EXHAUST GAS RECIRCULATION

25-38 EXHAUST GAS RECIRCULATION LX EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page EXHAUST GAS RECIRCULATION SPECIFICATIONS TORQUE...38 TUBE-EXHAUST GAS RECIRCULATION REMOVAL 2.7L - LOWER TUBE...39 2.7L - UPPER TUBE...40 3.5L...42 INSTALLATION 2.7L - LOWER TUBE...44 2.7L - UPPER TUBE...45 3.5L...46 page ASSEMBLY-EXHAUST GAS RECIRCULATION VALVE DESCRIPTION...48 OPERATION...48 REMOVAL 2.7L...48 3.5L...49 5.7L...51 INSTALLATION 2.7L...53 3.5L...54 5.7L...56 EXHAUST GAS RECIRCULATION SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N m Ft. Lbs. In. Lbs. Tube to Exhaust Manifold Bolts 31 23 275 Tube to EGR valve Bolts 11-95 EGR Valve to Cyl. Head Bolts 31 23 275

LX EXHAUST GAS RECIRCULATION 25-39 TUBE-EXHAUST GAS RECIRCULATION REMOVAL 2.7L - LOWER TUBE 1. Disconnect negative battery cable. 2. Remove purge solenoid from bracket.

25-40 EXHAUST GAS RECIRCULATION LX 3. Relocate the purge solenoid. 4. Unlock and disconnect the electrical connector from EGR valve. 5. Remove the bolts from the lower tube to exhaust manifold. 6. Remove the lower tube bolts to EGR valve. 7. Remove lower tube from vehicle. 8. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. 9. Clean mounting surface. 2.7L - UPPER TUBE 1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3). 2. Disconnect negative battery cable.

LX EXHAUST GAS RECIRCULATION 25-41 3. Remove purge solenoid from bracket. 4. Relocate the purge solenoid. 5. Unlock and disconnect the electrical connector from EGR valve. 6. Remove upper tube bolts to EGR valve (2). 7. Remove upper tube from intake manifold. 8. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. 9. Clean mounting surface.

25-42 EXHAUST GAS RECIRCULATION LX 3.5L 1. Disconnect negative battery cable. 2. Remove purge solenoid from bracket. 3. Relocate the purge solenoid. 4. Unlock and disconnect the electrical connector from EGR valve. 5. Remove the wiper module, (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL). 6. Remove shock tower brace and relocate. 7. Remove the upper intake manifold, (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL).

LX EXHAUST GAS RECIRCULATION 25-43 8. EGR valve (2) and tube (1). 9. Remove tube bolts (1) to EGR valve (2). 10. Remove tube (1) from intake manifold. 11. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. 12. Clean mounting surface.

25-44 EXHAUST GAS RECIRCULATION LX INSTALLATION 2.7L - LOWER TUBE 1. Clean mounting surface. 2. Install the lower tube to vehicle. 3. Install the lower tube bolts to EGR valve. 4. Install the lower tube bolts to exhaust manifold. 5. Tighten the lower tube to EGR valve bolts to 11 N m (95 in. lbs.) torque. 6. Tighten the lower tube to exhaust manifold bolts to 31 N m (275 in. lbs.) torque.

LX EXHAUST GAS RECIRCULATION 25-45 7. Connect the electrical connector to EGR valve and lock. 8. Relocate the purge solenoid. 9. Install purge solenoid to bracket. 10. Connect negative battery cable. 2.7L - UPPER TUBE 1. Clean mounting surface. 2. Inspect rubber silicone seals on intake manifold end of EGR tube. 3. Install upper tube into the intake manifold, being careful that the silicone rubber seals are correctly installed and undamaged.. 4. Install new gasket between the EGR valve and tube and install bolts (2). 5. Tighten the upper tube to EGR valve bolts to 11 N m (95 in. lbs.) torque.

25-46 EXHAUST GAS RECIRCULATION LX 6. Connect the electrical connector to EGR valve and lock. 7. Relocate the purge solenoid. 8. Install purge solenoid to bracket. 9. Connect negative battery cable. 3.5L 1. Clean mounting surface. 2. Inspect rubber silicone seals on intake manifold end of EGR tube. 3. Install tube into the intake manifold being careful that the silicone rubber seals are correctly installed and undamaged.

LX EXHAUST GAS RECIRCULATION 25-47 4. Install the tube bolts to EGR valve. 5. Tighten the EGR tube to EGR valve bolts to 11 N m (95 in. lbs.) torque. 6. Connect the electrical connector to EGR valve and lock. 7. Install upper intake manifold, (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - INSTALLA- TION). 8. Install the shock tower brace. 9. Install the wiper module, (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION). 10. Relocate the purge solenoid. 11. Install purge solenoid to bracket. 12. Connect negative battery cable.

