Exhaust Gas Recirculation (EGR) Cooler Bypass Valve - Removal

REMOVAL





The EGR Cooler Bypass Valve Assembly (1) is mounted between the EGR crossover tube and the EGR cooler. Two mechanical cables (3) join the units together. An electrical drive servo (4) moves the cables (3) to operate a butterfly plate (2) within a cast manifold.

Parts 1, 2, 3 and 4 are serviced as one entire assembly. Do not attempt to disassemble unit.

1. Disconnect both negative battery cables.





2. Remove four bolts (1) and remove engine cover.





3. Loosen and remove two clamps (1) and (6) at ends of EGR crossover tube.
4. Remove clamp mounting bolt (3) at center of EGR crossover tube.
5. Remove EGR Crossover Tube (4).
6. Remove and discard gaskets at each end of tube (2) and (5).





7. Remove nuts (7) and remove upper heat shield (6).
8. Remove bolts (10), nut (8) and remove lower heat shield (9).
9. Remove bolts (5) and (14).
10. Separate the bypass valve (4) from exhaust transfer connection (15) and discard gasket (3).





11. Disconnect electrical connector (1).
12. Remove bracket bolts (2) at outside of mounting bracket.





13. Remove bracket bolts at inside of mounting bracket.





14. Remove EGR cooler bypass valve assembly (1) from engine.