EGR Valve: Service and Repair

REMOVAL
1. Disconnect the battery ground cable .
2. Remove the engine air cleaner.
3. Disconnect the rear downstream Heated Oxygen Sensor (HO2S) electrical connector.
4. Disconnect the Exhaust Gas Recirculation (EGR) cooler inlet hose from the throttle body. Plug the outlet on the throttle body.
5. Disconnect the EGR cooler outlet hose from the thermostat housing. Plug the coolant connection on the thermostat housing.
6. Raise and support the vehicle.

Crossmember:

7. Remove the six crossmember bolts and remove the crossmember.
8. Remove the three RH wheel splash guard bolts.

Oxygen Sensor Connectors:

9. Disconnect the front downstream HO2S electrical connector.
10. Position a jack to support the three way catalytic converter.

Exhaust Inlet Pipe:

11. Remove the three front exhaust manifold to exhaust inlet pipe nuts.

Catalytic Convertor:

12. Remove the two exhaust inlet pipe to three way catalytic converter nuts.
13. Remove the three rear exhaust manifold-to-exhaust inlet pipe nuts.
14. Remove the exhaust inlet pipes.
15. Disconnect the EGR valve to exhaust manifold tube from the EGR valve.
16. Disconnect the Exhaust Gas Recirculation Valve Position (EVP) sensor electrical connector.
17. Remove the two EGR valve bolts.
18. Disconnect the vacuum hose from the EGR valve.
19. Remove the power steering fluid line clamp and position the power steering pressure hose out of the way. This will allow for the removal of the EGR valve.

EGR Valve:

20. Remove the EGR valve and the gasket.

INSTALLATION
1. Position the EGR valve and gasket on the engine.
2. Install the EGR valve bolts. Tighten to 19-25 Nm (14-18 lb ft).
3. Connect the vacuum hose to the EGR valve.
4. Connect the EGR valve to exhaust manifold tube. Tighten the fitting to 57-74 Nm (44-54 lb ft).
5. Install the power steering fluid line clamp. Tighten to 8-13 Nm (6-9 lb ft).
6. Connect the EVP sensor electrical connector.
7. Position the exhaust inlet pipes.
8. Install the rear and front exhaust manifold to exhaust inlet pipe nuts. Tighten to 37-52 Nm (27-38 lb ft).
9. Install the three way catalytic converter to exhaust inlet pipe nuts. Tighten to 64-89 Nm (47-66 lb ft).
10. Remove the jack supporting the three way catalytic converter.

Oxygen Sensor Connectors:

11. Connect the front downstream HO2S electrical connector.
12. Install the three RH wheel splash guard bolts.

Crossmember:

13. Install the crossmember. Tighten the bolts to 94-126 Nm (69-93 lb ft).
14. Lower the vehicle.
15. Unplug the coolant connection on the thermostat housing and connect the EGR coolant outlet hose to the thermostat housing.
16. Unplug the outlet on the throttle body and connect the EGR cooler inlet hose to the throttle body.
17. Connect the rear downstream HO2S electrical connector.
18. Install the engine air cleaner.
19. Connect the battery ground cable.