REMOVAL AND INSTALLATION
- Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
- Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
- Disconnect the EGR valve electrical connector.
- Release the clamp and remove the upper radiator hose from the coolant outlet adapter.
- Release the clamp and remove the EGR coolant outlet hose from the EGR valve.
- Remove the 2 bolts and the EGR valve. Discard the gasket. To install, tighten to 20 Nm (177 lb-in).
- Clean the mating surfaces of any residual gasket material.
- To install, reverse the removal procedure.
- Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
Scheme 7
Scheme 7: Positive Crankcase Ventilation (PCV) System Components - Exploded View
| Item | Part Number | Description |
|---|
| 1 | 6A666 | PCV valve |
| 2 | 6758A | Crankcase ventilation tube clamp |
| 3 | 6758 | Crankcase ventilation tube |
| 4 | 6A785A | Crankcase vent oil separator gasket |
| 5 | 6A785 | Crankcase vent oil separator |
| 6 | W500214 | Crankcase vent oil separator bolt (8 required) |
- For additional information, refer to the procedures.
- Remove the intake manifold. For additional information, refer to «ENGINE - 2.3L»(ref-291902) article.
- Depress the 2 tabs and remove the PCV valve from the crankcase vent oil separator.
- Release the clamp and remove the crankcase ventilation tube.
- To install, reverse the removal procedure.
- Remove the intake manifold. For additional information, refer to «ENGINE - 2.3L»(ref-291902) article.
- Remove the 8 bolts and the crankcase vent oil separator and gasket. To install, tighten to 10 Nm (89 lb-in).
- To install, reverse the removal procedure. Clean the engine block mating surface.
Scheme 8
Scheme 8: Secondary Air Injection System (AIR) Components - Exploded View
| Item | Part Number | Description |
|---|
| 1 | W500223 | Secondary Air Injection (AIR) valve bolt (2 required) |
| 2 | 9E499 | AIR valve vacuum tube |
| 3 | 9B466 | AIR valve-to-exhaust manifold hose |
| 4 | W525857 | AIR valve hose clamp |
| 5 | 9F491 | AIR valve |
| 6 | 9F805 | Air cleaner outlet pipe |
| 7 | | AIR pump hose clamp (part of 9S477) |
| 8 | W500032 | AIR pump bolt (3 required) |
| 9 | 9A486 | AIR pump |
| 10 | 14A624 | AIR pump electrical connector |
| 11 | | AIR pump hose clamp (part of 9B458) |
| 12 | | AIR pump hose clamp (part of 9B458) |
| 13 | 9B458 | AIR pump-to-air cleaner outlet pipe |
| 14 | 9S477 | AIR pump-to-AIR valve hose |
| 15 | | AIR pump hose clamp (part of 9S477) |
| 16 | | Wire harness retainer clips (part of 12B637) |
- For additional information, refer to the procedures.
Note. Crimp-style clamps retain the hoses to the Secondary Air Injection (AIR) pump, therefore the pump and hoses are removed as an assembly.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
- If equipped, remove the 7 screws and the underbody cover.
- Disconnect the AIR pump electrical connector.
- Release the wire harness retainer clips from the AIR pump hose.
- Disconnect the AIR pump hose from the air cleaner outlet pipe.
- Disconnect the AIR pump hose from the AIR valve.
- Remove the 3 bolts and the AIR pump and hoses as an assembly. To install, tighten to 30 Nm (22 lb-ft).
- To install, reverse the removal procedure.
- Remove the vacuum tube from the Secondary Air Injection (AIR) valve.
- Release the clamp and remove the AIR pump-to-AIR valve hose.
- Remove the 2 bolts and the secondary AIR valve. To install, tighten to 10 Nm (89 lb-in).
- Release the clamp and remove the AIR valve-to-exhaust manifold hose.
- To install, reverse the removal procedure.
