EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL/INSTALLATION - HYBRID

Coolant Outlet

1. Drain the cooling system. See Removal and Replacement.

2. Remove the air cleaner outlet pipe. See - Air Cleaner Outlet Pipe Removal/Installation.

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

4. Release the clamp and remove the coolant bypass hose from the coolant outlet.

5. Release the clamp and remove the heater hose from the coolant outlet.

6. Remove the 4 bolts and the coolant outlet and gasket.

- To install, tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

7. Disconnect the EGR valve electrical connector.

8. Release the clamp and remove the coolant hose from the EGR valve.

9. Remove the 2 bolts and the EGR valve.

- To install, tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.

10. Remove and discard the EGR valve gasket.

- Clean and inspect the EGR gasket mating surfaces.

CAUTION: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 exhaust gas recirculation (EGR) valve gasket.
11. To install, reverse the removal procedure.

NOTE:Install a new EGR valve gasket.
12. Fill and bleed the cooling system. See Removal and Replacement.