Emissions Control: Removal & Installation RAM Pickup 1500

INSTALLATION

1. Install the Diesel Exhaust Fluid (DEF) supply pump (6) . Tighten bolts (4) to 25 N.m (18 ft. lbs.) .
2. Connect the DEF supply pump harness connector (5).
3. Connect the DEF pressure line (3).
4. Connect the DEF return line (2).
5. Connect the DEF supply line (1).
6. Connect both negative battery cables.

Scheme 51

The diesel exhaust fluid pump has three quick connect service port fitting. There is an inlet (3) , backflow (2) , and outlet service port fitting (1) that has an O-ring seal which is serviceable. Each quick connect service port fitting is unique to its location and can not be switched with another service port fitting.

The inlet quick connect service port (1) is equipped with a screen filter.

The backflow quick connect service port (2) is equipped with a screen filter and an inserted orifice.

The outlet quick connect service port (1) is not equipped with a screen filter.

Do not attempt to remove the screen filters or orifice as then are not removable, they can only be cleaned. If the quick connect service port fitting is damaged in any way then the quick connect service port fitting must be replaced.

Scheme 52

1. Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
2. Disconnect the appropriate quick connect line fitting (1, 2, or 3) from the Diesel Exhaust Fluid (DEF) supply pump (6). Refer to «STANDARD PROCEDURE - QUICK-CONNECT FITTINGS»(ref-457834-S33306886662012030200000) .
3. Clean the area surrounding Diesel Exhaust Fluid (DEF) fitting.
4. Remove the appropriate DEF pump fitting (1, 2, or 3) from the DEF fluid pump.
5. Inspect the DEF fluid pump fitting and O-ring seal (1) for damage and replace as necessary.

Scheme 53

1. Do not attempt to remove the screen filter or orifice from the quick connect service port fitting.
2. Using shop air and a rubber tip blow gun, blow air through the backside (1) of the inlet fitting onto a white piece of paper and inspect for debris on the paper (2).
3. If debris is found in service fitting then remove the Diesel Exhaust Fluid (DEF) tank level temperature sensor and inspect the filter and replace as necessary. Refer to «SENSOR, Diesel Exhaust Fluid Level/Temperature , Removal»(ref-457800-S08110948552012030200000) .
4. If necessary clean the DEF tank. Refer to «TANK, Diesel Exhaust Fluid , Cleaning»(ref-457800-S39267662452012030200000) .

1. If necessary, install a new O-ring seal (1).
2. Install the appropriate Diesel Exhaust Fluid (DEF) pump fitting (1, 2, or 3) into the DEF fluid pump. Tighten pump fitting 4 N.m (35 in. lbs.).
3. Connect the appropriate quick connect line fitting (1, 2, or 3) to the Diesel Exhaust Fluid (DEF) supply pump (6).
4. Lower the vehicle.

Note. For clarity purposes the Dosing Control Unit was removed from the frame mounting bracket.

1. Position the Diesel Exhaust Fluid (DEF) dosing control unit to bracket. Tighten bolts (1) to 12 N.m (106 in. lbs.) . NOTE: For clarity purposes the Dosing Control Unit was removed from the frame mounting bracket.
2. Connect the DEF dosing control unit (2) harness connector (1).
3. Connect both negative battery cables.

