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 elec-
trical 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 con-
troller adjusts the duty cycle of 128 Hz power sup-
plied to the solenoid coil to obtain the correct
position.

REMOVAL

REMOVAL - 2.7L

The EGR valve attaches to the rear of the right

cylinder head.

(1) Disconnect negative battery cable.

EXHAUST GAS RECIRCULATION

25 - 19

(2) Remove air inlet tube and resonator and

bracket.

(3) Disconnect electrical connector from solenoid.
(4) Remove EGR upper tube screws at EGR valve.
(5) Remove EGR valve mounting screws.
(6) Remove

screws

from

EGR

lower

tube

exhaust manifold.

(7) Remove EGR valve and lower tube as an

assembly.

(8) Clean gasket surfaces. Discard old gasket. If

necessary, clean EGR passages.

REMOVAL - 3.5L

(1) Disconnect negative battery cable.
(2) Remove air inlet tube and resonator.
(3) Disconnect

electrical

connector

from

EGR

valve.

(4) Remove EGR tube mounting screws at EGR

valve (Fig. 1).

The EGR valve attaches to the rear of the right

cylinder head.

(5) Remove EGR valve mounting screws.
(6) Clean gasket surfaces. Discard old gasket. If

necessary, clean EGR passages.

INSTALLATION

INSTALLATION - 2.7L

(1) Loosely install EGR valve and lower tube, use

a new gasket between tube and EGR valve.

(2) Install EGR valve to rear of Cylinder head, do

not tighten screws.

(3) Loosely install screws to lower EGR tube to

exhaust manifold, use new gasket between tube and
exhaust manifold.

(4) Install new gasket between the EGR valve and

upper tube and install bolts.

(5) Tighten EGR valve to cylinder head screws to

31 N·m (275 in. lbs.) torque.

(6) Tighten the EGR tube’s to EGR valve bolts to

11 N·m (95 in. lbs.) torque.

(7) Tighten EGR lower tube to exhaust manifold

screws to 31 N·m (275 in. lbs.) torque.

(8) Attach electrical connector to solenoid.
(9) Install the resonator bracket.
(10) Install air inlet tube and resonator.
(11) Connect negative battery cable.

INSTALLATION - 3.5L

(1) Loosely install EGR valve and new gasket on

cylinder head (Fig. 2).

(2) Using a new gasket, loosely install the EGR

tube and mounting screws.

(3) Tighten EGR valve to cylinder head screws to

31 N·m (275 in. lbs.) torque.

(4) Tighten the EGR tube to EGR valve screws to

11 N·m (95 in. lbs.) torque.

(5) Attach electrical connector to solenoid.
(6) Install air inlet tube and resonator.
(7) Connect negative battery cable.

Fig. 1 EGR tube and Valve - 3.2/3.5L

1 - EGR TUBE
2 - EGR VALVE

Fig. 2 EGR tube and Valve

1 - EGR TUBE
2 - EGR VALVE

25 - 20

EXHAUST GAS RECIRCULATION

EGR VALVE (Continued)

EGR TUBE - 2.7L

REMOVAL

REMOVAL - 2.7L UPPER TUBE

The EGR tube attaches to the intake manifold ple-

num on both sides of the throttle body and the EGR
valve (Fig. 3).

(1) Disconnect negative battery cable.
(2) Remove air inlet tube and resonator.
(3) Remove throttle cable bracket and reposition.
(4) Remove EGR tube mounting screws at intake

manifold plenum (Fig. 4).

(5) Remove EGR tube mounting screws at EGR

valve.

(6) Remove EGR upper tube.
(7) 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.

REMOVAL - 2.7L LOWER TUBE

(1) Disconnect negative battery cable.
(2) Remove air inlet tube and resonator and brack-

(3) Remove EGR tube mounting screws at EGR

valve (Fig. 5).

(4) Remove EGR tube mounting screws at exhaust

manifold.

INSTALLATION

INSTALLATION - 2.7L UPPER TUBE

The EGR tube attaches to the intake manifold ple-

num on both sides of the throttle body and the EGR
valve (Fig. 6).

(1) inspect rubber silicone seals on intake manifold

end of EGR tube.

Fig. 3 EGR Tube—2.7L

Fig. 4 PCV Valve—2.7L Engine

1 - PCV VALVE
2 - THROTTLE BODY
3 - EGR TUBE

Fig. 5 EGR Tube at Intake Manifold

1 - EGR TUBE
2 - IGNITION COILS
3 - EGR TUBE
4 - MAKE UP AIR TUBE

EXHAUST GAS RECIRCULATION

25 - 21

(2) Install upper tube into the intake manifold,

being careful that the silicone rubber seals are cor-
rectly installed and undamaged..

(3) Install new gasket between the EGR valve and

tube and install bolts.

(4) Tighten the EGR upper tube to intake manifold

plenum screws to 11 N·m (95 in. lbs.) torque.

(5) Tighten the EGR upper tube to EGR valve

bolts to 11 N·m (95 in. lbs.) torque.

(6) Install the throttle cable bracket to intake

manifold.

(7) Install air inlet tube and resonator.
(8) Connect negative battery cable.

INSTALLATION - 2.7L LOWER TUBE

(1) Install new gasket between the EGR valve and

tube and loosely install bolts.

(2) Install new gasket between the exhaust mani-

fold and tube and loosely install bolts.

(3) Tighten the EGR tube to EGR valve bolts to 11

N·m (95 in. lbs.) torque.

(4) Tighten the EGR tube to exhaust manifold

bolts to 31 N·m (275 in. lbs.) torque.

(5) Install

air

inlet

tube

and

resonator

and

bracket.

(6) Connect negative battery cable.

EGR TUBE - 3.5L

REMOVAL - 3.5L

The EGR tube attaches to the bottom of the intake

manifold plenum beside the throttle body (Fig. 8).

(1) Disconnect negative battery cable.
(2) Remove air inlet tube and resonator.
(3) Remove EGR tube mounting clips at intake

manifold plenum (Fig. 7).

(4) Loosen transmission to throttle body bracket

(Fig. 8). Remove 2 nuts and 1 bolt and remove
bracket off of studs.

(5) Remove EGR tube mounting screws at EGR

valve.

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.

(6) Remove EGR tube.

Fig. 6 EGR TUBE - 2.7L

Fig. 7 EGR Tube Clips

1 - EGR VALVE
2 - EGR TUBE
3 - CLIP

Fig. 8 Bracket and EGR Tube

1 - EGR TUBE
2 - BRACKET
3 - EGR VALVE

25 - 22

EXHAUST GAS RECIRCULATION

EGR TUBE - 2.7L (Continued)

Content .. 406 407 408 409 ..