EGR Valve: Service and Repair

EGR Valve Replacement:

WARNING: EGR components transport hot exhaust gases. Contact with hot EGR components may cause severe burns. Wear protective gloves or allow the vehicle sufficient time to cool.

1. Disconnect the EGR tube from the EGR valve.
2. Disconnect the EGR Valve Position (EVP) sensor electrical connector from the EVP sensor.
3. Remove the vacuum line from the EGR valve.
4. Remove the two EGR mounting bolts and remove the EGR valve from the engine.
5. Clean the mating surfaces being careful not to let gasket material enter the intake manifold.
6. If replacing the EGR valve remove the EVP sensor and install it on the new valve.
7. Using a new gasket, install the EGR valve and mounting bolts. Torque the bolts to 17-25 lbs. ft. (19-29 N-m).
8. Connect the EVP sensor electrical connector to the EVP sensor.
9. Connect the EGR tube to the EGR valve. Torque the nut to 25-35 lbs. ft. (34-48 N-m).
10. Install the vacuum line on the EGR valve.
11. START the engine and check for exhaust leaks.