EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE












REMOVAL







1. Disconnect the EGR valve electrical connector.







2. Disconnect the charge air cooler tube.







3. Remove the intake adapter.

NOTE: Intake manifold removed for clarity.







4. Remove the throttle plate adapter.







5. Remove the bolts and rotate the EGR valve counterclockwise.

CAUTION: Do not pull the EGR valve out or damage to the EGR valve will occur.







6. Install the special tool and remove the EGR valve.







7. Remove and discard the O-rings.
8. Using an appropriate brush, clean the EGR port. Vacuum out the ash and foreign material from inside the intake manifold.

INSTALLATION







1. Install new O-rings and lubricate with clean engine oil.







2. Install the EGR valve and bolts.







3. Install the throttle plate adapter.







4. Install the intake adapter.







5. Install the charge air cooler tube.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.






6. Connect the EGR valve electrical connector.