:	Jul 11, 2007

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Disconnect the battery ground cable.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Drain the cooling system.

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Remove the auxiliary battery tray.

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Remove the RH exhaust gas recirculation (EGR) valve outlet tube.

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Remove the fuel line bracket.   Release the fuel lines.   Remove the bolt.

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Disconnect the EGR valve electrical connector.

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Disconnect the coolant inlet hose from the EGR valve.   Release the clip.

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Disconnect the coolant outlet hose from the EGR valve.   Remove the bolt.   Release the clip.

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Remove the EGR valve inlet tube.   Release the clip.   Remove the 2 bolts.   Remove and discard the gasket.   Remove and discard the clip.

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Remove the RH front wheel and tire.

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Remove the upper suspension arm and brake line heat shields for access.

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Remove the RH EGR valve and cooler assembly.   Remove the 3 bolts.

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Remove the RH exhaust manifold heat shield.   Remove the 3 bolts.

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Remove the 2 exhaust cross-over pipe nuts.

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Remove the remaining exhaust cross-over pipe nut.

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Remove the RH exhaust manifold.   Remove the 6 nuts.   Remove and discard the gasket.   Remove and discard the studs.

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Tighten the exhaust manifold studs to 13 Nm (10 lb.ft).   Install a new gasket.

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:   Tighten the retaining nuts in the sequence shown. Install the RH exhaust manifold.   Tighten the nuts to 24 Nm (18 lb.ft).

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Tighten the exhaust cross-over pipe nut to 24 Nm (18 lb.ft).

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Tighten the 2 exhaust cross-over pipe nuts to 24 Nm (18 lb.ft).

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Install the RH exhaust manifold heat shield.   Install the bolts and tighten to 10 Nm (7 lb.ft).

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Install the RH EGR valve and cooler assembly.   Install the EGR valve bolts, but do not fully tighten at this stage.

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:   Do not fully close the retaining clip at this stage. Install the EGR valve inlet tube.   Install a new gasket.   Install a new clip.   Loosely install the 2 EGR valve inlet tube bolts.

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Fully close the clip.

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Tighten the two EGR valve inlet tube bolts to 10 Nm (7 lb.ft).

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Tighten the three EGR valve bolts to 10 Nm (7 lb.ft).

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Install the upper suspension arm and brake line heat shields.

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Install the wheel and tire.

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Tighten the EGR valve bolt to 10 Nm (7 lb.ft).

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Connect the coolant outlet hose to the EGR valve.

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Connect the coolant inlet hose to the EGR valve.

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Connect the EGR valve electrical connector.

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Install the fuel line bracket.   Install the fuel line retaining bracket bolt and tighten to 10 Nm (7 lb.ft).   Secure the fuel lines.

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Install the RH EGR valve outlet tube.

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Install the auxiliary battery tray.

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Connect the battery ground cable.

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Fill and bleed the cooling system.