OEM Dodge Ram 3500 EGR Cooler

Dodge Ram 3500 EGR Cooler Parts and Q&A

• EGR Valve
  68026995AB
  Q:

  How to install the EGR Cooler on Dodge Ram 3500?

  A:

  In pick-up models, first clean the gasket mating surfaces on castings 4 (EGR cooler) and 15 (EGR cooler bypass valve assembly). Position the EGR cooler bypass valve assembly to the engine and place a new gasket 3 between castings 4 and 15. Install bolts 5 and 14, but do not tighten them yet. Install bracket bolts 2 on the outside of the mounting bracket, but hold them loose for now as well. Subsequently, fit the bracket bolts onto the inner side of the fitting bracket but do not tighten. Tighten bolts 5 and 14 to 24 Nm (18 ft. lbs.) torque and after that, tighten the outside bracket bolts 2 and the inside bracket bolts the same way. Make electrical connection 1 and then clean both ends of the EGR crossover tube and both connection points of old gasket material. New gaskets (doughnuts), 2 and 5, are to be fitted to each end of the tube before positioning EGR crossover tube 4 to the engine and then loosely installing bolt 3 at the tube's centre. First, tighten EGR tube clamp 1 to a torque of 10 Nm (7 ft. lbs.). Next, clamp 6 is similarly tightened to the same torque level. Finally, the clamp bolt 3 is to be tightened to a torque of 10 Nm (7 ft. lbs.) Put the upper heat shield 6 and nuts 7 in place, using 24 Nm (18 ft. lbs.) torque to tighten them. Next, put the lower heat shield 9 in place along with bolts 10 and nut 8, using 24 Nm (18 ft. lbs.) torque to tighten them. In conclusion, install EGR tube cover 1 with four bolts 2 and reconnect both negative battery cables to both batteries.
• EGR Cooler
  68048991AA
  Q:

  How to remove and replace the EGR Cooler on the cab chassis on Dodge Ram 3500?

  A:

  In order to remove and replace the cab chassis EGR cooler, initially install the EGR cooler support bracket if it has been removed, tightening the mounting bolts finger tight; if it is installed, loosen the bolts to finger tight. Fit the EGR cooler on the flange of the exhaust manifold with the aid of a new gasket and screw the flange nuts finger tight. Install exhaust transfer manifold with a new gasket and tighten nuts to finger-tight. Using a new gasket and clamp, secure EGR cooler to exhaust transfer manifold such that the bellows pilot is centered in the EGR cooler outlet. Clamp should be tightened finger-tight only. Before finger-tightening the EGR cooler mounting bolts, the new O-rings should be lubricated with a soapy water solution. Connect the rear coolant tube to connection and using new O-rings and install bolt finger tight. If supplied, install the transmission fill tube back to the EGR cooler finger tight. Make the nuts on the EGR cooler inlet flange to the exhaust manifold to 60 Nm (44 ft. lbs.). Using a crisscross pattern, tighten bolts and to 24 Nm (18 ft. lbs.) to subsequently fit the EGR cooler to the mounting bracket. Using a torque wrench, tighten the EGR valve cooler mounting bracket-to-cylinder head bolts to 36 N.m (27 lb.ft). Before installation, lubricate the new O-rings with a soapy water solution. Afterward, install the forward coolant tube to the EGR cooler using a new O-ring. Tighten the nuts on the exhaust transfer manifold to a torque of 43 Nm (18 ft. lbs.) and clamp to a torque of 10 Nm (89 in. lbs.). If the fill tube has a socket, torque its nut to 10 Nm (89 in. lbs.). Fit the breather tube and attach the breather hose, tightening bolt to a torque of 24 Nm (18 ft. lbs.). Install the EGR cooler bypass valve, generator, and outlet tube to the turbocharger, tightening the clamp to 11 Nm (95 in. lbs.). Attach the breather hose (3); install the air cleaner assembly; if fitted, the EGR heat shield. Finally, install the engine cover, and tighten bolts to 10 Nm (89 in. lbs.), connect the negative battery cables, fill the cooling system, start the engine, and check for coolant or exhaust leaks.