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EGR Cooler Manifold

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exhaust Gas Recirculation (EGR) System -- Diesel
GC0147869Courtesy of CHRYSLER GROUP, LLC
  1. Clean all gasket mating surfaces.
  2. If removed, install the engine coolant temperature sensor onto the EGR cooler manifold (1). Refer to SENSOR, COOLANT TEMPERATURE, INSTALLATION .
  3. If removed, install the thermostat housing onto the EGR cooler manifold (1). Refer to HOUSING, COOLANT OUTLET, INSTALLATION .
  4. If removed, install the EGR vacuum solenoid onto the EGR cooler manifold (1). Refer to INSTALLATION .
  5. If removed, install the Exhaust Gas Recirculation (EGR) valve onto the EGR cooler manifold (1). Refer to INSTALLATION .
    Fig 2: Four Bolts
    GC0147886Courtesy of CHRYSLER GROUP, LLC
  6. Position the EGR cooler manifold and a new gasket to the engine.
  7. Install the four bolts (1, 2 and 3) that secure the EGR cooler manifold to the engine. Tighten the bolts to 3 N.m (27 in. lbs.).
    Fig 3: Wiring Harness Connector
    GC0147884Courtesy of CHRYSLER GROUP, LLC
  8. Connect the wiring harness connector (1) to the EGR valve.
  9. Connect the oil cooler coolant hose (2) and engage the retaining clip (3). Make sure the retaining clip and hose connector are fully engaged.
    Fig 4: Bolts & EGR Tube
    GC0147912Courtesy of CHRYSLER GROUP, LLC
  10. Using a new gasket, install the EGR tube (2). Refer to TUBE, EXHAUST GAS RECIRCULATION, INSTALLATION .
    Fig 5: Clamp & Heater Hose
    GC0147882Courtesy of CHRYSLER GROUP, LLC
  11. Connect the heater hose (1) to the heater tube and securely tighten the hose clamp (2).
    Fig 6: Wiring Harness Connector, Clamp & Hose
    GC0147881Courtesy of CHRYSLER GROUP, LLC
  12. Connect the wiring harness connector (1) to the engine coolant temperature sensor.
  13. Connect the degassing hose (2) to the heater tube and securely tighten the hose clamp (3).
    Fig 7: Clamp & Particulate Filter Intermediate Pressure Hose
    GC0147879Courtesy of CHRYSLER GROUP, LLC
  14. Connect the particulate filter intermediate pressure hose (1) and tighten the hose clamp (2) securely.
    Fig 8: Vacuum Supply Hose & EGR Vacuum Hoses
    GC0147876Courtesy of CHRYSLER GROUP, LLC
  15. Connect the vacuum hose (3) for the EGR vacuum valve solenoid.
  16. If required, connect the vacuum hose (2) for the EGR vacuum solenoid.
  17. Connect the vacuum supply hose (1) for the vacuum reservoir.
  18. Connect the coolant hose to the thermostat housing outlet. Refer to HOUSING, COOLANT OUTLET, INSTALLATION .
    Fig 9: Engine Oil Dipstick Tube Bolt & Wire Harness Connector
    GC0147875Courtesy of CHRYSLER GROUP, LLC
  19. Connect the wire harness connector (1) to the EGR vacuum solenoid.
  20. Reposition the engine oil dipstick tube and install the retaining bolt (2). Tighten the bolt to 2 N.m (18 in. lbs.).
  21. Install the charge air cooler outlet tube to the EGR flow control valve.
  22. Install the engine air cleaner housing and inlet tube.
  23. Connect the negative battery cable.
  24. Fill the cooling system. Refer to STANDARD PROCEDURE .
    Fig 10: Engine Cover
    GC0157479Courtesy of CHRYSLER GROUP, LLC
  25. Install the engine cover (1).
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