Air leak

  • 3.5L
  • 6 CYL
  • 2WD
  • 136,000 MILES
It's leaking where the EGR tube goes into the plenum. Replaced the blue seal and still leaking. Is there some kind of other seal that goes in the plenum? I'm thinking something is missing that I'm not aware of.
Thursday, October 29th, 2020 AT 5:35 AM

1 Reply

  • 108,154 POSTS

If the seal gets damaged in any way, it will leak. Take a look through the directions below and see if there is anything you did differently.


2008 Dodge Charger V6-3.5L
Vehicle Powertrain Management Emission Control Systems Exhaust Gas Recirculation EGR Tube Service and Repair Removal and Replacement EGR Tube - Installation 3.5L

pic 1

1. Clean mounting surface.
2. Install new rubber silicone seals on intake manifold end of EGR tube.
3. Lubricate the EGR mounting tube hole in the intake manifold with clean soapy water. Do not lubricate the EGR tube or seal.
4. Install tube into the intake manifold being careful that the silicone rubber seals are correctly installed and undamaged.

Pic 2

5. Install the tube bolts to EGR valve.
6. Tighten the EGR tube to EGR valve bolts (1). Tighten to 15 Nm (11 ft. Lbs.) Torque.

Pic 3

7. Connect the electrical connector to EGR valve and lock.
8. Verify that no wiring harnesses or hoses are contacting the EGR tube.
9. Install upper intake manifold, See: Intake Manifold > Removal and Replacement > Intake Manifold - Installation.

Pic 4

NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.

10. Verify the upper EGR tube seal (1) is positioned correctly on the EGR tube assembly.

Pic 5

NOTE: The EGR tube flange does not need to be flush with the intake manifold to be sealed. The EGR tube flange can be up to 2mm from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed.

11. Install the EGR tube (3), and verify the seal is correctly positioned in the intake manifold.

Pic 6

12. Install the shock tower brace.
13. Install the wiper module, See: Wiper Motor > Removal and Replacement > Wiper Module - Installation.
14. Install purge solenoid to bracket.
15. Connect negative battery cable.


Let me know.

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Thursday, October 29th, 2020 AT 1:09 PM

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