EGR Tube: Service and Repair

REMOVAL

1. 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 rear Heated Oxygen Sensor (HO2S) electrical connector.

3. Raise and support the vehicle.

Crossmember Assembly:

4. Remove the six crossmember bolts and remove the crossmember.

5. Remove the three RH wheel splash guard bolts.

Heated Oxygen Sensor Electrical Connector:

6. Disconnect the front HO2S electrical connector.

7. Position a jack to support the three way catalytic converter.

Heated Oxygen Sensor:

8. Remove the three front exhaust manifold-to-exhaust inlet pipe nuts.

Catalytic Converter:

9. Remove the two exhaust inlet pipe-to-three way catalytic converter nuts.

10. Remove the three rear exhaust manifold-to-exhaust inlet pipe nuts.

11. Remove the exhaust inlet pipes.

12. Disconnect the EGR valve-to-exhaust manifold tube fitting from the EGR valve.

13. Disconnect the EGR valve-to-exhaust manifold tube fitting from the rear exhaust manifold.

14. Remove the EGR valve-to-exhaust manifold tube.

INSTALLATION

1. Position the EGR valve-to-exhaust manifold tube on the EGR valve and the rear exhaust manifold.

2. Connect the EGR valve-to-exhaust manifold tube fittings to the EGR valve and the rear exhaust manifold. Tighten the EGR valve-to-exhaust manifold tube fittings to 57-74 Nm (44-54 lb ft).

3. Position the exhaust inlet pipes.

4. Install the rear and front exhaust manifold-to-exhaust inlet pipe nuts. Tighten the exhaust manifold-to-exhaust inlet pipe nuts to 37-52 Nm (27-38 lb ft).

5. Install the three way catalytic exhaust inlet pipe nuts. Tighten the three way catalytic converter-to-exhaust inlet pipe nuts to 64-89 Nm (47-66 lb ft).

6. Remove the jack supporting the three way catalytic converter.

Heated Oxygen Sensor Electrical Connector:

7. Connect the front HO2S electrical connector.

8. Install the three RH wheel splash guard bolts.

Crossmember Assembly:

9. Install the crossmember. Tighten the crossmember bolts to 94-126 Nm (69-93 lb ft).

10. Lower the vehicle.

11. Connect the rear HO2S electrical connector.

12. Install the battery ground cable.