wolcott wrote:
I just removed the original turbo to EGR hoses and replaced them with SAMCO hoses. The SAMCO hoses look good (I ordered yellow ones) and seem to work well. The old hoses were in surprisingly good shape, a combination of ORM modification plus a Provent installed at 5000 miles seemed to help keep them alive. Even so, at 50,000 miles in Florida they were showing signs of fatigue. However, after replacing the hoses, I was very glad that I did not have to do it out in the woods, because it was definitely more than a ½ hour job for me. After doing it, I’d recommend the following procedure.
1. Get at least one spare clamp for the hose that goes from the intercooler to the EGR valve. The Norma clamps that the Libby used as factory clamps have a thick (.1") spring loaded section that is a problem to get onto the hose and the EGR valve projection. A good, thin, lined hose clamp makes clamping the hose to the EGR much easier. You will need a clamp that goes over a 3-1/16" OD hose.
2. Count on removing the battery tray to get decent access to the EGR valve. I found this much easier than trying to attach the hose and hose clamp without good access. The EGR unfortunately has a only about a 3/4" inch projection sticking out to attach the hose to, and since this hose has to be clamped well, you want to be sure the clamp is square with the hose and tightened well. Removing the battery tray takes about ½ hour, you take out the battery, remove all the harnesses attached to the battery tray, remove the fuse box, and then remove 3 nuts–one under the battery, one right by the fender under a wiring harness, and one about 4" down from the battery tray surface under the fuse box. The battery tray then pulls out.
3. Replacing the hose from the turbo to the intercooler is easy, it is a little tight to get at the turbo area, but there is a good projection on the turbo to slide the hose over, and plenty of room to tighten the clamp. For the other side, (intercooler to EGR) remove the old hose, and then position the new hose and clamp over the EGR valve projection and tighten the clamp well. I found it best to put the clamp adjustment under the EGR, but this depends on the type of hose clamp you are using. Then the hoses can be clamped to the intercooler and the vehicle put back together.