EGR Valve: Service and Repair

Fig 1 EGR Valve:

REMOVAL
1. Disconnect negative battery cable.
2. Remove air inlet tube and resonator.
3. Remove throttle cable bracket and reposition.
4. Remove EGR tube mounting screws at intake manifold plenum.
5. Disconnect electrical connector from solenoid.
6. The EGR valve attaches to the rear of the right cylinder head.
7. Remove EGR upper tube screws at EGR valve.
8. Remove EGR valve mounting screws.
9. Remove screws from EGR lower tube at exhaust manifold.
10. Remove EGR valve and lower tube as an assembly
11. Clean gasket surfaces. Discard old gasket. If necessary, clean EGR passages.

INSTALLATION
1. Loosely install EGR valve and lower tube, use a new gasket between tube and EGR valve.
2. Install EGR valve to rear of Cylinder head, do not tighten screws.
3. Loosely install screws to lower EGR tube to exhaust manifold
4. Install rubber silicone seals on intake manifold end of EGR tube.
5. Install upper tube into the intake manifold, being careful to be sure silicone rubber seals is correctly installed and undamaged.
6. Install new gasket between the EGR valve and tube and install bolts.
7. Tighten the EGR upper tube to intake manifold plenum screws to 9 Nm (80 in. lbs.) torque.
8. Tighten the EGR tube's to EGR valve bolts to 11 Nm (95 in. lbs.) torque.
9. Tighten EGR lower tube to exhaust manifold screws to 22 Nm (200 in. lbs.) torque.
10. Tighten EGR valve to cylinder head screws to 22 Nm (200 in. lbs.) torque.
11. Attach electrical connector to solenoid.
12. Install the throttle cable bracket to intake manifold.
13. Install air inlet tube and resonator.
14. Connect negative battery cable.