EGR Valve: Service and Repair

EXHAUST GAS RECIRCULATION (EGR) VALVE

Special Tool(s):

Special Tool(s)







Removal
1. Disconnect the battery ground cable.







2. Remove the pushpin retainers and upper air deflector.







3. Remove the bolts for the power steering bracket.







4. Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position it aside.







5. Disconnect the coolant hoses from the air cleaner outlet tube.







6. NOTE: Air cleaner side shown, other side similar.

Loosen the clamps and remove the air cleaner outlet tube.







7. Loosen the clamps and remove the charge air cooler (CAC) duct.







8. Remove the bolts and position the manifold absolute pressure (MAP) sensor and the ground wire aside.







9. Remove the bolts and disconnect the pushpin retainer. Position the cowl wiring harness aside.







10. Loosen the clamp for the CAC duct.







11. Remove the bolts for the CAC tube and oil fill tube.
12. Remove the engine cover.







13. Loosen the clamp at the turbocharger outlet hose.







14. Disconnect the oil fill tube at the valve cover.







15. Remove the retaining nuts, CAC tube, oil fill tube and bracket.







16. NOTE: Intake manifold removed for clarity.

Remove the bolts and intake adapter.
- Cover the opening after the intake adapter is removed.







17. Remove the secondary fuel filter and drain the housing.Install the fuel filter and cover.
- Tighten to 14 Nm (10 lb-ft).







18. Disconnect the fuel tubes at the secondary fuel filter and position them aside.







19. Remove the 2 bolts and position the secondary fuel filter assembly aside.

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

Disconnect the EGR valve assembly electrical connector.

21. CAUTION: Do not attempt to remove the EGR valve without the use of the EGR valve removal tool or damage to the EGR valve will occur.

Remove the bolts and rotate the EGR valve counterclockwise.







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







23. Remove and discard the O-ring seals and the EGR gaskets.
24. Using the appropriate brush, clean the EGR port. Vacuum the ash and foreign material from inside the intake manifold.

Installation







1. Position the secondary fuel filter housing and install the bolts.
- Tighten to 24 Nm (18 lb-ft).







2. Connect the fuel tubes at the secondary fuel filter.
- Tighten to 26 Nm (19 lb-ft).







3. Install a new EGR gasket. Install new O-ring seals and lubricate with clean engine oil.

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

Position the EGR valve and install the 2 bolts.
- Tighten to 13 Nm (10 lb-ft).

5. Connect the EGR valve assembly electrical connector.







6. NOTE: Clean and inspect the gasket.

Install a new gasket if necessary. Install the intake adapter and bolts.
- Tighten to 13 Nm (10 lb-ft).







7. CAUTION: Use care not to damage the turbocharger outlet hose when installing the CAC tube.

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

Install the CAC tube, oil fill tube, bracket and retaining nuts.







8. Connect the oil fill tube at the valve cover.







9. Install the bolts for the CAC tube and oil fill tube.







10. Tighten the clamp for the turbocharger outlet pipe.
- Tighten to 12 Nm (9 lb-ft).

11. Install the engine cover.







12. Tighten the clamp for the CAC duct.
- Tighten to 12 Nm (9 lb-ft).







13. Position the cowl wiring harness. Install the bolts and connect the pushpin retainer.
- Tighten to 2 Nm (18 lb-in).







14. Position the MAP sensor and install the bolt. Position the ground wire and install the bolt.
1 Tighten the MAP sensor bolt to 5 Nm (44 lb-in).
2 Tighten the ground wire bolt to 8 Nm (71 lb-in).







15. Install the CAC duct and tighten the clamps.
- Tighten to 12 Nm (9 lb-ft).







16. NOTE: Air cleaner side shown, other side similar.

Install the air cleaner outlet tube and tighten the clamps.







17. Connect the coolant hoses to the air cleaner outlet tube.







18. Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and bolts, then install the power steering fluid indicator.







19. Install the bolts for the power steering reservoir bracket.







20. Install the upper air deflector and pushpin retainers.
21. Connect the battery ground cable.