GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Prix 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Exhaust Gas Recirculation Inlet Pipe Replacement

Removal Procedure

    Object Number: 911016 Size: SH
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement for the 3.8L engine.
  2. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 1 Replacement .
  3. Remove the exhaust manifold heat shield bolts (2).
  4. Remove the exhaust manifold heat shield.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    6. Object Number: 911025 Size: SH
  6. Remove the exhaust gas recirculation (EGR) valve inlet adapter pipe mounting bolt (1) from the exhaust manifold.
  7. Lower the vehicle.
  8. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  9. Remove the EGR valve outlet pipe. Refer to Exhaust Gas Recirculation Outlet Pipe Replacement .

    10. Object Number: 911021 Size: SH
  10. Remove the EGR valve inlet adapter pipe bolts (2).
  11. Remove the EGR valve inlet adapter pipe (1).

Installation Procedure

    Object Number: 911021 Size: SH
  1. Install the EGR valve inlet adapter pipe (1).

    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. Install the EGR valve inlet adapter pipe bolts (2).

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  3. Raise the vehicle.

    4. Object Number: 911025 Size: SH
  4. Install the EGR valve inlet adapter pipe bolt (1) to the exhaust manifold.

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

  5. Lower the vehicle.
  6. Install the EGR valve outlet pipe. Refer to Exhaust Gas Recirculation Outlet Pipe Replacement .
  7. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .

    8. Object Number: 911016 Size: SH
  8. Install the exhaust manifold heat shield.
  9. Install the exhaust manifold heat shield bolts (2).

    10. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  10. Install the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 1 Replacement .
  11. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement for the 3.8L engine.