Federal Models

INSPECTION

Removal

1. Disconnect negative terminal cable from battery.

CAUTION: Work must be started after 90 seconds trom the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

2. Disconnect exhaust gas recirculation valve connector.
3. Drain engine coolant.
4. Remove exhaust gas recirculation valve.





- Disconnect the following hoses:
- Vacuum hose (from port E of vacuum switch valve) from exhaust gas recirculation valve. (1)
- Vacuum hose (from port G of vacuum switch valve) from exhaust gas recirculation vacuum modulator. (2)
- Vacuum hose (from exhaust gas recirculation vacuum modulator) from exhaust gas recirculation valve. (3)
- Water bypass hose (from idle air control valve) from exhaust gas recirculation valve. (4)
- Water bypass hose (from rear water bypass joint) from exhaust gas recirculation valve. (5)





- Disconnect the vacuum modulator bracket from the exhaust gas recirculation valve.





- Remove the 2 nuts, exhaust gas recirculation valve and gasket.
5. Remove exhaust gas recirculation valve adaptor.
- Disconnect the exhaust gas recirculation gas temperature sensor.





- Disconnect the positive crankcase ventilation hose from the exhaust gas recirculation valve adaptor.





- Remove the 2 bolts, 2 nuts, exhaust gas recirculation valve adaptor and gasket.
6. Remove exhaust gas recirculation gas temperature sensor from exhaust gas recirculation valve adaptor.





- Mount the exhaust gas recirculation valve adaptor in a vise.
- Remove the exhaust gas recirculation gas temperature sensor.
- Remove the connector bracket from the sensor connector.

Installation

1. Reinstall exhaust gas recirculation gas temperature sensor to exhaust gas recirculation valve adaptor.
- Mount the exhaust gas recirculation valve adaptor in a vise.
- Install the exhaust gas recirculation gas temperature sensor to the adaptor.

Torque: 20 Nm (14 ft lb)

- Install the connector bracket to the sensor connector.





2. Reinstall exhaust gas recirculation valve adaptor.
- Install a new gasket, the exhaust gas recirculation valve adaptor and connector bracket with the 2 bolts and 2 nuts.

Torque: 18 Nm (13 ft lb)

NOTICE: Do not touch the air intake chamber and adaptor surfaces of the gasket with your hand.





- Connect the positive crankcase ventilation hose to the exhaust gas recirculation valve adaptor.
- Connect the exhaust gas recirculation gas temperature sensor.
3. Reinstall exhaust gas recirculation valve.





- Place a new gasket on the exhaust gas recirculation valve adaptor.

NOTICE: Do not touch the adaptor and exhaust gas recirculation valve surfaces of the gasket with your hand. Align the port holes of the gasket and adaptor. Be careful of the installation direction.





- Install the exhaust gas recirculation valve with the 2 nuts.

Torque: 18 Nm (13 ft lb)





- Install the vacuum modulator bracket to the exhaust gas recirculation valve.





- Connect the following hoses:
- Vacuum hose (from port E of vacuum switch valve) from exhaust gas recirculation valve. (1)
- Vacuum hose (from port G of vacuum switch valve) from exhaust gas recirculation vacuum modulator. (2)
- Vacuum hose (from exhaust gas recirculation vacuum modulator) from exhaust gas recirculation valve. (3)
- Water bypass hose (from idle air control valve) from exhaust gas recirculation valve. (4)
- Water bypass hose (from rear water bypass joint) from exhaust gas recirculation valve. (5)
4. Reconnect negative terminal cable to battery.
5. Refill with engine coolant.