Installation

EGR Valve Removal / Replacement:

EGR VALVE INSTALLATION
1. Install EGR valve.



(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 13 Nm (9 ft lb)
(b) Install the EGR pipe with the 2 union nuts.
Torque: 59 Nm (43 ft lb)
(c) Connect the following hoses to the EGR valve:



(1) Vacuum hose (from port E of VSV)
(2) EGR hose (from vacuum modulator)

2. Install EGR gas temperature sensor.



(a) Install the EGR gas temperature sensor.
Torque: 20 Nm (14 ft lb)
(b) Connect the sensor connector, and install the sensor connector to the bracket on the intake manifold.

3. Install throttle body.



(a) Attach a new gasket to the intake manifold, facing the protrusion downward.

(b) Type A:



- Install the throttle body with the 4 bolts.
HINT: Different bolt lengths are used for the upper and lower sides.
Bolt length:
for upper side - 45 mm (1.77 in.)
for lower side - 55 mm (2.17 in.)
Torque: 19 Nm (14 ft lb)

(c) Type B:



- Install the throttle body with the 2 bolts and 2 nuts.
Torque: 19 Nm (14 ft lb)

(d) Connect the following hoses:
(1) Vacuum hose (from upper port of TVV for EVAP) to port "P" of throttle body
(2) Vacuum hose (from port "Q" of EGR vacuum modulator) to port "E" of throttle body
(3) Vacuum hose (from port "R" of EGR vacuum modulator) to port "R" of throttle body
(4) PCV hose (from cylinder head) to throttle body

4. Connect control cables to throttle body.
Connect the following cables:



(a) Accelerator cable
(b) A/T throttle control cable
5. Install air cleaner cap.



(a) Connect the air cleaner hose to the throttle body.
(b) Install the air cleaner cap to the air cleaner case with the 4 clamps.
(c) Tighten the hose clamp.
(d) Connect the following connector, cord, cables and hoses:
(1) IAT sensor connector
(2) California only: High-tension cord to air cleaner hose
(3) Accelerator cable to clamp
(4) Cruise control actuator cable to clamps
(5) California only: Air hose for idle-up to air cleaner hose

6. Connect negative (-) terminal cable to battery.