Installation Procedure
- Position the EGR valve housing assembly gasket (2) and EGR valve housing assembly (1) in place and hand start the fasteners.
- Install and tighten Exhaust Gas Recirculation Valve Adapter Nuts (2) (Qty: 4) to 25 N.m (18 lb ft)
- Install and tighten Exhaust Gas Recirculation Manifold Brace Bolt (3) to 58 N.m (43 lb ft)
- Connect the EGR bypass vacuum tube (1).
- Connect the exhaust gas recirculation valve temperature sensor electrical connector. Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1
- Connect the EGR valve electrical connector.
- Install and tighten Fuel Return Hose Bracket Bolt (1) to 22 N.m (16 lb ft)
- Install Front Wheelhouse Liner - Left side. Refer to Front Wheelhouse Liner Replacement (without ZR2)Front Wheelhouse Liner Replacement (with ZR2)
- Position the EGR pipe seal (3), gasket (2) and pipe in place then hand start the fasteners.
- Tighten the EGR pipe fasteners (1) to 25 N.m (18 lb ft)
- Tighten the EGR pipe fasteners (2) to 11 N.m (8 lb ft)
- Install Oil Level Indicator Tube. Refer to Oil Level Indicator Tube Replacement
- Connect the cooler hoses (1) to the EGR valve housing (2).
- Install Exhaust Gas Recirculation Cooler. Refer to Exhaust Gas Recirculation Cooler Replacement
- Connect Power Brake Booster Vacuum Hose @ Power Brake Booster. Refer to Power Brake Booster Vacuum Hose Replacement (LWN)
- Install Plenum Front Panel. Refer to Plenum Front Panel Replacement
- Install Charge Air Cooler Outlet Duct. Refer to Charge Air Cooler Outlet Duct Replacement
- Install Intake Manifold Cover Insulator. Refer to Intake Manifold Cover Insulator Replacement (Top of Engine)Intake Manifold Cover Insulator Replacement (Left Side)
CAUTION:
Refer to Fastener Caution .
NOTE:
Install NEW seal and gasket to ensure proper sealing.
CAUTION:
Refer to Fastener Caution .
NOTE:
Install NEW clamps to ensure proper hose sealing.