Exhaust Gas Recirculation Cooler Inlet Pipe Replacement
Single Use Fasteners and Components
  • Exhaust Gas Recirculation Cooler Inlet Pipe Gasket
  • Exhaust Gas Recirculation Pipe Seal
  • Exhaust Gas Recirculation Valve Inlet Gasket

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning: Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.

Removal Procedure
  1. Drain the cooling system.Cooling System Draining and Filling
  2. Plenum Front Panel Outer Reinforcement»Remove—Plenum Front Panel Outer Reinforcement Removal and Installation

    3. Object ID: 5150211
  3. Air Cleaner Outlet Duct Clamp(1)»Loosen[2x]
  4. Air Cleaner Outlet Front Duct(2)»Remove

    5. Object ID: 5171779
  5. Oil Filler Cap»Remove
  6. Intake Manifold Cover Bolt(1)»Remove
  7. Intake Manifold Cover(2)»Remove
  8. Install the oil filler cap after removal of the intake manifold cover (2) to prevent debris from falling into the engine.

    9. Object ID: 5150241
  9. Air Cleaner Outlet Duct Clamp(1)»Loosen
  10. Air Cleaner Outlet Duct(2)»Remove

    11. Object ID: 5170071
  11. Remove the 3 rear engine wiring harness channel nuts (1).
  12. Position the rear engine wiring harness channel (2) out of the way.

    13. Object ID: 5620997
  13. Remove the engine coolant outlet pipe bracket bolt (1) and position the engine coolant air bleed hose (2) out of the way.

    14. Object ID: 5204431

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  14. Exhaust Gas Recirculation Cooler Bolt(1)»Remove[2x]

    15. Object ID: 5206053
  15. Turbocharger Coolant Feed Pipe Bolt(3)»Remove

    16. Object ID: 5204427
  16. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
  17. Exhaust Gas Recirculation Outlet Pipe Bolt(2)»Remove

    18. Object ID: 5204428
  18. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Remove[2x]

    19. Object ID: 5628860
  19. Exhaust Gas Recirculation Cooler Outlet Pipe(1)»Remove
  20. Exhaust Gas Recirculation Pipe Seal(2)»Remove and DISCARD
  21. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Remove and DISCARD

    22. Object ID: 5186629
  22. Hose Clamp(1)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
  23. Exhaust Gas Recirculation Manifold Cooling Return Hose(2)@Exhaust Gas Recirculation Cooler Inlet Pipe»Reposition

    24. Object ID: 5810913
  24. Hose Clamp(1)»Disengage[2x]—Hose Clamp Replacement Guidelines - Spring Type
  25. Exhaust Gas Recirculation Valve Cooling Return Hose(2)@Exhaust Gas Recirculation Cooler Inlet Pipe»Remove
  26. Thermostat Bypass Hose(3)@Exhaust Gas Recirculation Cooler Inlet Pipe»Remove

    27. Object ID: 5620866
  27. Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(1)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
  28. Exhaust Gas Recirculation Valve Cooling Feed Hose(2)»Remove

    29. Object ID: 5810915
  29. Exhaust Gas Recirculation Manifold Cooling Return Hose(2)@Exhaust Gas Recirculation Pipe Clip(1)»Separate
  30. Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose(3)@Exhaust Gas Recirculation Pipe Clip(1)»Separate

    31. Object ID: 5207655
  31. Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(2)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
  32. Remove the exhaust gas recirculation valve cooling return hose (3) from the exhaust gas recirculation valve.

    33. Object ID: 5205974
  33. Disconnect the exhaust gas recirculation valve electrical connector.
  34. Exhaust Gas Recirculation Valve Bolt(1)»Remove[2x]
  35. Remove the exhaust gas recirculation valve (2) with the exhaust gas recirculation cooler inlet pipe.
  36. Exhaust Gas Recirculation Valve Inlet Gasket(3)»Remove and DISCARD

    37. Object ID: 5186755
  37. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Remove[2x]

    38. Object ID: 5186777
  38. Exhaust Gas Recirculation Cooler Inlet Pipe(1)»Remove
Cleaning and Inspection Procedure - Conditional

Note: The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation.


