EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION VALVE REPLACEMENT

REMOVE OR DISCONNECT
1. Negative (-) battery cable.
2. Throttle body from air intake chamber. Refer to Throttle Body Replacement.

Removing EGR Vacuum Modulator Hoses:

3. EGR vacuum modulator-to-EGR valve hose from EGR valve and EGR hose from bottom of EGR vacuum modulator.

Removing Fuel Feed/Return Pipe/Hose Bracket and Engine Hanger:

4. Two bolts and fuel feed/return pipe/hose bracket from lower LH side of intake manifold.
5. One bolt, one nut and engine hanger assembly from engine.

EGR Valve-to-Pipe Connection:

^ Loosen EGR valve-to-pipe connection nut.

EGR Valve Vacuum Hose And EGR Temperature Sensor:

6. EGR SV valve-to-EGR valve vacuum hose from EGR valve.
7. EGR temperature sensor electrical connector.

Removing EGR Valve and Pipe:

8. Four nuts, two gaskets and EGR valve and pipe from vehicle.

DISASSEMBLE
1. EGR valve from EGR valve pipe.
2. EGR temperature sensor and gasket from EGR valve.

Inspecting EGR Valve:

Inspect
EGR valve for heavy carbon deposits and sticking. Replace as necessary.

ASSEMBLE
1. EGR temperature sensor along with a new gasket to EGR valve.
2. EGR valve to pipe; secure with one nut (Do not tighten fully).

INSTALL OR CONNECT
1. Two new gaskets and EGR valve and pipe to cylinder head and intake manifold; secure with four nuts.

NOTICE: Gaskets should be installed with protrusion facing downward.

^ Tighten EGR Valve and pipe nuts to 13 Nm (9 lb. ft.).
^ Tighten EGR valve-to-EGR valve pipe nut to 59 Nm (43 lb. ft.).

2. EGR temperature sensor electrical connector.
3. EGR SV valve-to-EGR valve vacuum hose to EGR valve.
4. A new gasket to throttle body and engine hanger assembly to engine; secure with one nut and one bolt. Tighten engine hanger assembly nut and bolt to 28 Nm (21 lb. ft.).
5. Fuel feed/return pipe/hose bracket to lower LH side of intake manifold; secure with two bolts. Tighten fuel feed/return pipe/hose bracket bolts to 10 Nm (89 lb. ft.).
6. EGR vacuum modulator-to-EGR valve hose to EGR valve and EGR hose to bottom of EGR vacuum modulator.
7. Throttle body to air intake chamber.
8. Negative (-) battery cable. Tighten negative (-) battery cable-to-negative (-) battery terminal retainer to 15 Nm (11 lb. ft.).