EGR Tube: Service and Repair

LOWER TUBE

REMOVAL




1. Disconnect negative battery cable.




2. Remove purge solenoid from bracket.




3. Relocate the purge solenoid.
4. Unlock and disconnect the electrical connector from EGR valve.




5. Remove the bolts from the lower tube to exhaust manifold.
6. Remove the lower tube bolts to EGR valve.
7. Remove lower tube from vehicle.
8. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum.
9. Clean mounting surface.

INSTALLATION




1. Clean mounting surface.




2. Install the lower tube to vehicle.
3. Install the lower tube bolts to EGR valve.
4. Install the lower tube bolts to exhaust manifold.
5. Tighten the lower tube to EGR valve bolts to 11 Nm (95 in. lbs.) torque.
6. Tighten the lower tube to exhaust manifold bolts to 31 Nm (275 in. lbs.) torque.




7. Connect the electrical connector to EGR valve and lock.
8. Relocate the purge solenoid.
9. Install purge solenoid to bracket.
10. Connect negative battery cable.

UPPER TUBE

REMOVAL




1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3).
2. Disconnect negative battery cable.




3. Remove purge solenoid from bracket.




4. Relocate the purge solenoid.
5. Unlock and disconnect the electrical connector from EGR valve.




6. Remove upper tube bolts to EGR valve (2).
7. Remove upper tube from intake manifold.
8. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum.
9. Clean mounting surface.

INSTALLATION







1. Clean mounting surface.
2. Inspect rubber silicone seals on intake manifold end of EGR tube.
3. Install upper tube into the intake manifold, being careful that the silicone rubber seals are correctly installed and undamaged..
4. Install new gasket between the EGR valve and tube and install bolts (2).
5. Tighten the upper tube to EGR valve bolts to 11 Nm (95 in. lbs.) torque.




6. Connect the electrical connector to EGR valve and lock.
7. Relocate the purge solenoid.




8. Install purge solenoid to bracket.
9. Connect negative battery cable.