleaner assembly. Refer to BODY, Air Cleaner, Installation, 3.7L BODY, Air Cleaner, Installation, 4.7L BODY, Air Cleaner, Installation, 5.7L BODY, Air Cleaner, Installation, 6.7L .

Fig 16: Engine Cover Bolts
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Install engine cover and tighten bolts (1) to 10 N.m (89 in. lbs.).
Connect negative battery cable(s).
Fill coolant system. Refer to Standard Procedure .
Start engine and check for coolant or exhaust leaks.