25-48 EXHAUST GAS RECIRCULATION LX ASSEMBLY-EXHAUST GAS RECIRCULATION VALVE DESCRIPTION The EGR valve consists of three major components. First there is the pintle, valve seat, and housing which contains and regulates the gas flow. Second there is the armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects to the two connectors in the connector assembly. The third major component which senses pintle position and is connected to the three connectors in the electrical connector. OPERATION The exhaust gas recirculation flow is determined by the engine controller. For a given set of conditions, the engine controller knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The engine controller adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct position. REMOVAL 2.7L 1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3). 2. Disconnect negative battery cable. 3. Remove purge solenoid from bracket.

LX EXHAUST GAS RECIRCULATION 25-49 4. Relocate the purge solenoid. 5. Unlock and disconnect the electrical connector from EGR valve. 6. Remove the bolts from the EGR tube to exhaust manifold. 7. Remove the lower tube bolts to EGR valve and remove tube(3). 8. Remove upper tube bolts to EGR valve (2). 9. Remove the EGR valve mounting bolts (1). 10. Remove valve from vehicle. 11. Clean mounting surface. 3.5L 1. Disconnect negative battery cable. 2. Remove purge solenoid from bracket.

25-50 EXHAUST GAS RECIRCULATION LX 3. Relocate the purge solenoid. 4. Unlock and disconnect the electrical connector from EGR valve. 5. Remove the wiper module, (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL). 6. Remove shock tower brace and relocate. 7. Remove the upper intake manifold, (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL). 8. EGR valve (2) and tube (1).

LX EXHAUST GAS RECIRCULATION 25-51 9. Remove tube bolts (1) to EGR valve (3). 10. Remove tube (1) from intake manifold. 11. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. 12. Remove EGR valve mounting bolts (2). 13. Remove EGR valve from vehicle. 14. Clean mounting surface. 5.7L The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold.

25-52 EXHAUST GAS RECIRCULATION LX 1. Disconnect electrical connector (1) from EGR solenoid (2). 2. Remove two bolts (3) connecting EGR tube (4) to valve assembly. 3. Remove gasket located between EGR tube flange and EGR valve assembly. 4. Remove two mounting bolts (2). 5. Separate valve assembly (3) from cylinder head (1). 6. Remove and discard metal gasket located between cylinder head and valve assembly.

LX EXHAUST GAS RECIRCULATION 25-53 INSTALLATION 2.7L 1. Clean mounting surface. 2. Install EGR valve. 3. Install the EGR valve mounting bolts (1). 4. Inspect rubber silicone seals on intake manifold end of EGR tube. 5. Install upper tube into the intake manifold, being careful that the silicone rubber seals are correctly installed and undamaged.. 6. Install new gasket between the EGR valve and upper tube and install bolts (2). 7. Install the lower tube to exhaust manifold. 8. Install new gasket between the EGR valve and lower tube and install bolts (3). 9. Tighten the lower tube to EGR valve bolts (3) to 11 N m (95 in. lbs.) torque. 10. Tighten the lower tube to exhaust manifold bolts to 31 N m (275 in. lbs.) torque. 11. Tighten the upper tube to EGR valve bolts (2) to 11 N m (95 in. lbs.) torque. 12. Tighten EGR valve to cylinder head bolts (1) to 31 N m (275 in. lbs.) torque.

25-54 EXHAUST GAS RECIRCULATION LX 13. Connect the electrical connector to EGR valve and lock. 14. Relocate the purge solenoid. 15. Install purge solenoid to bracket. 16. Connect negative battery cable. 3.5L 1. Clean mounting surface. 2. Inspect rubber silicone seals on intake manifold end of EGR tube. 3. Install tube into the intake manifold being careful that the silicone rubber seals are correctly installed and undamaged.

LX EXHAUST GAS RECIRCULATION 25-55 4. Install new gasket between the EGR valve (3) and tube and install bolts (1). 5. Tighten the EGR tube to EGR valve bolts to 11 N m (95 in. lbs.) torque. 6. Connect the electrical connector to EGR valve and lock. 7. Install upper intake manifold, (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - INSTALLA- TION). 8. Install the shock tower brace. 9. Install the wiper module, (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION). 10. Relocate the purge solenoid. 11. Install purge solenoid to bracket. 12. Connect negative battery cable.

25-56 EXHAUST GAS RECIRCULATION LX 5.7L 1. Position a new metal gasket between cylinder head (1) and valve assembly (3). 2. Install two mounting bolts (2) and tighten. Refer to Torque Specifications. 3. Clean EGR tube where it joins EGR valve. 4. Position new gasket between EGR tube flange and EGR valve assembly. 5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts. Refer to Torque Specifications. 6. Connect electrical connector (1) to EGR solenoid (2).