For 1990-2009 cars

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the front suspension support brace (1). Refer to Front Suspension Support Brace Replacement in Front Suspension.
4. Remove the four fasteners and the engine surge tank cover (1).
5. Disconnect the following electrical connectors:

• | The throttle position (TP) sensor (2)

• | The mass air flow (MAF) sensor (1)

• | The idle air control (IAC) valve (3)

6. Disconnect the ground terminal (5) from the intake collector.
7. Remove the clamp bracket (4) from the intake collector.
8. Disconnect the following electrical connectors:

• | The manifold absolute pressure (MAP) sensor

• | The evaporative emission (EVAP) canister purge valve (2)

• | The exhaust gas recirculation (EGR) valve (7)

9. Disconnect the following hoses:

• | The positive crankcase ventilation (PCV) hose from the cylinder head cover (9)

• | The breather hose from the throttle body (6)

• | The EVAP canister purge valve hose (1)

• | The water hose (8)

• | The heater hoses (3, 5)

10. Remove the EGR pipe (4).
11. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .
12. Remove the intake manifold collector.
13. Remove the two EGR valve retaining bolts.
14. Remove the EGR valve from the intake collector.
15. Clean the EGR valve gasket from the intake collector.

### Installation Procedure

1. Install the EGR valve with a new gasket to the intake collector.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Secure the EGR valve to the intake collector with the two retaining bolts.

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

3. Install the intake collector and the throttle body assembly to the intake manifold. Refer to Throttle Body Assembly Replacement .
4. Install the exhaust gas recirculation (EGR) pipe (4).
5. Connect the following hoses:

• | The PCV hose to the cylinder head cover (9)

• | The breather hose to the throttle body (6)

• | The EVAP canister purge valve hose (1)

• | The water hose (8)

• | The heater hoses (3, 5)

6. Connect the following electrical connectors:

• | The manifold absolute pressure (MAP) sensor

• | The EVAP canister purge valve (1)

• | The exhaust gas recirculation (EGR) valve (2)

7. Install the clamp bracket (4) to intake collector.
8. Install the ground terminal (5) to intake collector.
9. Connect the following electrical connectors:

• | The throttle position (TP) sensor (2)

• | The mass air flow (MAF) sensor (1)

• | The idle air control (IAC) valve (3)

10. Install the engine surge tank cover (1) and secure with the four fasteners.
11. Install the front suspension brace (1). Refer to Front Suspension Support Brace Replacement in Front Suspension.
12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
13. Connect the negative battery cable.

Tighten
Tighten the bolt to 8 N·m (72 lb in).