1. Install the rear tank strap (1). Tighten nut (2) to 54 N.m (40 ft. lbs.).
2. Install the front tank strap (1). Tighten nut (2) to 54 N.m (40 ft. lbs.).
3. Install the coolant control valve assembly (2). Tighten bolt (1) to 54 N.m (40 ft. lbs.).
4. Position and connect the DEF coolant lines (7) into routing clip (8).
5. Position and connect the DEF coolant lines (5) into routing clip (6).
6. Connect the DEF supply (3) and return (4) lines to DEF tank.
7. Connect the coolant supply (1) and return lines (2) to DEF tank.
8. Position the DEF tank into place, but not fully mounted.
9. Connect the coolant control valve harness connector (1).
10. Connect the wire harness loom retainers (2) to bracket.
11. Connect the DEF tank level/temperature sensor harness connector (1).
12. Install the DEF tank (2) into place. Tighten bolts (1) to 108 N.m (80 ft. lbs.).
13. Remove the transmission jack.
14. Connect the DEF supply (2) and return (3) lines to DEF supply pump.
15. Connect the DEF supply/return line heater harness connector (1).
16. Connect the fill tube (1) to DEF tank (2).
17. Connect the fill tube vent line (2) to fluid limit vent valve (1).
18. Clip coolant lines bracket (3) to frame rail and install push pin (4).
19. Connect the coolant lines (1 and 2) going to DEF tank.
20. Fill the cooling system. Refer to «STANDARD PROCEDURE - FILLING»(ref-457792-S00576723282012030200000) .
21. Connect both negative battery cables.

Scheme 54

1. Remove the Diesel Exhaust Fluid (DEF) filler tube cap.
2. Disconnect the fill tube vent line (2) from fluid limit vent valve (1).
3. Disconnect the fill tube (1) from DEF tank (2).
4. Remove screws and the DEF fill tube.

1. Install the Diesel Exhaust Fluid (DEF) fill tube and securely tighten fasteners.
2. Connect the fill tube (1) to DEF tank (2).
3. Connect the fill tube vent line (2) to fluid limit vent valve (1).
4. Install the DEF filler tube cap.

1. Lubricate the Diesel Exhaust Fluid (DEF) filter element O-rings.
2. Install the new DEF filter element (1) into the DEF supply pump.
3. Install the DEF filter cap (1). Tighten cap (1) to 20 N.m (177 in. lbs).
4. Connect both negative battery cables.

REMOVAL

Note. The Diesel Exhaust Fluid (DEF) supply and return lines share the same wire harness connectors. Servicing requires both lines to be removed together.

1. Disconnect both negative battery cables.
2. Disconnect the supply and return line heater harness connector (1).
3. Disconnect the supply (2) and return (3) line from the Diesel Exhaust Fluid (DEF) supply pump. Refer to «STANDARD PROCEDURE - QUICK-CONNECT FITTINGS»(ref-457834-S33306886662012030200000) .
4. Disconnect the fill tube vent line (2) from fluid limit vent valve (1). Refer to «STANDARD PROCEDURE - QUICK-CONNECT FITTINGS»(ref-457834-S33306886662012030200000) .
5. Disconnect the fill tube (1) from DEF tank (2). Refer to «STANDARD PROCEDURE - QUICK-CONNECT FITTINGS»(ref-457834-S33306886662012030200000) .
6. Position a transmission jack under DEF tank.
7. Remove bolts (1) and partially lower the DEF tank (2).
8. Disconnect the supply and return lines (7) from routing clip (8).
9. Disconnect and remove the supply (3) and return (4) lines from the DEF tank. Refer to «STANDARD PROCEDURE - QUICK-CONNECT FITTINGS»(ref-457834-S33306886662012030200000) .

Note. The Diesel Exhaust Fluid (DEF) supply and return lines share the same wire harness connectors. Servicing requires both lines to be removed together.

1. Connect and install the supply (3) and return (4) line to the Diesel Exhaust Fluid (DEF) tank.
2. Connect the supply and return lines (7) to routing clip (8).
3. Install the DEF tank (2). Tighten bolts (1) to 60 N.m (44 ft. lbs.).
4. Connect the fill tube (1) to DEF tank (2).
5. Connect the fill tube vent line (2) to fluid limit vent valve (1).
6. Connect the supply (2) and return (3) line to the DEF pump.
7. Connect the supply and return line heater harness connector (1).
8. Connect both negative battery cables.

1. Install the DEF pressure line (2) at injector (3).
2. Connect the DEF pressure line retainer at the frame rail and coolant lines (1).
3. Connect the DEF pressure line (1) at the DEF supply pump.
4. Connect the Diesel Exhaust Fluid (DEF) pressure line heater harness connector (2).
5. Connect both negative battery cables.

