EGR Valve: Service and Repair
EXHAUST GAS RECIRCULATION (EGR) VALVERemover, EGR Valve:
Special Tool(s)
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.
2. Loosen the clamp and disconnect the charge air cooler duct.
Early build vehicles
3. Disconnect the throttle position (TP) control module electrical connector.
4. Disconnect the TP sensor electrical connector.
5. NOTE: Intake manifold removed for clarity.
Remove the intake adapter.
6. Remove the throttle plate adapter.
Late build vehicles
7. NOTE: Intake manifold removed for clarity.
Remove the intake adapter.
All vehicles
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. 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.
Late build vehicles
3. NOTE: Clean and inspect the gasket. Install a new gasket, if necessary.
Install the intake adapter.
Early build vehicles
4. NOTE: Clean and inspect the gaskets. Install new gaskets if necessary.
Install the throttle plate adapter.
5. Install the intake adapter.
6. Connect the TP sensor electrical connector.
7. Connect the TP control module electrical connector.
All vehicles
8. Install the charge air cooler duct and tighten the clamp.
9. Connect the EGR valve assembly electrical connector.