GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 RELAY Ext. 🢒 Engine 🢒 Engine Controls - 3.5L (LX9) 🢒 Exhaust Gas Recirculation Valve Replacement

Removal Procedure

    Object Number: 1544746 Size: SH
  1. Remove the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement .
  2. Disconnect the electrical connector (1) from the exhaust gas recirculation (EGR) valve (2).
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the transaxle fill tube bolt to the transaxle case.
  5. Remove the transaxle fill tube nut at the EGR valve and reposition the fill tube.
  6. Lower the vehicle.

    7. Object Number: 1239053 Size: SH
  7. Remove the EGR pipe bolt and carefully pull the pipe assembly back.
  8. Remove the EGR valve bolts.
  9. Remove EGR valve.
  10. Remove the EGR valve gasket.
  11. 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: Refer to Fastener Notice in the Preface section.

  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).


    Object Number: 1544746 Size: SH
  6. Connect the electrical connector (1) to the EGR valve (2).
  7. Raise the vehicle.
  8. Position the transaxle fill tube to the normal installed position and install the fill tube nut at the EGR valve.

    9. Tighten
    Tighten the nut to 113 N·m (115 lb in).

  9. Install the transaxle fill tube bolt to the transaxle case.

    10. Tighten
    Tighten the bolt to 113 N·m (115 lb in).

  10. Lower the vehicle.
  11. Install the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement .