This procedure covers the removal and replacement of the EGR (Exhaust Gas Recirculation) tube on the 6.7L Cummins diesel engine, including disconnection from the exhaust manifold and EGR valve.

Warnings

Tools required

Parts

• EGR tube assembly × 1 — Use OEM specification
• EGR tube gasket (upper) × 1 — Use OEM specification
• EGR tube gasket (lower) × 1 — Use OEM specification

Preparation

1. Ensure engine has been off for at least 2 hours and exhaust system is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery cable to prevent accidental DPF regeneration during work
4. Apply penetrating oil to all EGR tube flange bolts and allow to soak for 15-20 minutes
5. Remove engine cover by releasing retaining clips

Procedure

1. 1

   Access EGR System Components
   Remove the heat shield covering the EGR tube by removing the retaining bolts. The heat shield is located on the driver's side of the engine between the turbocharger and EGR valve. Set aside heat shield and hardware.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect Upper EGR Tube Connection
   Locate the upper flange connection at the EGR valve on the intake side. Remove the flange bolts securing the EGR tube to the EGR valve. Support the tube as you remove the final bolt to prevent it from falling. Remove and discard the old gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
3. 3

   Disconnect Lower EGR Tube Connection
   Access the lower connection at the exhaust manifold outlet. Remove the exhaust flange bolts connecting the EGR tube to the exhaust manifold. You may need to work from underneath the vehicle for better access. Once bolts are removed, carefully separate the tube from the exhaust manifold and remove the old gasket.
   ⚠If bolts are severely corroded or begin to strip, stop and apply additional penetrating oil. Broken exhaust studs will require extraction and significantly increase repair time.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Remove EGR Tube Assembly
   With both connections free, maneuver the EGR tube out of the engine bay. Note the routing and any mounting brackets or clips that may need to be released. The tube may require rotation and careful angling to clear surrounding components including the turbocharger and intake piping.
5. 5

   Clean Mating Surfaces
   Using a wire brush and scraper, thoroughly clean both the EGR valve flange and exhaust manifold flange surfaces. Remove all carbon deposits, old gasket material, and corrosion. Both surfaces must be clean and flat for proper sealing. Inspect flanges for warping or cracks.
   ℹ️Heavy carbon buildup is normal on EGR components. Ensure all deposits are removed from sealing surfaces to prevent exhaust leaks.
6. 6

   Prepare New EGR Tube
   Unpack the new EGR tube assembly and verify it matches the original configuration. Apply anti-seize compound to the threads of all exhaust flange bolts. Position new gaskets on both the upper (EGR valve) and lower (exhaust manifold) flanges.
7. 7

   Install EGR Tube
   Carefully maneuver the new EGR tube into position, following the reverse of the removal routing. Align the tube with both the exhaust manifold and EGR valve flanges. Start all bolts hand-tight on both connections before proceeding to ensure proper alignment.
8. 8

   Torque Lower Flange Connection
   Torque the exhaust flange bolts at the exhaust manifold connection in a crisscross pattern to ensure even gasket compression. Begin with 50% of final torque value, then proceed to full specification.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
9. 9

   Torque Upper Flange Connection
   Torque the flange bolts at the EGR valve connection in a crisscross pattern. Begin with 50% of final torque value, then proceed to full specification to ensure even gasket seating.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Reinstall Heat Shield
    Position the heat shield over the EGR tube and install the retaining bolts. Torque to specification. Ensure heat shield does not contact the EGR tube and has proper clearance from surrounding components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
11. 11

    Complete Installation
    Reinstall the engine cover. Reconnect the negative battery cable. Ensure all tools and parts have been removed from the engine bay and no fasteners have been left loose.

Reassembly

1. Double-check all flange connections are properly torqued and heat shield is secured
2. Verify no tools or loose parts remain in engine bay
3. Ensure all connections are properly seated and gaskets are not pinched or displaced

Verification

• Start engine and allow to idle for 5 minutes while monitoring for exhaust leaks at both EGR tube connections
• Listen for unusual hissing sounds near the EGR tube indicating exhaust leaks
• After engine reaches operating temperature, visually inspect both flange connections for signs of exhaust gas leakage (soot marks or discoloration)
• Road test vehicle under moderate load and verify no check engine light or EGR-related fault codes appear
• After initial test drive, re-inspect connections while engine is warm for any signs of leaks that may develop under heat cycling

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