#### REMOVAL & INSTALLATION

##### Bimetal Vacuum Switching Valve (BVSV)

The Bimetal Vacuum Switching Valve (BVSV) is threaded into the Idle Speed Control (ISC) valve bolted to the throttle body.

Fig. 1: The BVSV is threaded into the IAC bolted to the throttle body

1. Drain the coolant from the system into a suitable container.
2. Unscrew the BVSV from the Idle Speed Control (ISC) valve.

   To install:

3. Apply liquid sealer to the first 2–3 threads of the BVSV. Carefully thread the valve into the ISC and first tighten the valve to 9 ft. lbs. (12), then tighten the valve until it reached this position. Maximum torque of the valve is 25 ft. lbs. (34 Nm).

   NOTE: Do not rotate the valve counter-clockwise in order to align the port as shown.

   Fig. 2: On the second pass of tightening the BVSV, ensure the valve faces between this angle

4. Fill the cooling system. Start the engine, check and top off the fluid level.

##### Thermal Vacuum Valve (TVV)

The Thermal Vacuum Valve (TVV) is threaded into the IAC valve bolted to the throttle body. Note the position of the valve prior to removal, it must be facing the same direction on installation.

1. Drain the coolant the from the engine.
2. Disconnect the vacuum hoses from the charcoal canister and throttle body.
3. Remove the TVV from the Intake Air Control (IAC).

   To install:

4. Apply adhesive to 2 or 3 of the threads of the TVV, first tighten the valve to 9 ft. lbs. (12 Nm), then tighten it to 25 ft. lbs. (34 Nm) in the position it was removed from.

   Fig. 3: Apply adhesive to the first 2 or 3 threads of the valve prior to installation

5. Reattach the vacuum hoses.
6. Refill the cooling system. Start the engine, check and top off the fluid level.

##### Vacuum Switching Valve (VSV)

Disconnect the wiring from the VSV. Label and removed the vacuum hoses from the valve. Loosen the nut and extract the VSV from the No. 2 air inlet duct.

##### EGR Gas Temperature Sensor

The EGR gas temperature sensor is located near the EGR valve usually threaded into the intake manifold.

1. Remove the engine access hole cover.
2. Located the EGR gas temperature sensor and unscrew it from the engine. If the old gasket is unreusable, discard it
3. Install a new gasket if necessary. place the sensor into position and tighten to 14 ft. lbs. (20 Nm).
4. Install the remaining components.

##### Check Valve

1. Remove the check valve from the engine.
2. Blow air into the orange side of the pipe and check for air flow from the orange side.

   Fig. 4: Testing the check valve for air flow on each side

3. Blow air into the orange side of the pipe and check that no air flows from the black side.
4. If the testing is not as specified, replace the check valve.
5. Reinstall the check valve with the orange side facing the No. 2 air inlet duct side.

   Fig. 5: Only install the check valve with the orange side facing the No. 2 air inlet duct

##### EGR Valve

NOTE: To access and remove the EGR valve the engine must be lowered and the both motor mounts removed.

1. Drain the coolant from the engine.
2. Remove the left engine access hole cover.
3. Remove the motor mount bolts and nuts.
4. Jack up the engine and remove the motor mounts.
5. Slowely lower the engine being careful not to rest the engine weight on the oil filter housing. Place a block of wood where the motor mounts had been to support the engine.
6. Label and disconnect the vacuum hoses from the throttle body to the EGR valve.
7. Label and disconnect the vacuum modulator hose.

   Fig. 7: Remove the union nut, EGR nuts 91) and by-pass hoses (2)

8. Remove the bolt holding the EGR pipe and intake manifold.
9. Remove the 3 nuts and bolt, then extract the EGR valve with the pipe from the intake manifold and cylinder head.
10. Inspect and discard if necessary the gasket fro the valve.

    To install:

11. Install two new gaskets and the EGR valve with the pie attached to the intake manifold and cylinder head. Tighten the three nuts and bolt to 13 ft. lbs. (18 Nm).
12. Install the bolt holding the EGR pipe to the intake manifold and tighten to 13 ft. lbs. (18 Nm).
13. Connect the No. 3 and 4 water by-pass hoses.
14. Insatall the EGR vacuum modulator and bracket with the two bolts and tighten to 9 ft. lbs. (12 Nm).
15. Attach the vacuum modulator hose. connect the three vacuum hoses to the No. 1 vacuum pipe.

##### EGR Vacuum Modulator

1. Unbolt the vacuum modulator bracket and extract.
2. Label and disconnect the hoses attached to the modulator.
3. Pull the clips apart and remove the modulator.

   To install:

4. Insert the modulator into the bracket clips.
5. Attach the hoses in their proper positions.

   Fig. 8: The throttle body ports are marked for the proper hoses

6. Postion the bracket/modulator assembly on the engine and secure the mounting bolts to 9 ft. lbs. (12 Nm).