VALVE, Exhaust Gas Recirculation (EGR): Removal: 3.5L

WARNING: The normal operating temperature of the exhaust gas recirculate (EGR) valve and tube is very high. Therefore, never work around or attempt to service any engine component until it is completely cooled.

NOTE: It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired. Disconnecting the battery for at least two minutes will remove all power from the controller and reset these cells to normal default values.

Fig 1: PURGE SOLENOID BRACKET

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1. Use a scan tool to record any Diagnostic Trouble Codes (DTCs).
2. Disconnect and isolate the negative battery cable.
3. Remove and relocate the purge solenoid from its mounting bracket.
   Fig 2: ELECTRICAL CONNECTOR - 3.5L

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4. Unlock and disconnect the electrical connector from the EGR valve.
   Fig 3: Removing/Installing Cowl Panel

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5. Remove the cowl panel (1) and wiper module. Refer to Electrical/Wipers/Washers/LINKAGE, Wiper Arm - Removal .
6. Remove and reposition the strut tower support (6).
   Fig 4: EGR Valve Mounting Bolts - 3.5L

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7. Remove the EGR tube bolts (1) from the EGR valve (3).
   Fig 5: EGR VALVE AND TUBE - 3.5L

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8. Remove the EGR tube (1) from the EGR valve (2) and intake manifold.
   Fig 6: Identifying Inner EGR Tube Seal

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   NOTE: When removing the EGR tube, be careful not to drop the silicone rubber seal (1) into the intake manifold. Replace the EGR tube gasket and silicone rubber seal any time the EGR tube is removed from the intake manifold.
   Fig 7: EGR Valve Mounting Bolts - 3.5L

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9. Remove the EGR valve mounting bolts (2) and remove the EGR valve from vehicle.
   CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum.
10. Clean the mounting surface.