Remove and replace the EGR valve on a 2018-2024 Toyota Camry 2.5L I4 engine to restore proper exhaust gas recirculation function.

Warnings

Tools required

Parts

• EGR valve assembly × 1 — Use OEM Toyota part number for 2.5L A25A-FKS engine
• EGR valve gasket × 1 — Use OEM specification
• EGR tube gasket × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on all four corners to release mounting grommets
4. Take photos of electrical connector orientation and vacuum line routing for reference during reassembly

Procedure

1. 1

   Disconnect EGR valve electrical connector
   Locate the EGR valve on the passenger side of the engine near the intake manifold. Press the locking tab on the electrical connector and pull straight out to disconnect. Move the harness aside to provide clearance.
2. 2

   Remove engine cover screws if present
   Some models have small cover screws securing decorative covers near the EGR area. Remove these screws and set covers aside for reassembly.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect EGR tube fitting
   Using a 14mm socket, loosen and remove the EGR tube fitting that connects the EGR valve to the exhaust manifold. If the fitting is difficult to turn, apply penetrating oil and wait 10 minutes. The tube may need to be gently wiggled to break the gasket seal.
   ⚠The EGR tube fitting may be carbon-fouled. Do not force if seized - apply heat or additional penetrating oil as needed.
   Torque spec

   EGR Tube Fitting35 Nm (26 lb-ft)
4. 4

   Remove EGR valve mounting bolts
   Using a 12mm socket with extension, remove the two EGR valve mounting bolts that secure the valve to the intake manifold. Support the EGR valve with one hand while removing the final bolt to prevent it from falling.
   Torque spec

   EGR Valve Bolts25 Nm (18 lb-ft)
5. 5

   Remove EGR valve assembly
   Carefully pull the EGR valve away from the intake manifold. The valve may be stuck due to carbon buildup on the gasket surface. Gently twist while pulling if needed. Remove and discard the old EGR valve gasket.
6. 6

   Clean mounting surfaces
   Use a wire brush or plastic scraper to clean carbon deposits from the EGR valve mounting surface on the intake manifold and the EGR tube connection point. Wipe surfaces clean with a shop rag. Ensure no debris falls into the intake manifold opening.
   ⚠Cover the intake manifold opening with a clean rag while cleaning to prevent carbon debris from entering the engine.
7. 7

   Inspect EGR tube
   Examine the EGR tube for cracks, excessive carbon buildup, or damage. Replace if compromised. Remove and discard the old EGR tube gasket.
8. 8

   Install new EGR tube gasket
   Position the new EGR tube gasket on the EGR valve mounting surface. Ensure the gasket is properly seated in the locating groove.
9. 9

   Install new EGR valve
   Place the new EGR valve gasket on the intake manifold mounting surface. Position the new EGR valve assembly onto the intake manifold, aligning the mounting bolt holes. Start both mounting bolts by hand to ensure proper thread engagement.
10. 10

    Torque EGR valve mounting bolts
    Using a torque wrench, tighten the EGR valve mounting bolts in a cross pattern to ensure even gasket compression. Torque to specification.
    Torque spec

    EGR Valve Bolts25 Nm (18 lb-ft)
11. 11

    Reconnect EGR tube fitting
    Install a new EGR tube gasket if applicable. Align the EGR tube with the valve and start the fitting by hand. Use a torque wrench with 14mm socket to tighten the EGR tube fitting to specification.
    Torque spec

    EGR Tube Fitting35 Nm (26 lb-ft)
12. 12

    Reconnect electrical connector
    Push the electrical connector onto the EGR valve until you hear and feel a positive click. Gently tug on the connector to verify it is securely locked in place.
13. 13

    Reinstall engine covers
    If removed earlier, reinstall any engine covers and secure with cover screws torqued to specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reinstall engine cover by aligning mounting grommets and pressing firmly until seated
2. Reconnect negative battery terminal and tighten securely
3. Do not start the engine until verification procedures are complete

Verification

• Turn ignition to ON position (do not start engine) and verify no warning lights illuminate on dashboard
• Start the engine and allow it to idle for 2 minutes, listening for vacuum leaks or abnormal sounds near the EGR valve
• Rev engine gently to 2000 RPM and verify smooth operation with no hesitation
• Use an OBD-II scanner to verify no EGR-related fault codes are present (P0400-P0409 range)
• Perform a test drive and verify normal acceleration and no check engine light illumination
• After test drive, inspect EGR valve connections for any signs of exhaust or vacuum leaks while engine is at operating temperature

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