GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 3.5L (LX9) 🢒 Exhaust Gas Recirculation Valve Replacement

Removal Procedure

    Object Number: 1239053 Size: SH
  1. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  2. Remove the EGR pipe bolt and carefully pull the pipe assembly back.
  3. Remove the EGR valve bolts.
  4. Remove EGR valve.
  5. Remove the EGR valve gasket.
  6. Clean and inspect the EGR valve gasket mating surfaces.

Installation Procedure

    Object Number: 1239053 Size: SH
  1. Install a new EGR valve gasket.
  2. Install the EGR valve.

    3. 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.

  3. Install the EGR valve bolts.

    4. Tighten
    Tighten the bolt to 30 N·m (22 lb ft).

  4. Install the EGR pipe to the EGR valve.
  5. Install the EGR pipe .

    6. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  6. Connect the EGR valve electrical connector.