    Object ID: 5845629
  1. Clean the exhaust gas recirculation valve (1).
  2. Inspect the exhaust gas recirculation valve (1).
  3. Replace the exhaust gas recirculation valve (1) if any damage is found.
Installation Procedure

    Object ID: 5186777
  1. Exhaust Gas Recirculation Cooler Inlet Pipe(1)»Install

    2. Object ID: 5186755

    Caution: Refer to Fastener Caution.

  2. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Install and tighten[2x]—Fastener Specifications

    3. Object ID: 5205974
  3. Exhaust Gas Recirculation Valve Inlet Gasket(3)»Install NEW
  4. Install the exhaust gas recirculation valve (2) with the exhaust gas recirculation cooler inlet pipe and do not tighten.
  5. Exhaust Gas Recirculation Valve Bolt(1)»Install[2x]—Fastener Specifications
  6. Connect the exhaust gas recirculation valve electrical connector.

    7. Object ID: 5207655
  7. Install the exhaust gas recirculation valve cooling return hose (3) to the exhaust gas recirculation valve.
  8. Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(2)»Engage—Hose Clamp Replacement Guidelines - Spring Type

    9. Object ID: 5810915
  9. Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose(3)@Exhaust Gas Recirculation Pipe Clip(1)»Install
  10. Exhaust Gas Recirculation Manifold Cooling Return Hose(2)@Exhaust Gas Recirculation Pipe Clip(1)»Install

    11. Object ID: 5620866
  11. Exhaust Gas Recirculation Valve Cooling Feed Hose(2)»Install
  12. Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(1)»Engage—Hose Clamp Replacement Guidelines - Spring Type

    13. Object ID: 5810913
  13. Thermostat Bypass Hose(3)@Exhaust Gas Recirculation Cooler Inlet Pipe»Install
  14. Exhaust Gas Recirculation Valve Cooling Return Hose(2)@Exhaust Gas Recirculation Cooler Inlet Pipe»Install
  15. Hose Clamp(1)»Engage[2x]—Hose Clamp Replacement Guidelines - Spring Type

    16. Object ID: 5186629
  16. Exhaust Gas Recirculation Manifold Cooling Return Hose(2)@Exhaust Gas Recirculation Cooler Inlet Pipe»Install
  17. Hose Clamp(1)»Engage—Hose Clamp Replacement Guidelines - Spring Type

    18. Object ID: 5204438
  18. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Install NEW
  19. Exhaust Gas Recirculation Pipe Seal(2)»Install NEW
  20. Exhaust Gas Recirculation Cooler Outlet Pipe(1)»Install

    21. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  21. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Install and hand tighten[2x]

    22. Object ID: 5204427
  22. Install and hand tighten the exhaust gas recirculation outlet pipe bolt (2).
  23. Install the turbocharger coolant return hose clip (1).

    24. Object ID: 5204431
  24. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

    25. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  25. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications

    26. Object ID: 5204427
  26. Exhaust Gas Recirculation Outlet Pipe Bolt(2)»Tighten in sequence[2x]—Fastener Specifications
  27. Install the turbocharger coolant return hose clip (1).

    28. Object ID: 5204431
  28. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications

    29. Object ID: 5206053
  29. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Install and tighten—Fastener Specifications

    30. Object ID: 5620997
  30. Engine Coolant Air Bleed Hose(2)»Reposition
  31. Engine Coolant Outlet Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications

    32. Object ID: 5170071
  32. Install the rear engine wiring harness channel (2).
  33. Engine Wiring Harness Bracket Nut(1)»Install and tighten[3x]—Fastener Specifications.

    34. Object ID: 5150241
  34. Air Cleaner Outlet Duct(2)»Install
  35. Air Cleaner Outlet Duct Clamp(1)»Tighten—Fastener Specifications

    36. Object ID: 5171779
  36. Oil Filler Cap»Remove
  37. Intake Manifold Cover(2)»Install
  38. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  39. Oil Filler Cap»Install

    40. Object ID: 5150211
  40. Air Cleaner Outlet Front Duct(2)»Install
  41. Air Cleaner Outlet Duct Clamp(1)»Tighten[2x]—Fastener Specifications
  42. Plenum Front Panel Outer Reinforcement(1)»Install—Plenum Front Panel Outer Reinforcement Removal and Installation
  43. Fill the cooling system to the proper level.Cooling System Draining and Filling
  44. Start the engine and check for exhaust leaks.