EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE







Exploded View

Removal and Installation

All vehicles
1. Disconnect the battery ground cable.
2. Drain the cooling system.







3. Disconnect the coolant bypass hose.







4. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

Vehicles equipped with a manual transmission
5. Remove the shifter.

All vehicles
6. Remove the rear driveshaft.







7. Remove the bolts retaining the exhaust inlet crossover pipe to the muffler. Discard the exhaust converter outlet gasket.
- To install, tighten to 40 Nm (30 lb-ft).







8. Remove the bolts retaining the exhaust inlet crossover pipe to the exhaust manifold and remove the RH exhaust pipe.







9. NOTE: Manual transmission shown, automatic transmission similar.

Support the transmission with a suitable transmission jack.







10. Detach the transmission electrical connector from the crossmember.







11. Remove the 6 bolts (3 on each side) retaining the crossmember to the frame.







12. Remove the retaining nuts and the crossmember.
- To install, tighten to 99 Nm (73 lb-ft).

13. Lower the transmission enough to allow access to the EGR valve.







14. Disconnect the EGR coolant hose.







15. Remove the bolts and the EGR valve.
- Discard the gasket.
- To install, tighten to 25 Nm (18 lb-ft).

16. NOTE: Clean the gasket mating surfaces and install new gaskets.

To install, reverse the removal procedure.