Service Procedure

1. Remove air inlet resonator/upper air cleaner housing.

NOTE:
Make sure orifice at valve cover nipple-to-air cleaner hose connection remains located in valve cover nipple. Place shop towel over throttle body opening to avoid contamination.





2. Remove EGR valve and tube assembly (EGR plate only on NS vehicles) as shown in figure 1.

NOTE:
To avoid damage to EGR transducer, disconnect transducer hose from tube, then disconnect electrical connector.





3. On NS (minivan) vehicles: Remove nut from stud as shown in figure 2, and move heater hose/tube bracket assembly aside.





4. On JA Vehicles: Remove fasteners attaching power steering hoses to cylinder head as shown in figure 3, and move the hoses rearward.





5. On JA Vehicles: Disconnect wiring to ignition coil and to noise suppressor (Figure 4).





6. Insert both provided plug expanders into the plug expander installation tool (Miller Special Tool # 6986). Apply grease or dum-dum to the flat side of the plugs to hold them into the tool (Figure 5).





7. Install tool onto cylinder head using the 2 EGR valve mounting holes and the power steering hose bracket hole. Torque mounting bolts to 200 in-lbs (22 Nm) starting with the rear bolt (Figure 6).

NOTE:
The oil galley plug boss height has been increased on new cylinder heads. If the tool will not mount to the head because of interference with the boss. check the build code of the cylinder head as shown in figure 7. Cylinder heads with a build code of K95 or later (ie., L95, A96, etc.) have already been repaired and therefore, no further action is necessary.

8. Press inboard plug expander into inboard oil galley plug by torquing plug expander tool screw to 200 in-lbs. (22 Nm) (Figure 6).

9. Remove plug expander tool screw and install it into the outboard hole in the tool. Press outboard plug expander into outboard oil galley plug by torquing plug expander screw to 200 in-lbs. (22 Nm) again (Figure 6).

10. Remove plug expander installation tool.





11. Install provided plug bracket so that the dimples in bracket are against oil galley plug expanders as shown in figure 8. Attach bracket with provided torx head screw and torque to 200 in-lbs.(22 Nm) or until the breakaway head separates.

12. On JA Vehicles: Attach power steering hose bracket to plug bracket using the provided nut. Torque nut to 105 in-lbs (11 Nm) (Figure 8). Install remaining two power steering hose fasteners and torque to 75 in-lbs (8 Nm) (Figure 3).

13. On JA Vehicles: Install wiring to ignition coil and to noise suppressor (Figure 4).

14. On NS (minivan) Vehicles: Install heater hose/tube bracket assembly onto stud and tighten nut securely (Figure 2).

15. Install EGR valve and tube assembly (EGR plate only on NS) using the provided gaskets. Torque EGR valve screws to 200 in-lbs (22 Nm), and EGR tube screws to 95 in-lbs (10 Nm) (Figure 1).

16. Install air inlet resonator/upper air cleaner housing.

17. Start engine and assure that no oil leaks from either oil galley plug.