Cooler, Exhaust Gas RECIRCULATION (EGR): Installation

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1. Clean the O-ring sealing surface.
2. Install NEW  O-ring seals (8) onto the EGR cooler and mounting bracket (9).
3. Lubricate and install the NEW  lower O-ring seals (7) onto spacers (6) and install the spacers into EGR cooler mounting bracket (9).
4. Lubricate and install the NEW  upper O-ring seals (5) onto EGR cooler (4).
5. Install the EGR and cooler assembly (4).
   • Tighten the bolt (1) to 25 N.m (18 ft. lbs.).
   • Tighten the nuts (2) to 25 N.m (18 ft. lbs.).

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6. Install the bolt (1) at the rear EGR cooler bypass valve support bracket (2) and tighten to 25 N.m (18 ft. lbs.).

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7. Using a NEW  gasket, install the turbocharger-to-EGR cooler tube (2). Tighten the bolts (1) to 25 N.m (18 ft. lbs.).

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8. Connect the EGR cooler vacuum bypass hose (1).

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9. Connect the EGR valve wire harness connector (1).
10. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
11. Fill the cooling system. Refer to STANDARD PROCEDURE .
12. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
13. Install the front skid plate. Refer to FRONT SKID PLATE INSTALLATION .
14. Connect the negative battery cable.