EGR Valve: Service and Repair

Exhaust Gas Recirculation Valve Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

Important: Do not try to disassemble the linear EGR valve. Service only as a complete assembly.


Important: Carefully note the position of the linear EGR valve before removal. Do not rotate the linear EGR valve 180 degrees.


2. EGR system cleaning procedure. Refer to Exhaust Gas Recirculation Pipe Replacement Service and Repair.

Caution: Avoid breathing fumes and swallowing EGR exhaust deposits when removing components for cleaning as bodily injury may result.




3. Remove the linear EGR valve electrical connector.
4. Remove the linear EGR valve flange bolts (4).

Notice: The Linear EGR valve is an electrical component. DO NOT soak in any liquid cleaner or solvent because damage may result.

5. Remove the linear EGR valve (3).
6. Remove the linear EGR valve flange gasket (2) form the intake manifold (1).
7. Clean the linear EGR valve gasket surface.

Installation Procedure




1. Install the new linear EGR valve flange gasket (2) to the intake manifold (1).
2. Install the linear EGR valve (3).

Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the linear EGR valve flange bolts (4).

1. Tighten the bolts the first time to 10 Nm (89 lb in) each.
2. Tighten the bolts a final time to 22 Nm (16 lb ft) each.

4. Install the linear EGR valve electrical connector.
5. Connect the negative battery cable.