EGR Valve: Service and Repair

Fig 2 Intake Manifold EGR Port:

The EGR tube attaches to the bottom of the intake manifold plenum beside the throttle body (Fig. 2).

REMOVAL
1. Disconnect negative battery cable.
2. Remove air inlet tube and resonator.

Fig 3 EGR Tube:

3. Remove EGR tube mounting clips at intake manifold plenum (Fig. 3).
4. Remove Intake Plenum.
5. Remove the fuel rail.
6. Disconnect electrical connector from EGR valve.
7. Remove EGR tube mounting screws at EGR valve.

CAUTIONS:
- When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold.
- Clean gasket surfaces on the EGR valve -- any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum.

8. Remove EGR tube.
9. The EGR valve attaches to the rear of the right cylinder head.
10. Remove EGR valve mounting screws.
11. Clean gasket surfaces. Discard old gasket. If necessary, clean EGR passages.

INSTALLATION
1. Loosely install EGR valve and new gasket on cylinder head.

Fig 4 Mounting The EGR Tube To EGR Valve:

2. Using new gaskets, loosely install the EGR tube and mounting screws. Make sure that the tube is parallel with the mounting surface of the EGR valve (Fig. 4).
3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in. lbs.) torque.
4. Install rubber silicone seals on intake manifold end of EGR tube.
5. Attach electrical connector to solenoid.
- Install fuel rail.
6. Install upper tube into the intake manifold, being careful to be sure silicone rubber seals is correctly installed and undamaged.
- Install Intake Plenum.
7. Install clips for the EGR tube to intake manifold plenum.
8. Tighten EGR valve to cylinder head screws to 22 Nm (200 in. lbs.) torque.
9. Install air inlet tube and resonator.
10. Connect negative battery cable.