EGR valve and EGR cooler cleaning (6.4L Hemi and diesel engine)

(every 60,000 miles or 48 months)

Note: These procedures will be performed at the first 60,000 mile interval by Dodge deal­ers at no cost in the following states: Cali­fornia, Maine, Massachusetts, New Mexico, New York, Vermont, Connecticut, Oregon and Rhode Island.

EGR valve cleaning (diesel engines only)

1. Remove the EGR valve (see Emissions and engine control systems).

2. Remove the EGR valve motor and its shim from the valve.

3. Press down on the valve keeper retainer using fingers, then remove the keepers. If the retainer is stuck, carefully tap it with a hammer and a 5/8-inch socket to loosen it. Remove the retainer, the keepers and the valve spring.

4. Push on the end of the valve stem to move the valve face away from the valve seat, then use a plastic scrub brush to clean the housing, valve surfaces and all other area of the valve.

5. Obtain Mopar EGR system cleaner or an equivalent and mix it with four parts water. Soak the EGR valve assembly in this solution for an hour. Move the valve occasionally to clean it. Scrub the assembly again to remove all deposits.

6. Rinse the assembly in warm water and dry all parts.

7. Assemble the valve spring, keepers and retainer. Install the EGR valve (see Emissions and engine control systems).

EGR cooler cleaning

(6.4L Hemi and diesel models)

8. Disconnect the negative cables from both batteries.

9. Remove the engine cover.

10. Drain the cooling system (Cooling system servicing (draining, flushing and refilling)).

11. Remove the air filter housing (see Chapters Fuel and exhaust systems – gasoline engines Fuel and exhaust systems – diesel engine).

12. Detach the breather tube, then remove the turbo outlet tube.

13. Remove the alternator (see Engine electrical systems).

14. Remove the EGR cooler bypass valve.

15. Remove the clamp from the EGR cooler­to-exhaust transfer manifold, then remove the exhaust transfer manifold.

16. Remove the nut and move the EGR cooler filler tube out of the way.

17. Use large pliers to remove the forward coolant tube from the EGR cooler.

18. Remove the breather tube.

19. Remove the three EGR cooler mount­ing bolts and the two nuts from the mounting studs.

20. Remove the EGR cooler and its gasket. Discard the gasket.

21. Run hot tap water through the cooler for ten minutes.

22. Obtain a plug and install it into the end outlet of the cooler so that it will hold the cleaning solution.

23. Obtain Mopar EGR system cleaner or an equivalent and mix it with four parts hot water.

24. Stand the cooler upright, then fill it with the cleaning solution and allow it to stand for an hour.

25. Drain the cooler, then rinse it thoroughly with hot tap water and dry it.

26. Install a new cooler gasket and replace the cooler in the reverse of the removal proce­dure.

Resetting the EVIC emissions system service required light

27. Some models have an «Emissions Sys­tem Service Required» light. After completing the maintenance, it will be necessary to reset the light.

28. Without starting the engine, turn the key to the On position.

29. Slowly depress the accelerator pedal to the floor two times within 10 seconds.

30. Turn the key to the Off/Lock position.

31. Start the engine and verify on the EVIC that the indicator message is on longer illu­minated. Repeat the procedure above if it still appears.