1. For Diesel Exhaust Fluid (DEF) return line removal, refer to «LINE, Diesel Exhaust Fluid Supply , Removal»(ref-457800-S26134489772012030200000) .

Note. The supply and return lines are serviced and removed together.

1. For Diesel Exhaust Fluid (DEF) return line installation, refer to «LINE, Diesel Exhaust Fluid Supply , Installation»(ref-457800-S06135126322012030200000) .

1. Install and connect the DEF ambient temperature sensor (1) to the harness connector (2).
2. Connect both negative battery cables.

1. Disconnect both negative battery cables.
2. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Disconnect the coolant lines (1 and 2) going to Diesel Exhaust Fluid (DEF) tank.
4. Remove push pin (4) and unclip coolant lines bracket (3) from frame rail.
5. Position a transmission jack under DEF tank.
6. Remove bolts (1) and partially lower the DEF tank (2).
7. Disconnect the DEF engine coolant control valve harness connector (1).
8. Disconnect the coolant supply (1) and return lines (2) from DEF tank.
9. Disconnect the coolant lines (5) at routing clip (6).
10. Remove bolt (1) and the DEF engine coolant control valve assembly (2).

1. Install the coolant control valve assembly (2). Tighten bolt (1) to 54 N.m (40 ft. lbs.) .
2. Position and connect the DEF coolant lines (5) into routing clip (6).
3. Connect the coolant supply (1) and return lines (2) to DEF tank.
4. Connect the coolant control valve harness connector (1).
5. Install the DEF tank (2) into place. Tighten bolts (1) to 108 N.m (80 ft. lbs.).
6. Remove the transmission jack.
7. Clip coolant lines bracket (3) to frame rail and install push pin (4).
8. Connect the coolant hoses (1 and 2) going to DEF tank.
9. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
10. Connect both negative battery cables.

1. Disconnect both negative battery cables.
2. Disconnect the CP sensor harness connector (7).
3. Remove bolt (6) and the CP sensor (5) from valve cover (4).

1. Check condition of sensor O-ring.
2. Install the CP sensor (5) into valve cover (4). Tighten bolt (6) to 3 N.m (27 in. lbs.) .
3. Connect the CP sensor harness connector (7).
4. Connect both negative battery cables.

Scheme 55

1. Disconnect both negative battery cable.
2. Disconnect exhaust gas pressure sensor harness connector (1).
3. Remove exhaust gas sensor (3).

1. Install exhaust gas pressure sensor (3). Tighten to 18 N.m (159 in. lbs.) .
2. Connect exhaust gas pressure sensor harness connector (1).
3. Connect both negative battery cable.

Scheme 56

The CCV system contains the following components

1. Cylinder Head Cover Assembly (7)
2. Breather Element (2)
3. Breather Cover (1)
4. Crankcase Pressure Sensor (3)
5. Crankcase Differential Regulator (CDR) Valve; a part of the breather filter cover (1)

The cylinder head cover assembly (7) is made of a composite material. The cover has a recessed area for the breather element and passages for oil draining from the breather element, back to the crankcase. The breather element is serviced separately. The drain tubes have one-way check valves (4), (5) and (6) that prevent oil from being forced up the tubes by excessive crankcase pressure. The external fittings to the breather tube and breather drain tube are serviceable.

Scheme 57

The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from siphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine.

The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2).

1. Obtain a new gasket (3). Before positioning the new gasket (3), be sure to clean mating surfaces at the top of air flow control valve and the bottom of air intake connection (2).
2. Install four mounting bolts (4) and (6). Tighten four bolts to 10 Nm (89 in. lbs.) .
3. Connect the electrical connector at point (2).
4. Connect the air cooler duct to bottom of air flow control valve. Install and tighten the duct clamp.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

