Exhaust Gas Recirculation (EGR) Valve
EXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENTREMOVAL PROCEDURE
1. Drain cooling system.
2. Remove air cleaner outlet duct
3. Remove the turbocharger boost sensor bracket bolt.
4. Remove the turbocharger boost sensor with bracket.
5. Remove the intake heater and gasket.
6. Remove the upper intake manifold tube nuts and upper tube.
7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
8. Remove EGR inlet cooling hose (2) from cooling tube (1).
9. Remove the EGR outlet cooling hose (1) from cooling tube (2).
10. Remove the EGR assembly to intake manifold nuts.
11. Remove the EGR assembly to exhaust pipe nuts.
12. Remove the EGR assembly to EGR bracket (2) bolts.
13. Remove the EGR assembly from the engine.
14. Remove the EGR to EGR cooling tube bolts (1).
15. Separate the EGR valve from the EGR cooling tube.
INSTALLATION PROCEDURE
1. Install the EGR valve to the EGR cooling tube.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the EGR to EGR cooling tube bolts (1).
Tighten
Tighten bolts to 20 N.m (15 lb ft).
3. Install the EGR assembly to the engine.
4. Install the EGR assembly to EGR bracket bolts.
Tighten
Tighten bolts to 20 N.m (15 lb ft).
5. Install the EGR assembly to exhaust pipe nuts.
Tighten
Tighten nuts to 20 N.m (15 lb ft).
6. Install the EGR assembly to intake manifold nuts.
Tighten
Tighten nuts to 19 N.m (14 lb ft).
7. Install EGR outlet cooling hose (1) to EGR cooling tube (2).
8. Install the EGR inlet cooling hose (2) to the EGR cooling tube (1).
9. Connect the EGR vacuum hose to the EGR valve.
10. Install the upper intake manifold tube and nuts.
Tighten
Tighten the nuts to 10 N.m (89 lb in).
11. Install the intake heater and gasket.
Tighten
Tighten the heater to 50 N.m (37 lb ft).
12. Install the turbocharger boost sensor with bracket.
13. Install the turbocharger boost sensor bracket bolt.
Tighten
Tighten the bolt to 10 N.m (89 lb in).
14. Install air cleaner outlet duct.
15. Fill cooling system.