EGR Control Solenoid: Service and Repair

REMOVAL




1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3).
2. Disconnect negative battery cable.




3. Remove purge solenoid from bracket.




4. Relocate the purge solenoid.
5. Unlock and disconnect the electrical connector from EGR valve.




6. Remove the bolts from the EGR tube to exhaust manifold.
7. Remove the lower tube bolts to EGR valve and remove tube(3).
8. Remove upper tube bolts to EGR valve (2).
9. Remove the EGR valve mounting bolts (1).
10. Remove valve from vehicle.
11. Clean mounting surface.

INSTALLATION




1. Clean mounting surface.




2. Install EGR valve.
3. Install the EGR valve mounting bolts (1).
4. Inspect rubber silicone seals on intake manifold end of EGR tube.
5. Install upper tube into the intake manifold, being careful that the silicone rubber seals are correctly installed and undamaged..
6. Install new gasket between the EGR valve and upper tube and install bolts (2).
7. Install the lower tube to exhaust manifold.
8. Install new gasket between the EGR valve and lower tube and install bolts (3).
9. Tighten the lower tube to EGR valve bolts (3) to 11 Nm (95 in. lbs.) torque.
10. Tighten the lower tube to exhaust manifold bolts to 31 Nm (275 in. lbs.) torque.
11. Tighten the upper tube to EGR valve bolts (2) to 11 Nm (95 in. lbs.) torque.
12. Tighten EGR valve to cylinder head bolts (1) to 31 Nm (275 in. lbs.) torque.




13. Connect the electrical connector to EGR valve and lock.
14. Relocate the purge solenoid.




15. Install purge solenoid to bracket.
16. Connect negative battery cable.