EGR Valve: Service and Repair

Exhaust Gas Recirculation (EGR) Valve - 6.0L Diesel

















Removal

1. Disconnect the battery ground cable. For additional information, refer to Battery.

2. Remove the 6 pushpin retainers and upper air deflector.





3. Remove the 4 bolts for the power steering bracket.





4. Remove the 3 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 (ACL) outlet pipe.





6. NOTE: ACL side shown, other side similar.

Loosen the clamps and remove the ACL outlet pipe.





7. Loosen the clamps and remove the Charge Air Cooler (CAC) tube.





8. Remove the 2 bolts and position the Manifold Absolute Pressure (MAP) sensor and the ground wire aside.





9. Remove the 3 bolts and disconnect the pushpin retainer. Position the cowl wiring harness aside.





10. Loosen the clamp for the CAC tube.





11. Remove the 3 bolts for the CAC tube and oil fill tube.





12. Remove the engine cover.

13. Loosen the clamp at the CAC tube.





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





15. Remove the 2 retaining nuts, CAC tube, oil fill tube and bracket.





16. NOTE: Intake manifold removed for clarity.

Remove the 4 bolts and intake adapter.

- Cover the opening after the intake adapter is removed.





17. Remove the EGR baffle and gasket.





18. Remove the secondary fuel filter and drain the housing. Install the fuel filter and cover.
- Tighten to 14 Nm (124 lb-in).





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





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





21. NOTE: The EGR valve assembly has an internal EGR position sensor.

Disconnect the EGR valve assembly electrical connector.

22. NOTICE: Do not attempt to remove the Exhaust Gas Recirculation (EGR) valve without the use of the EGR Valve Remover Tool or damage to the EGR valve may occur.

Remove the 2 bolts and rotate the EGR valve counterclockwise.

23. Install the EGR Valve Remover and remove the EGR valve.





24. Remove and discard the O-ring seals and the EGR gasket.





25. Using the Injector Sleeve Brush Set, 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 2 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. NOTICE: Failure to completely seat the Exhaust Gas Recirculation (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 (115 lb-in).

5. Connect the EGR valve assembly electrical connector.

6. NOTE: Inspect the gasket for gouges and damage. Replace the gasket as necessary.

Install the gasket and EGR baffle.





7. NOTE: Clean and inspect the gasket. Install a new gasket if necessary.

Install the intake adapter and 4 bolts.

- Tighten to 13 Nm (115 lb-in).





8. NOTICE: Use care not to damage the turbocharger outlet hose when installing the Charge Air Cooler (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 2 retaining nuts.





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





10. Install the 3 bolts for the CAC tube and oil fill tube.





11. Tighten the clamp for the CAC tube.
- Tighten to 12 Nm (106 lb-in).





12. Install the engine cover.

13. Tighten the clamp for the CAC tube.
- Tighten to 12 Nm (106 lb-in).





14. Position the cowl wiring harness. Install the 3 bolts and connect the pushpin retainer.
- Tighten to 2 Nm (18 lb-in).





15. 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).





16. Install the CAC tube and tighten the clamps.
- Tighten to 12 Nm (106 lb-in).





17. NOTE: ACL side shown, other side similar.
Install the ACL outlet pipe and tighten the clamps.





18. Connect the coolant hoses to the ACL outlet pipe.





19. Remove the power steering fluid indicator. Install the power steering reservoir mounting bracket and 3 bolts, then install the power steering fluid indicator.





20. Install the 4 bolts for the power steering reservoir bracket.





21. Install the upper air deflector and 6 pushpin retainers.





22. Connect the battery ground cable. For additional information, refer to Battery.