NUMBER:
GROUP:
DATE:

09-009-20
09 - Engine
June 13, 2020

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of FCA US LLC.

This Service Bulletin is also being released as Rapid Response Transmittal (RRT) 20-037,
dated June 13, 2020. All applicable Un-Sold RRT VINs have been loaded. To verify this RRT
service action is applicable to the vehicle, use VIP or perform a VIN search in
DealerCONNECT/Service Library. All repairs are reimbursable within the provisions of
warranty.
SUBJECT:
Improperly Installed Exhaust Gas Recirculation (EGR) Valve
OVERVIEW:
This bulletin involves removing and inspecting the vacuum tube, EGR tube gaskets, tube flange
mounting bolts and possibly replacing the EGR tube gaskets and torquing the flange bolts.
MODELS:
2018 - 2019

(DS)

RAM 1500 Pickup

NOTE: This bulletin applies to vehicles within the following markets/countries: North
America and APAC.
NOTE: This bulletin applies to vehicles built on or after November 25, 2018 (MDH 1125XX)
and built on or before December 13, 2019 (MDH 1213XX) equipped with a 3.0L Turbo
Diesel Engine (Sales Code EXF).
SYMPTOM/CONDITION:
Customers may experience a Malfunction Indicator Lamp (MIL) illumination. Upon further
investigation the technician may find that the following Diagnostic Trouble Code (DTC) has been
set:
• P245B - EGR-Cooler-Bypass-Control-Circuit-Performance.
The customer may also notice one or more of the following:
• An exhaust smell in the cabin.
• A whistle noise coming from the engine compartment.
DIAGNOSIS:
Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in
DealerCONNECT/Service Library, verify all related systems are functioning as designed. If
Diagnostic Trouble Codes (DTCs) or symptom conditions, other than the ones listed above are
present, record the issues on the repair order and repair as necessary before proceeding further
with this bulletin.
If a customer’s VIN is listed in VIP or your RRT VIN list or DTC, perform the Diagnostic Procedure.
This RRT only applies to vehicles on the RRT VIN list.

09-009-20

-2-

1. Remove the engine cover. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: 09 - Engine, 3.0L Turbo Diesel/Cover, Engine/
Removal.
2. Remove the fuel injector silencer (Fig. 1) .

Fig. 1
Fuel Injector Silencer

3. Inspect the vacuum tube is fully seated in the vacuum actuator and there is no gap present
(Fig. 2) .

Fig. 2
No Gap And Gap Shown On
1 - Vacuum Tube Fully Seated (No Gap Present) In The Vacuum Actuator
2 - Vacuum Tube Not Fully Seated (Gap Is Present) In The Vacuum Actuator

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09-009-20

NOTE: To ensure the vacuum hose is fully seated on the vacuum actuator, a soapy water
solution may be used to facilitate fully seating the vacuum hose on the vacuum
actuator. Ensure components are dry afterwards if soapy water is used.
4. Is the vacuum tube fully seated in the vacuum actuator (Fig. 3) ?
• YES >>> Proceed to Step 5 of the Diagnostic Procedure.
• NO >>> Fully seat the vacuum tube on the vacuum actuator. Proceed to Step 5 of the
Diagnostic Procedure.

Fig. 3
Vacuum Tube And Vacuum Actuator
1 - Vacuum Tube
2 - Vacuum Actuator

5. Inspect both the upper and lower EGR tube gaskets (inlet – from turbo/outlet – to intake) that
are mated to the EGR valve and that all gasket tabs showing on the exterior of the tube
flange (Fig. 4) .
Also inspect that all upper and lower EGR tube flange bolts are tight (Fig. 4) .

09-009-20

-4-

Fig. 4
Example Of Lower Tube Flange Bolts, Flange And Gasket Tabs (Upper Tube Similar)
1 - Lower Tube Flange Bolts
2 - Lower Tube Flange
3 - Gasket Tabs Shown Properly Installed On Exterior Of Flange

