For 1990-2009 cars

### Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
5. Remove the battery and tray. Refer to Battery Tray Replacement.
6. Remove the ECM. Refer to Engine Control Module Replacement.
7. Remove the fuel injector sight shield bracket.
8. Remove the engine wiring harness bracket.
9. Remove the EGR cooler outlet pipe.
10. Disconnect the surge tank-to-water pipe hose.
11. Disconnect the heater-to-water pipe hose.
12. Remove the water pipe retaining bolt from the engine block on the front.
13. Remove the EGR valve.
14. Remove the water pipe retaining bolts from the engine block on the rear and side.
15. Lower the water pipe
16. Remove the EGR cooler.
17. Remove the EGR cooler inlet pipe from the exhaust manifold.

### Installation Procedure

1. Install the EGR cooler inlet pipe to the exhaust manifold.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the EGR cooler with the engine wiring harness bracket and tighten.

• | The EGR cooler inlet pipe retaining nuts to 33 N·m (24.3 lb ft).

• | The EGR cooler retaining bolt to 20 N·m (14.8 lb ft).

3. Install the EGR valve.
4. Install the water pipe retaining bolt onto the engine block and tighten.

• | The EGR valve retaining nuts to EGR cooler to 20 N·m (14.8 lb ft).

• | The EGR valve retaining bolts to EGR inlet pipe to 20 N·m (14.8 lb ft).

• | The water pipe retaining bolt (M6) to 9 N·m (79.7 lb in).

• | The water pipe retaining bolt (M8) to 20 N·m (14.8 lb ft).

5. Install the EGR cooler outlet pipe.
6. Install the water pipe retaining bolt onto the engine block on the front and tighten.

• | The EGR cooler outlet pipe retaining bolts and nuts to 20 N·m (14.8 lb ft).

• | The water pipe retaining bolt (M8) to 20 N·m (14.8 lb ft).