1. Disconnect both negative battery cables.
2. Remove bolts (1) and the EGR crossover tube cover (2).
3. Loosen and remove two clamps (1 and 3) at ends of EGR crossover tube (2).
4. Disconnect the EGR temperature sensor harness connector (4).
5. Remove clamp mounting bolt (5) at center bottom of EGR crossover tube.
6. Remove EGR crossover tube (2).
7. Remove and discard gaskets at each end of tube (2).
8. Remove nuts (7) and remove upper heat shield (6).
9. Remove bolts (10), nut (8) and remove lower heat shield (9).
10. Remove bolts (5) and (14).
11. Separate the bypass valve (4) from exhaust transfer connection (15) and discard gasket (3).
12. Disconnect EGR bypass valve harness connector (1).
13. Remove bracket bolts (2) at outside of mounting bracket.
14. Remove bracket bolts at inside of mounting bracket.
15. Remove EGR cooler bypass valve assembly (1).

1. Clean gasket mating surfaces on castings (4) and (15).
2. Position EGR cooler bypass valve assembly to engine.
3. Position new gasket (3) between castings (4) and (15).
4. Install bolts (5) and (14). Do not tighten bolts at this time.
5. Install the inside bracket bolts (1). Tighten bolts (1) to 10 N.m (89 in. lbs.).
6. Install the outside bracket bolts (2). Tighten bolts (2) to 24 N.m (18 ft. lbs.).
7. Connect EGR bypass valve harness connector (1).
8. Tighten bolts (5) and (14) to 24 N.m (18 ft. lbs.).
9. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 10 N.m (89 in. lbs.).
10. Install upper heat shield (6) and nuts (7). Tighten nuts to 10 N.m (89 in. lbs.).
11. Clean each end of EGR crossover tube and its connection points of any old gasket material
12. Install new gaskets to each end of the EGR crossover tube (2).
13. Position EGR crossover tube (2) to engine.
14. Install bolt (5) finger tight at center bottom of the EGR crossover tube.
15. First, tighten EGR tube clamp (1) to 10 N.m (89 in. lbs.), then tighten clamp (3) to 10 N.m (89 in. lbs.).
16. Tighten EGR crossover tube bolt (5) to 10 N.m (89 in. lbs.).
17. Connect the EGR temperature sensor harness connector (4).
18. Install the EGR crossover tube cover (2). Tighten bolts (1) to 10 N.m (89 in. lbs.).
19. Connect and both negative battery cables.

Scheme 62

Scheme 63

1. Disconnect both negative battery cables.
2. Remove bolts (1) and the EGR crossover tube cover (2).
3. Loosen clamp (1). Remove clamp (3) at end of EGR crossover tube (2).
4. Remove bolt (5) at center bottom of EGR crossover tube.
5. Disconnect the EGR valve harness connector.
6. Remove the four EGR valve assembly mounting bolts (1).
7. Remove EGR valve assembly (2) from intake connector (3) by prying up.
8. Remove crossover tube gasket (1) and clean EGR valve. Also clean end of EGR tube of any old gasket material.
9. Remove two gaskets on bottom EGR valve (4). Clean bottom of EGR valve and top of its intake connection point of any old gasket material.

1. Connect vapor line quick-connect fitting (3) to solenoid.
2. Connect vapor line quick-connect fitting (4) to solenoid.
3. Connect electrical wiring connector (2) to solenoid.
4. Carefully push the solenoid assembly (1) straight down onto the tongue-type bracket without bending the two vapor lines.

Scheme 64

The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position.

Scheme 65

The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing.

Scheme 66

The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM.

The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum.

During refueling, pressure is built up in the evaporative system. When pressure reaches approximately.5 inches of water, the large check valve unseats and pressure vents to the fresh air filter.

Conversely, when the system cools, and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieves the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts.

The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks.

The ESIM weights seal the EVAP. system during engine off conditions. If the EVAP. system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1α - ? H20, the vacuum switch closes. The switch closure sends a signal to the PCM. In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events.

If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition.

Conditions for running the intrusive test are

1. After the vehicle is started, the engine coolant temperature must be within 50°F (10°C) of ambient to indicate a cold start.
2. The fuel level must be between 12% and 88%.
3. The engine must be in closed loop.
4. Manifold vacuum must be greater than a minimum specified value.
5. Ambient temperature must be between 39°F and 98°F (4°C and 37°C) and the elevation level must be below 8500 feet (2591 meters).

