EGR Valve: Service and Repair
REMOVAL1. Disconnect the battery ground cable.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.
2. Disconnect the O2 sensor electrical connector.
3. Remove the engine air cleaner.
4. Disconnect the 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.
6. Raise and support the vehicle.
Crossmember Assembly:
7. Remove the six crossmember bolts and remove the crossmember.
8. Remove the three wheel splash guard bolts.
Heated Oxygen Sensor Electrical Connector:
9. Disconnect the front O2 sensor electrical connector.
10. Position a jack to support the three-way catalytic converter.
Heated Oxygen Sensor:
11. Remove the three front exhaust manifold-to-exhaust inlet pipe nuts.
Catalytic Converter:
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 EGR Valve Position sensor electrical connector.
17. Remove the EGR valve bolts.
18. Disconnect the EGR valve vacuum hoses 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 EGR valve gasket.
INSTALLATION
1. Position the EGR valve and the EGR valve gasket on the engine.
2. Install the EGR valve bolts. tighten the EGR valve bolts 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 EGR-to-exhaust manifold tube fitting to 57-74 Nm (44-54 lb ft).
5. Install the power steering fluid line clamp. Tighten the power steering line fluid clamp to 8-13 Nm (6-9 lb ft).
6. Connect the EGR valve position sensor electrical connector.
7 Position the exhaust inlet pipes.
8. Install the rear and front exhaust manifold-to-exhaust inlet pipes nuts. Tighten the exhaust manifold-to-exhaust inlet pipes nuts to 37-52 Nm (27-38 lb ft).
9. Install the three-way catalytic converter-to-exhaust inlet pipe nuts. Tighten the three-way catalytic converter-to-exhaust inlet pipe nuts to 64-89 Nm (47-66 lb ft).
10. Remove the jack supporting the three-way catalytic converter.
Heated Oxygen Sensor Electrical Connector:
11. Connect the front O2 sensor electrical connector.
12. Install the right side wheel splashguard bolts.
Crossmember Assembly:
13. Install the crossmember. Tighten the crossmember 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 house 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 O2 sensor electrical connector.
18. Install the engine air cleaner.
19. Connect the battery ground cable.