EGR Valve: Service and Repair

Exhaust Gas Recirculation (EGR) Valve






Coolant Hoses










Motor Electronics Cooling System (MECS) Expansion Tank










Transaxle High-Voltage Electrical Wire Harness










Engine Wire Harness










Coolant Outlet Adapter










EGR Valve









Removal and Installation

1. Depower the High Voltage Traction Battery (HVTB) system. For additional information, refer to High Voltage Traction Battery High-Voltage Traction Battery Systems Depowering.

2. Drain the cooling system. For additional information, refer to Engine Cooling - Hybrid Service and Repair.

3. Remove the Throttle Body (TB). For additional information, refer to Fuel Charging and Controls - Hybrid Service and Repair.

4. Release the clamp and separate the upper heater hose.

5. Release the clamp and remove the bypass hose from the coolant outlet adapter.

6. Release the clamp and remove the upper radiator hose from the coolant outlet adapter.

7. Release the clamp and remove the heater hose from the EGR valve.

8. Remove the bolt and the nut and position the Motor Electronics Cooling System (MECS) coolant expansion tank aside.
- To install, tighten to 9 Nm (80 lb-in).

9. Disconnect the EGR valve electrical connector.

10. Release the engine wire harness retainer from the valve cover stud.

11. Remove the high-voltage wire harness bolt.
- To install, tighten to 9 Nm (80 lb-in).

12. Disconnect the transaxle high-voltage electrical connector.

13. Carefully position the upper heater hose aside.

14. Release the clamp and remove the lower heater hose from the coolant outlet adapter.

15. Remove the 4 bolts and position the coolant outlet adapter aside.
- To install, tighten to 10 Nm (89 lb-in).

16. Remove the 2 bolts and the EGR valve.
- To install, tighten to 20 Nm (177 lb-in).

17. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the coolant outlet adapter gasket.

Remove the coolant outlet adapter and discard the gasket.

- Clean and inspect the coolant outlet adapter mating surfaces.

18. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the Exhaust Gas Recirculation (EGR) valve gasket.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces

NOTE: Do not reuse the EGR valve gasket.

Remove and discard the EGR valve gasket.

- Clean and inspect the EGR gasket mating surfaces.

19. To install, reverse the removal procedure.

20. Fill and bleed the cooling system. For additional information, refer to Engine Cooling - Hybrid Service and Repair.