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  #25  
Old 07-23-2011, 04:55 PM
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Re: How To: Install a new EGR

egr comes with metal gasket iirc, the metal/paper tube gasket, then the blue ring gasket for the IM.
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  #26  
Old 07-23-2011, 05:18 PM
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Re: How To: Install a new EGR

Doing this soon! Can't wait!
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  #27  
Old 07-24-2011, 09:22 PM
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Re: How To: Install a new EGR

Quote:
Originally Posted by tig488 View Post
egr comes with metal gasket iirc, the metal/paper tube gasket, then the blue ring gasket for the IM.
Did you buy from a dealer? Advanced Auto has them for cheaper ($43) but I'm not sure if it comes with the gaskets.
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Old 07-25-2011, 05:00 PM
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Re: How To: Install a new EGR

dealer
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  #29  
Old 07-25-2011, 06:15 PM
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Re: How To: Install a new EGR

Just changed all my plugs, they were pretty bad, gapped wayyy off at .070 - .075... I replaced them with copper gapped at .045 and just changed out the EGR valve while I was in there. I didn't have to cut the bolt or move the alt, I just managed to wiggle it around until I got it, same with putting the new one on I didn't have to trim the bolt either.

I also just lubed the blue rubber o-ring and slid it back into place without tearing it.

Just gettin it all finished up, hoping it runs better.

Next week is PCV, a thorough TB cleaning and catch can and diff and transfer case changes! Fun..
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  #30  
Old 07-25-2011, 08:57 PM
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Re: How To: Install a new EGR

congrats. if you know the blue o ring is in there you can slowly take it out. i didnt know if was there and when i pulled on the tube, presto, it tore.

your jeep will run 100x better.
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Old 07-25-2011, 10:43 PM
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Re: How To: Install a new EGR

Yeah, this thread helped a lot. I'm glad it was here so I knew what I was getting into exactly.

It fired right up, idled nice and smooth. And runs much better. Although I have an exhaust leak at the manifold. I have been trying to research if 6.1L manifolds with bolt up to a 5.7L with little mention of anything online. I saw a couple LX guys with it done, but nobody breaks it down in detail, which gaskets to use etc.. I'll keep looking.
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  #32  
Old 07-29-2011, 07:57 AM
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Re: How To: Install a new EGR

anyone know if they fixed this bolt for the 08's? Would make my life that much easier as I do not have a dremel to cut the bolt and I'm not about to pull the alternator yet. Guess I'll just have to pull it and see.

edit: I have the 5.7 HEMI
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  #33  
Old 07-29-2011, 09:17 AM
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Re: How To: Install a new EGR

Quote:
Originally Posted by .moneen. View Post
Yeah, this thread helped a lot. I'm glad it was here so I knew what I was getting into exactly.

It fired right up, idled nice and smooth. And runs much better. Although I have an exhaust leak at the manifold. I have been trying to research if 6.1L manifolds with bolt up to a 5.7L with little mention of anything online. I saw a couple LX guys with it done, but nobody breaks it down in detail, which gaskets to use etc.. I'll keep looking.
I have 6.1 Exhaust Manifolds. They aren't installed yet.

I want to get this EGR Valve done with. Just bought a new key off eBay and had to program it.
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  #34  
Old 08-06-2011, 06:52 PM
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Re: How To: Install a new EGR

Quote:
Originally Posted by tig488 View Post
My 05 WK has been stalling lately, and i got a CEL with 0406 for a DTC code which is high EGR input voltage, so I figured Id swap it out. I paid 72 plus tax at my stealership along with a new hood prop.

Knowing what I know now, this is a 30 minute job, maybe a little less for those with a CAI. Ive tried to cut this process down to the bare essentials. I did a few other things like install a new hood prop, remove all the stock intake stuff getting ready for my Airaid, I also messed with serp belt and alternator, which is not needed for this.

First remove the intake components, which includes a 10mm bolt my the TB, a ring clamp on the TB, and I also took out the complete airbox, and stock intake plumbing by the headlight. I also unbolted the radiator overflow tank to make it easier to move, its just 1 bolt. Once you get all that out, you see this...

...to uplug it, you slide a small red piece in and to the right then unplug it.

new one, comes with a metal gasket and 2 bolts.


Then use a 8mm socket to undo the vent tube (circled in red above) that goes to the TB, it just slides out of the TB with little effort. Be careful with this little guy, its a small rubber gasket used to seal off the inlet of the TB. I tried to slide mine, but it was stuck to the tube, so of course it tore. I had to reuse it or else the tube is loose, so now I get a hiss where its leaking. Gotta pick up one at the Jeep place on monday.


Next use a 10mm socket to remove the bolts on the EGR. The inside one will come all the way out, the outer one will go until it hits the alternator. I tried all I could to move the alternator and it wont move far enough. I then used a dremel to cut the bolt between the EGR and head, be careful. Make sure the bolt is lose enough so you can turn it by hand or with pliers once the EGR is off.


Cut...I covered the hole up so no dust or metal shavings would get in there.


Then reinstall using the metal gasket that comes with it. I used a new bolt that was included, and a M8 x 1.25, 16mm bolt fomr Lowes. Another member said use a 20mm, but I bought both and the 16mm fit perfect, mine had a 13mm hex head.


Once its installed, reinstall the vent tube with the 8mm bolts, dont forget the paper gasket at the EGR and the small rubber gasket up at the TB.


Jeep really screwed up on this. There is literally less than 2 threads holding this thing on, all they had to do was make it 2-3mm shorter and it would be much easier.


Hope that helps anybody that might try to do this themselves. I really enjoy working on cars. I havent done much to my Jeep but Im about to start doing some stuff so Ill post up some more threads when I do them. I posted my 2 previous projects that i had before the Jeep. I did pretty much all the work on them except the engine build.

My turbod G35 coupe. Started out with a vortech supercharger then went with a GT35R single turbo, full coilover suspension with upgraded control arms, fully customized big brake kit F&R, several different sets of rims, and different stereo setups, pretty much my fav car. I won 1st place at nopi nationals 2 years in a row with it.




My 96 GT35R, built motor KA 240.


thank you!
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  #35  
Old 08-08-2011, 12:34 PM
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Re: How To: Install a new EGR

anyone do the EGR on the 4.7 yet? dealer quoted me $160 parts and labor.
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  #36  
Old 08-08-2011, 04:52 PM
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Re: How To: Install a new EGR

Tell the dealer they are smoking crack! I'm sure someone here can help you out.
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