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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: Engine Cover
GC0148021Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect and isolate the negative battery cable.
  2. Remove the engine cover (1).
  3. Drain the cooling system. Refer to STANDARD PROCEDURE .
  4. Remove the air cleaner body and inlet tube.
  5. Remove the charge air cooler outlet tube from the Exhaust Gas Recirculation (EGR) flow control valve and position it out of the way.
    Fig 2: Engine Oil Dipstick Tube Bolt & Wire Harness Connector
    GC0147875Courtesy of CHRYSLER GROUP, LLC
  6. Remove the engine oil dipstick tube bolt (2) and carefully position the tube out of the way.
  7. Disconnect the wire harness connector (1) from the EGR vacuum solenoid.
    Fig 3: Vacuum Supply Hose & EGR Vacuum Hoses
    GC0147876Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the radiator hose from the thermostat housing outlet and position the hose out of the way. Refer to HOUSING, COOLANT OUTLET, REMOVAL .
  9. Disconnect the vacuum supply hose (1) for the vacuum reservoir.
  10. If required, disconnect the vacuum hose (2) for the EGR valve solenoid.
  11. Disconnect the vacuum hose (3) for the EGR vacuum valve solenoid.
    Fig 4: Clamp & Particulate Filter Intermediate Pressure Hose
    GC0147879Courtesy of CHRYSLER GROUP, LLC
  12. Loosen the clamp (1) and disconnect the particulate filter intermediate pressure hose (2).
    Fig 5: Wiring Harness Connector, Clamp & Hose
    GC0147881Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the wiring harness connector (1) from the engine coolant temperature sensor.
  14. Loosen the clamp (1) and disconnect the coolant hose (2) from the thermostat housing.
    Fig 6: Clamp & Heater Hose
    GC0147882Courtesy of CHRYSLER GROUP, LLC
  15. Loosen the clamp (2) and disconnect the heater hose (1) from the heater tube.
    Fig 7: Bolts & EGR Tube
    GC0147912Courtesy of CHRYSLER GROUP, LLC
  16. Remove the EGR tube (2). Refer to TUBE, EXHAUST GAS RECIRCULATION, REMOVAL .
    Fig 8: Wiring Harness Connector
    GC0147884Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the wiring harness connector (1) from the EGR valve.
  18. Disengage the retaining clip (3) and disconnect the coolant hose (2) to the engine oil cooler.
    Fig 9: Four Bolts
    GC0147886Courtesy of CHRYSLER GROUP, LLC
  19. Remove the four bolts (1, 2 and 3) that secure the EGR cooler manifold to the engine.
  20. Remove the EGR cooler manifold and gasket from the engine and place the manifold on a workbench.
    Fig 10: Exhaust Gas Recirculation (EGR) System -- Diesel
    GC0147869Courtesy of CHRYSLER GROUP, LLC
  21. If required, remove the EGR valve from the EGR cooler manifold (1). Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR), REMOVAL .
  22. If required, remove the EGR vacuum solenoid from the EGR cooler manifold. Refer to SOLENOID, EXHAUST GAS RECIRCULATION (EGR), 2.0L DIESEL, REMOVAL .
  23. If required, remove the thermostat housing from the EGR cooler manifold. Refer to HOUSING, COOLANT OUTLET, REMOVAL .
  24. If required, remove the engine coolant temperature sensor from the EGR cooler manifold. Refer to SENSOR, COOLANT TEMPERATURE, REMOVAL .
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