The test is accomplished by the PCM activating the purge solenoid to create a vacuum in the evaporative system. The PCM then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test.

Even when all of the thresholds are met, a small leak won't be recorded until after the medium/large leak monitor has been run. This is accomplished by the PCM activating the purge solenoid to create a vacuum in the evaporative system. The PCM then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. If the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated.

The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test.

Stage one of the purge monitor is non-intrusive. The PCM monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the PCM commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded.

The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the PCM sees 0 rpm's, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick closed monitor to run.

The PCM also uses the ESIM to detect a loose or missing gas cap. The PCM controller looks for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is set. On the PCM, this is a three-trip fault before the code matures

The ESIM (EVAP System Integrity Monitor) switch is attached to the EVAP canister and is usually not serviceable. Replace the switch by replacing the EVAP canister. Refer to the appropriate EVAP canister removal/installation information.

If servicing separately, refer to the following

Scheme 67

The ESIM switch (2) is located on the EVAP canister (1) The illustration displays a typical EVAP Canister and a typical ESIM switch.

Scheme 68

Scheme 69

Scheme 70

1. Remove both plastic lines from switch by folding line tabs (2).
2. Disconnect electrical connector at switch.
3. Clean any dirt from ESIM switch and its lines.
4. A lock tab (see arrow in illustration) is used on the back of the switch. Push lock tab towards switch while rotating switch counterclockwise 1/4 turn for removal.
5. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill.

The following illustrations display a TYPICAL EVAP Canister and a typical ESIM switch. After installing any ESIM switch, the electrical connector on the switch must be in the 3 O'clock position. This step must be done for proper ESIM switch operation.

1. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill.
2. Be sure O-ring (2) and EVAP canister opening are clean. 1 - EVAP Canister 2 - ESIM Switch 3 - Electrical Connector CAUTION: The electrical connector (4) on the ESIM switch must be in 3 O'clock position after installation. This step must be done for proper switch operation.
3. Position ESIM switch (2) into EVAP canister (1) and rotate until electrical connector is in 3 O'clock position (3).
4. Connect electrical connector.
5. Connect plastic lines to ESIM switch.

Scheme 71

The PCV valve is located at the rear of the left cylinder head.

Scheme 72

1. Remove line (1) and rubber connector hose from PCV valve.
2. Unthread PCV valve (3) from metal fitting (2).

Scheme 73

1. Check condition of PCV valve rubber O-ring (2).
2. Clean fitting (2).
3. Install PCV valve (3) into fitting (2).
4. Install PCV line (1) and rubber connector to valve.

Scheme 74

The PCV valve (2) is mounted into the top/rear of the left valve cover.

1. Disconnect plastic line (1) from end of PCV valve.
2. Use a small screwdriver to disengage PCV valve from valve cover.

1. Clean out PCV valve opening at valve cover.
2. Check condition of PCV valve o-ring.
3. Apply engine oil to o-ring.
4. Place PCV valve (2) into valve cover.
5. Attach plastic line (1) to valve.

Scheme 75

The PCV valve (4) is mounted into the top of the intake manifold (1). This is located to the right / rear of the throttle body (2).

Scheme 76

1. The PCV valve is sealed to the intake manifold with 2 O-rings (2).
2. Remove PCV valve by rotating counter-clockwise 90 degrees until locating tabs (3) have been freed. After tabs have cleared, pull valve straight up from intake manifold.
3. After valve is removed, check condition of 2 valve O-rings (2).

1. Clean out intake manifold opening.
2. Check condition of two o-rings on PCV valve.
3. Apply engine oil to two o-rings.
4. Place PCV valve into intake manifold and rotate 90 degrees clockwise for installation.

