EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE












REMOVAL

All vehicles







1. NOTE: The exhaust gas recirculation (EGR) valve assembly has an internal exhaust gas recirculation position (EGRP) sensor.

Disconnect the EGR valve assembly electrical connector.

Early build







2. Loosen the clamp and disconnect the charge air cooler duct.

Late build







3. Loosen the clamp and disconnect the charge air cooler duct.

All vehicles







4. Disconnect the throttle position (TP) control module electrical connector.







5. Disconnect the TP sensor electrical connector.







6. NOTE: Intake manifold removed for clarity.

Remove the intake adapter.







7. Remove the throttle plate adapter.







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

Remove the bolts and rotate the EGR valve counterclockwise.







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







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

INSTALLATION

All vehicles







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







2. CAUTION: Failure to completely seat the EGR valve into the intake manifold before inserting the mounting bolts may result in engine damage.

Install the EGR valve and bolts.







3. NOTE: Clean and inspect the gaskets. Install new gaskets if necessary.

Install the throttle plate adapter.







4. Install the intake adapter.







5. Connect the TP sensor electrical connector.







6. Connect the TP control module electrical connector.

Early build







7. 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.

Install the charge air cooler duct and tighten the clamps.

Late build







8. 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.

Install the charge air cooler duct and tighten the clamp.

All vehicles







9. Connect the EGR valve assembly electrical connector.