GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Tracker - 4WD 🢒 Engine 🢒 Engine Controls - 1.6L 🢒 Exhaust Gas Recirculation Valve Pipe Replacement

Removal Procedure

    Object Number: 615485 Size: SH
  1. Allow the engine to cool down.
  2. Remove the two (3) fasteners.
  3. Remove the fastener (5) at the middle of the exhaust gas recirculation (EGR) pipe (4).
  4. Remove the two fasteners (6) near the EGR valve.
  5. Remove the upper gasket (2) and the lower gasket (7).
  6. Remove the EGR pipe (4).
  7. Clean any remaining gasket material from both contacting surfaces.

Installation Procedure

    Object Number: 615485 Size: SH
  1. Install the EGR pipe (4) with a new upper gasket (2) and a new lower gasket (7) to the intake manifold.

    2. 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 pipe (4) to the upper intake manifold with the two fasteners (3).

    3. Tighten
    Tighten the fasteners to 15 N·m (11 lb ft).

  3. Secure the EGR pipe (4) to the lower intake manifold with the two fasteners (6).

    4. Tighten
    Tighten the fastener to 10 N·m (88 lb in).

  4. Install the fastener (5) to the EGR pipe bracket.

    5. Tighten
    Tighten the fastener to 10 N·m (88 lb in).

  5. Start the engine and check for exhaust leaks.
  6. Repair as necessary.