NOTE: If the EGR tube flange bolts appear tight, it is recommended all flange bolts be
re-torqued.
6. Is the either upper or lower EGR tube gasket damaged, missing, gasket flange tabs not
showing or the flange bolts loose?
• YES >>> Proceed to Step 1 of the Repair Procedure.
• NO >>> Proceed to Step 7 of the Diagnostic Procedure.
7. Re-torque all the tube flange bolts to 25 N·m (18 ft. lbs.).
8. Install the fuel injector silencer and engine cover. Refer to the detailed service procedures
available in DealerCONNECT/Service Library under: 09 - Engine, 3.0L Turbo Diesel/Cover,
Engine/Installation.
This bulletin has been completed, use inspection LOP (25-01-43-90) to close the active RRT.
PARTS REQUIRED:
Qty.
1 (AR)

Part No.
CSNDVB12AA

Description
EGR Kit (contains both tube gaskets)

NOTE: Only the two EGR tube gaskets P/N 68211320AA will be used from the above EGR kit
for this Repair Procedure. The remaining components may be discarded.

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09-009-20

REPAIR PROCEDURE:
NOTE: If only one EGR tube to EGR valve gasket is damaged or missing, only replace that
tube gasket. Do not replace both tube gaskets, if both are not damaged or missing.
1. Is one EGR tube gasket damaged, missing or loose bolts were found?
•
a.
b.
•

YES >>> Replace either the upper or lower tube gasket.
For upper gasket tube replacement, proceed to Step 2 of the Repair Procedure.
For lower gasket tube replacement, proceed to Step 5 of the Repair Procedure.
NO >>> Both EGR tube gaskets are damaged or missing. Proceed to Step 2 of the Repair
Procedure.

NOTE: Do not discard the rubber upper tube to intake gasket (Fig. 5) . This rubber gasket is
to be re-used.

Fig. 5
Re-Use Rubber Upper Tube To Intake Gasket

2. Remove the upper EGR intake air tube. Discard the tube to EGR metal gasket. Refer to the
detailed service procedures available in DealerCONNECT/Service Library under: Service
Info>25 - Emissions Control/Exhaust Gas Recirculation, Diesel/Tube, Exhaust Gas Recirculation
(EGR)/Removal.
3. Clean surface and install the upper EGR intake air tube using a new tube to EGR gasket, with
gasket tabs bent over on the exterior of the flange (Fig. 4) . Refer to the detailed service
procedures available in DealerCONNECT/Service Library under: Service Info>25 - Emissions
Control/Exhaust Gas Recirculation, Diesel/Tube, Exhaust Gas Recirculation (EGR)/Installation.
4. Proceed to Step 14 of the Repair Procedure if just the upper tube gasket was replaced.
If the lower tube gasket needs to be replaced, proceed to Step 5 of the Repair Procedure.
5. Remove the intake air tube. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info>09 - Engine, 3.0L Turbo Diesel/Air Intake
System/Tube, Intake Air/Removal.

09-009-20

-6-

6. Remove the fuel injector silencer (Fig. 6) .

Fig. 6
Fuel Injector Silencer

7.
8.
9.
10.
11.
12.

13.

14.

NOTE: Do not remove the three bolts that fasten the EGR tube to the turbo housing. The
tube gasket can be replaced with the tube still fastened to the turbo housing.
Remove the two bolts holding the lower EGR tube to the EGR valve.
Carefully pull the lower EGR tube away from EGR valve and discard the gasket.
Clean surface and install the lower EGR tube using a new tube to EGR gasket, with gasket
tabs bent over on the exterior of the flange (Fig. 4) .
Install the EGR tube bolts and tighten the bolts to 25 N·m (18 ft. lbs.).
Install the fuel injector silencer (Fig. 6) .
Install the intake air tube. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info>09 - Engine, 3.0L Turbo Diesel/Air Intake
System/Tube, Intake Air/Installation.
Install the engine cover. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: 09 - Engine, 3.0L Turbo Diesel/Cover, Engine/
Installation.
Using the wiTECH 2, clear all DTCs that may have been set.

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09-009-20

POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:

Description

Skill Category

Amount

25-01-43-90

Tube, EGR gaskets, Vacuum
Tube, Flange Bolts - Inspect
(1 - Semi-Skilled)

10 - Diesel

0.2 Hrs.

25-01-43-91

Tube, EGR - Inspect and Replace
One Gasket
(1 - Semi-Skilled)
Tube, EGR - Inspect and Replace
Both Gaskets
(1 - Semi-Skilled)

10 - Diesel

0.5 Hrs.

10 - Diesel

0.7 Hrs.

25-01-43-92

FAILURE CODE:
ZZ

Service Action