1. Clean gasket area (1) at rear of left cylinder head where it joins base of EGR valve.
2. Clean EGR tube where it joins EGR valve.
3. Position new gasket between EGR valve and cylinder head.
4. Position EGR valve to cylinder head. Install and tighten two bolts (2). Torque to 9 N.m (80 in. lbs.).
5. Position new gasket (3) between EGR tube flange and EGR valve assembly.
6. Position EGR tube (1) to side of EGR valve. Position end of tube (6) into intake manifold. Install two bolts (2). Torque to 11 N.m (8.5 ft. lbs.).
7. Connect electrical connector (3) to top of EGR valve solenoid (1).
8. Connect negative battery cable.
9. Using a diagnostic scan tool, erase any previously recorded DTC's (Diagnostic Trouble Codes).

Scheme 77

The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head. An exhaust gas routing tube connects the EGR valve to the intake manifold.

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. Use a diagnostic scan tool to record any Diagnostic Trouble Codes (DTC).
2. Remove the throttle body resonator.
3. Perform the fuel system pressure release procedure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-457834-S40414819692012030200000) .
4. Disconnect and isolate the negative battery cable.
5. Disconnect the power brake booster vacuum hose (1) and the vapor canister purge hose (2) at the intake manifold.
6. Disconnect the EGR valve solenoid electrical connector (1).
7. Remove the EGR valve assembly retaining bolts (1).
8. Remove the EGR valve and the EGR routing tube from the engine as an assembly.
9. Remove and discard the metal gasket located between the cylinder head and the EGR valve assembly.
10. Remove the EGR valve routing tube retaining bolts (1) at the EGR valve assembly
11. Remove the EGR valve routing tube and discard the gasket.

Scheme 82

1. Clean the EGR valve mounting surface of the left cylinder head.
2. Clean the EGR valve surface where it joins the left cylinder head.
3. Clean the EGR valve surface where it joins the EGR valve routing tube.
4. Clean the EGR valve routing tube surface where it joins the EGR valve.
5. Install a new O-ring gasket on the EGR vale routing tube.
6. Position a new gasket between the EGR valve routing tube flange and the EGR valve assembly.
7. Position the EGR valve routing tube to the EGR valve assembly, install retaining bolts (1) and tighten to 11 N.m (8 ft. lbs.).
8. Position the new EGR valve gasket on the cylinder head.
9. Position the EGR valve routing tube into the intake manifold until the EGR valve routing tube flange (1) is flush with the intake manifold.
10. Align the EGR valve to the cylinder head while holding the EGR valve gasket in place.
11. Install the EGR valve assembly retaining bolts (1) and tighten to 9 N.m (80 in. lbs.).
12. Connect the EGR valve solenoid electrical connector (1).
13. Connect the fuel line to the fuel rail.
14. Connect the power brake booster vacuum hose (1) and the vapor canister purge hose (2) at the intake manifold.
15. Install the throttle body resonator.
16. Connect the negative battery cable.
17. Using a diagnostic scan tool, erase any previously recorded DTC's.

Scheme 83

The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold.

Scheme 84

1. Use a diagnostic scan tool to record any DTC's (Diagnostic Trouble Codes).
2. Disconnect and isolate the negative battery cable.
3. Disconnect electrical connector (1) from EGR solenoid (2).
4. Remove two bolts (3) connecting EGR tube (4) to valve assembly.
5. Remove gasket located between EGR tube flange and EGR valve assembly.
6. Remove two mounting bolts (2).
7. Separate valve assembly (3) from cylinder head (1).
8. Remove and discard metal gasket located between cylinder head and valve assembly.

1. Position a new metal gasket between cylinder head (1) and valve assembly (3).
2. Install two mounting bolts (2) and tighten to 20 ft. lbs. (27 N.m).
3. Clean EGR tube where it joins EGR valve.
4. Position new gasket between EGR tube flange and EGR valve assembly.
5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts to 20 ft. lbs. (27 N.m).
6. Connect electrical connector (1) to EGR solenoid (2).
7. Connect negative battery cable.
8. Using a diagnostic scan tool, erase any previously recorded DTC's (Diagnostic Trouble Codes).