EGR Tube

This procedure covers removal and replacement of the EGR tube on the 5.9L Cummins diesel engine, connecting the exhaust manifold to the EGR valve.

Warnings

Tools required

Parts

• EGR tube assembly × 1 — Use OEM specification
• EGR tube gasket (exhaust manifold end) × 1 — Use OEM specification
• EGR valve gasket × 1 — Use OEM specification
• Anti-seize compound × 1 — High-temp nickel-based

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after shutdown)
2. Disconnect negative battery cable
3. Remove engine cover if equipped
4. Apply penetrating oil to all EGR tube connection points and allow 15-30 minutes to soak
5. Have fire extinguisher nearby when working around exhaust components

Procedure

1. 1

   Access EGR valve area
   Remove the air intake tube from the intake horn to improve access to the EGR valve. Loosen the hose clamps at both ends and carefully remove the intake tube. Set aside in a clean area.
2. 2

   Disconnect EGR valve electrical connector
   Locate the electrical connector on the EGR valve body. Press the locking tab and carefully disconnect the connector. Move the wiring harness aside to prevent damage during tube removal.
3. 3

   Remove EGR valve mounting bolts
   Using a 10mm socket, remove the two bolts securing the EGR valve to its mounting bracket on the intake manifold. Support the EGR valve and tube assembly as the second bolt is removed to prevent it from falling.
4. 4

   Disconnect EGR tube from EGR valve
   Using a 15mm wrench, loosen and remove the nut connecting the EGR tube to the EGR valve. The EGR valve can now be moved aside slightly. Remove and discard the old gasket from this connection point.
5. 5

   Access exhaust manifold connection
   From underneath the vehicle or through the wheel well, locate the EGR tube connection at the passenger side exhaust manifold. This connection point is located near the front of the engine below the intake manifold.
6. 6

   Remove exhaust manifold mounting hardware
   Using an 18mm wrench, carefully loosen the tube fitting nut at the exhaust manifold. Work slowly to avoid breaking the manifold stud. If significant resistance is encountered, apply additional penetrating oil and wait before continuing. Remove the tube from the manifold and discard the old gasket.
7. 7

   Remove EGR tube assembly
   Carefully maneuver the EGR tube out of the engine bay. The tube may need to be rotated and angled to clear surrounding components. Inspect the tube for cracks, excessive carbon buildup, or damage to the flange surfaces.
8. 8

   Clean mounting surfaces
   Using a wire brush and shop rags, thoroughly clean the EGR valve mating surface and exhaust manifold flange. Remove all carbon deposits and old gasket material. Ensure surfaces are flat and free of debris. Inspect exhaust manifold stud for damage or excessive corrosion.
9. 9

   Prepare new EGR tube
   Inspect the new EGR tube for shipping damage. Install new gaskets on both ends of the tube. Apply a thin coat of high-temperature anti-seize compound to the threads of all connection nuts to prevent future seizure.
10. 10

    Install EGR tube to exhaust manifold
    Position the new EGR tube to the exhaust manifold flange with new gasket in place. Start the 18mm mounting nut by hand to ensure proper thread engagement. Snug the nut finger-tight but do not fully tighten yet. Final torque will be applied after EGR valve connection is made.
11. 11

    Connect EGR tube to EGR valve
    Position the EGR valve with new gasket onto the intake manifold bracket and align with the EGR tube. Install the 15mm connection nut and the two 10mm mounting bolts. Snug all fasteners but do not fully tighten yet to allow for alignment adjustment.
12. 12

    Torque all fasteners
    Working in sequence, torque the exhaust manifold connection to 25-30 ft-lbs, then torque the EGR valve connection nut to 20-25 ft-lbs. Finally, torque the two EGR valve mounting bolts to 18-20 ft-lbs. This sequence ensures proper sealing without distorting the tube.
13. 13

    Reconnect electrical and air intake
    Reconnect the EGR valve electrical connector until it clicks into place. Reinstall the air intake tube and secure with hose clamps. Reconnect the negative battery cable. Reinstall engine cover if equipped.

Reassembly

1. Ensure all electrical connections are secure and properly seated
2. Verify all hose clamps on intake tube are tight
3. Double-check that no tools or rags were left in the engine bay
4. Confirm battery cable is securely tightened

Verification

• Start the engine and allow it to idle for 2-3 minutes
• Listen for any exhaust leaks at both EGR tube connection points
• Check for abnormal smoke from the engine bay indicating exhaust leaks
• Use a scan tool to verify no EGR-related diagnostic trouble codes are present
• Rev engine to 2000 RPM briefly and recheck all connections for leaks
• Test drive vehicle and monitor for proper EGR operation and smooth acceleration
• After test drive, perform final visual inspection of all connections while engine is warm

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle