Tools needed: sockets(5/16, 7/16 deep, 10mm) 6" socket extension, ratchet, flathead screwdriver, wd-40, large adjustable wrench, #15 torx. If you are not mechanically inclined I would try without the help of an experienced mechanic.
Step 1. Remove the oil dipstick and set aside.
Remove the 4 screws holding the shroud on(5/16)
Remove the shroud and replace the oil dipstick.
Step 2. Remove the recirculating pipe by:
Loosen the 7/16 nuts on the 2 clamps( 1 at the exhaust gas cooler,
and 1 at the egr assembly.
Remove the 5/16 screw right in the middle of the pipe- it is hard to see
and get to.
Be careful not to lose the gaskets when removing the pipe as they will
fall into hard to get areas.
Set the pipe and clamps aside.
Step 3. Remove the 4(10mm) bolts holding the egr on to the intake horn.
Disconnect the harness from the egr(this will no longer be plugged in)
You may have to CAREFULLY pry the egr off the intake with a flathead
screwdriver- try not to damage the gaskets as they will be reused.
Set the egr aside
Step 4. Remove the 2 bolts holding the dipstick to the intake horn(10mm)
Remove the 5 bolts holdng the intake horn to the motor(10mm)
Loosen the 7/16 nut on the clamp at the bottom of the intake horn.
Don't take the clamp off, just slide it down.
Run a flathead screwdriver around that black boot to break the seal and
slide the boot off the intake.
Remove the intake from the motor- you may have to CAREFULLY pry off
with a flathead screwdriver-try not to damage the gasket.
Remove the 3 harnesses on the intake horn and cut the 2 wire ties
holding the harnesses on-that way you can do the next step.
Step 5. At the bottom of the intake horn where the boot was there is a butterfly
valve-it has to be removed.
Manually close the butterfly and take the large adjustable wrench and
lock it down on the side of the intake horn securing the butterfly closed.
Soak the two screws down good with wd-40 and let sit.
Using a # 15 torx CAREFULLY remove the 2 torx head screws
Remove the adjustable wrench opening the butterfly.
Using pliers CAREFULLY pull out the butterfly and set aside along with the
screws.
Step 6. Apply the bottom of the intake horn back into the black rubber boot.
Apply the intake horn to the motor securing the 5(10mm) bolts
Secure the clamp(7/16) holding the boot on tightly.
Apply the 2(10mm) screws to the oil dipstick holder and tighten.
Make sure all bolts are tightened appropriately.
Reattach the 3 harnesses to the intake horn(can be done prior to
mounting the intake horn for easier access)
Step 7. Apply the 2 block plates where the egr used to be and secure using
the 4(10mm) bolts and tighten appropriately.
Remeber the harness that was plugged into the egr is not being used
anymore.
Step 8. Place the round block plate along with the thin gasket into the clamp
that was used on the recirculating pipe at the exhaust gas cooler.
Tighten clamp down using a 7/16 socket.
Step 9. Remove the oil dipstick and apply the shroud
Reapply the oil dipstick
Apply 3 screws to the shroud and tighten. 1 will not be used since it was
held in by the egr.
You are now done, make sure everything is back in place and tightened down.
Keep the parts you removed in case you have to replace due to warrany issues.
It took me about an hour and good luck to you!! Hope this helped!
Sorry the butterfly removal pics didn't come out.
Topic: 6.7 EGR Delete (Read 10058 times)