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.

REMOVAL
1. Remove air cleaner outlet tube.
2. Disconnect EGR valve emission vacuum control hose.
3. Disconnect EGR Valve Position (EVP) sensor electrical connector.
4. Disconnect EGR valve to exhaust manifold tube.
5. Remove EGR mounting bolts and remove valve.

INSTALLATION
1. Clean the mating surfaces being careful not to let gasket material enter the intake manifold.
2. If replacing the EGR valve remove the EVP sensor and install it on the new valve.
3. Using a new gasket, install the EGR valve and mounting bolts.
- Torque bolts to 106-159 lbs. in. (12-18 N-m).
4. Connect the EGR tube to the EGR valve.
- Torque nut to 25-35 lbs. ft. (34-48 N-m).
5. Connect the EVP sensor electrical connector to the EVP sensor.
6. Install the vacuum line on the EGR valve.
7. START the engine and check for exhaust leaks.