EGR Valve: Service and Repair

WARNING: EGR components transport hot exhaust gases. Contact with hot EGR components may cause severe burns. Wear protective gloves or allow the vehicle sufficient time to cool.

Fuel Charging System:

1. Disconnect the EGR valve vacuum line, and disconnect the EGR transducer wire.
2. Remove the EGR transducer retaining nut.
3. Loosen the EGR supply tube at the exhaust manifold, and disconnect the supply tube from the EGR valve.
4. Remove the two EGR retaining bolts from the intake manifold and remove the EGR valve and transducer as an assembly.
5. Clean all mating surfaces being careful not to get foreign material in the intake manifold.
6. Connect the EGR valve to the EGR tube, making sure the tube is seated in the EGR valve correctly, and hand tighten.
7. Install the EGR valve and transducer assembly to the intake manifold with a new gasket. Torque the mounting bolts to 25 Nm (19 ft lb).
8. Torque the EGR supply tube at the EGR valve, and at the exhaust manifold to 41 Nm (30 ft lb).
9. Install the EGR valve transducer nut to the intake manifold, and torque the nut to 25 Nm (19 ft lb).
10. Connect the EGR transducer wire, and the EGR vacuum line.
11. START the engine and check for exhaust leaks.