EGR Valve: Service and Repair

REMOVAL

Intake System Components:

1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) disconnected and let run until engine dies. Then remove hose on outlet side of fuel filter. On DOHC V-6 engine, fuel system pressure can also be relieved by loosening the cold start valve banjo bolt.
2. Drain engine coolant below level of intake manifold.
3. Remove intake air duct from throttle body.
4. Remove cold start injector from intake manifold dynamic chamber.
5. Disconnect vacuum hoses, cables, electrical connectors, and water hoses from throttle body, BAC valve, and dynamic chamber.
6. Remove chamber with intake air pipe and throttle body, as an assembly.

Move Wiring Harness To Access EGR Valve:

6. Remove wiring harness hold-down brackets and pull harness away from EGR valve.
7. Remove EGR hoses and vacuum hose.
8. Disconnect EGR position sensor harness connector.

Removing EGR Valve:

9. Remove EGR valve.
10. Install in reverse order.

INSTALLATION NOTES:

1. Use a new gasket.
2. Be sure to clean all old gasket material from surfaces.