Exhaust Gas Recirculation (EGR) Valve

REMOVAL PROCEDURE




1. Drain cooling system. Refer to Draining and Filling Cooling System in Cooling System.
2. Remove air intake duct.
3. Remove the turbocharger boost sensor bracket bolt.
4. Remove the turbocharger boost sensor with bracket.
5. Remove the intake heater and gasket.
6. Remove the upper intake manifold tube nuts and upper tube.




7. Disconnect exhaust gas recirculation (EGR) valve vacuum hose.




8. Remove EGR inlet cooling hose (2) from cooling tube (1).




9. Remove EGR outlet cooling hose (1) from cooling tube (2).




10. Remove nuts retaining EGR assembly to intake manifold.




11. Remove nuts retaining EGR assembly to exhaust pipe.
12. Remove bolts retaining EGR assembly to EGR bracket.
13. Remove EGR assembly from engine.




14. Remove bolts (1) Retaining EGR to EGR cooling tube.
15. Separate EGR from EGR cooling tube.

INSTALLATION PROCEDURE




1. Install EGR to EGR cooling tube.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install bolts (1) to retain EGR to EGR cooling tube.

Tighten
Tighten bolts to 20 N.m (15 lb ft).




3. Install EGR assembly to engine.
4. Install bolts to retain EGR assembly to EGR bracket.

Tighten
Tighten bolts to 20 N.m (15 lb ft).

5. Install nuts to retain EGR assembly to exhaust pipe.

Tighten
Tighten nuts to 20 N.m (15 lb ft).




6. Install nuts to retain EGR assembly to intake manifold.

Tighten
Tighten nuts to 19 N.m (14 lb ft).




7. Install EGR outlet cooling hose (1) to EGR cooling tube (2).




8. Install EGR inlet cooling hose (2) to EGR cooling tube (1).




9. Connect EGR vacuum hose to EGR.




10. Install the upper intake manifold tube and nuts.

Tighten
Tighten the nuts to 10 N.m (89 lb in).

11. Install the intake heater and gasket.

Tighten
Tighten the intake heater to 50 N.m (37 lb ft).

12. Install the turbocharger boost sensor with bracket.
13. Install the turbocharger boost sensor bracket bolt.

Tighten
Tighten the bolt to 10 N.m (89 lb in).

14. Install air intake duct.
15. Fill cooling system. Refer to Draining and Filling Cooling System in Cooling System.