Page 358
REPAIR INSTRUCTIONS, PART 1
EGR Gas Tube Installation
[214 HN, HP, HR]
The following procedure covers the installation of
the EGR gas tubes in order of:
앫 Hot tube
앫 Cool tube, one-piece assembly
HOT TUBE INSTALLATION
Whenever an EGR hot tube clamp has been in
service and is removed, the retaining nut may gall
the threads of the T-bolt. Always install a new
T-bolt and nut in the clamp body whenever a
clamp has been removed. However, the body of
the clamp can be reused and should not be
replaced unless it is broken or damaged.
1. Install new seals in the flanges at each end
of the EGR hot tube. Place the hot tube in
position between the EGR valve and cooler
(Figure 431). Install new T-bolts and nuts in
the clamps and tighten to specification,
110 lb-in (12.4 N폷m).
431
Figure 431 — EGR Gas Hot Tube, Installed
2. Lightly tap the clamps with a hammer and
retighten them to specification.
3. Tighten the EGR valve retaining nuts to
specification, 40 lb-ft (55 N폷m).
4. Install the three spacer studs on the longer
EGR valve mounting studs. Tighten the
spacer studs to 40 lb-ft (54 N폷m).
5. Install a flat washer on top of each spacer
stud and then install the clamp bracket and
three bracket retaining nuts. Tighten the
nuts to 40 lb-ft (54 N폷m).
COOL TUBE INSTALLATION (ONE-PIECE
ASSEMBLY)
Early-production engines use flange-style
coupling adapters at both the EGR cooler and
mixer tube port connections in combination with
the one-piece cool tube. For current-production
engines, the coupling adapter is used only at the
EGR mixer tube port and not at the cooler port.
As production continues in the future, the need
for coupling adapters will be eliminated altogether
as the mixer tube cool-tube port design is
changed to accept a hose connection.
On vehicles so equipped, install the coupling
adapter(s) as follows before installing the cool
tube:
앫 Install a new wire-mesh gasket on the EGR
cool tube coupling adapter(s).
앫 Install the coupling adapter(s) to the EGR
cooler flange and/or the EGR mixer tube
flange using a band clamp. Tighten the band
clamp nut to 110 lb-in (12.4 N폷m).
On systems equipped with flange-style coupling
adapters on the EGR cool tube side of the
system, the flange clamps can be reused if there
is no damage and the threads are not corroded.
However, with damaged or corroded threads, the
flange clamps cannot be tightened to the proper
torque specification for a gas-tight seal. Replace
the T-bolt and nut or complete clamp assembly if
corrosion or damage is present.
1. EGR Gas Hot Tube
2. EGR Valve
3. EGR Cooler
5-111.bk Page 358 Monday, July 10, 2006 2:26 PM
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