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EGR Control Solenoid

Powertrain Management › Emission Control Systems
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Exhaust Gas Recirculation (EGR) Valve - Removal9 steps
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  1. Use a diagnostic scan tool to record any DTC's (Diagnostic Trouble Codes).
  2. Disconnect and isolate the negative battery cable. An exhaust gas routing tube (1) connects the EGR valve (4) to the intake manifold.
  3. Remove two tube mounting bolts (2).
  4. Remove tube (1) from solenoid (4). Slip opposite end of tube (6) from intake manifold.
  5. Remove gasket (3) located between EGR valve solenoid and tube flange.
  6. Disconnect electrical connector (3) at solenoid (1).
  7. Remove two EGR valve solenoid mounting bolts (2).
  8. Remove solenoid (1) from engine.
  9. Remove and discard gasket (1) located under EGR solenoid.
Exhaust Gas Recirculation (EGR) Valve - Installation9 steps
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  1. Clean gasket area (1) at rear of left cylinder head where it joins base of EGR valve.
  2. Clean EGR tube where it joins EGR valve.
  3. Position new gasket between EGR valve and cylinder head.
  4. Position EGR valve to cylinder head. Install and tighten two bolts (2). Tighten to 9 Nm (80 in. lbs.).
  5. Position new gasket (3) between EGR tube flange and EGR valve assembly.
  6. Position EGR tube (1) to side of EGR valve. Position end of tube (6) into intake manifold. Install two bolts (2). Tighten to 11 Nm (97 in. lbs.).
  7. Connect electrical connector (3) to top of EGR valve solenoid (1).
  8. Connect negative battery cable.
  9. Using a diagnostic scan tool, erase any previously recorded DTC's (Diagnostic Trouble Codes).
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
SOLENOID-EGR📷 2

Removal

The EGR Solenoid (3) is located on the top of valve cover.
1
Remove plastic engine cover.
2
Disconnect electrical connector (2).
3
Disconnect vacuum/pressure lines (1).
4
Remove two mounting bolts (4) and remove solenoid.

Installation

The EGR Solenoid (3) is located on the top of valve cover.
1
Position solenoid (3) to valve cover and install two mounting bolts (4).
2
Connect electrical connector (2).
3
Connect vacuum/pressure lines (1).
4
Install plastic engine cover.
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