EGR Valve: Service and Repair

Exhaust Gas Recirculation Valve Replacement

Tools Required

J 43181 Quick Connect Connector Removal Tool

Removal Procedure




1. Remove the generator.
2. Remove the intake manifold tube.
3. Remove the right exhaust pipe.
4. Remove the crankcase ventilation hose/pipe.
5. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill).
6. Remove the heater inlet pipe bracket bolt (1).
7. Using the J 43181 , disconnect the exhaust gas recirculation (EGR) cooler hose fitting (2) from the heater inlet pipe.




8. Reposition the EGR cooler pipe clamp (1) and remove the EGR cooler pipe hose from the EGR cooler tube.




9. Disconnect the engine wiring harness electrical connector (1) from the EGR valve.




10. Remove the EGR valve/cooler tube assembly bolts and nut.
11. Remove the EGR valve/cooler tube assembly from the engine and place on a clean work surface.




12. On the bench, remove the EGR valve to EGR cooler tube bolts (2).
13. Separate the EGR valve (3) from the EGR cooler tube (4).
14. Remove and discard the intake manifold tube gaskets (1) as required.




15. If required, remove the EGR bracket bolt, nut, and EGR bracket.

Installation Procedure






Notice: Refer to Fastener Notice.

1. If required, install the EGR bracket, the EGR bracket bolt, and nut.

Tighten the bolt and nut to 25 N.m (18 lb ft).




2. Install NEW intake manifold tube gaskets (1) as required.
3. Position the EGR valve (3) to the EGR cooler tube (4).
4. Install the EGR valve to EGR cooler tube bolts (2).

Tighten the bolts to 20 N.m (15 lb ft).




5. Install the EGR valve/cooler tube assembly to the engine.
6. Install the EGR valve/cooler tube assembly bolts and nut.

Tighten the bolts to 25 N.m (18 lb ft).




7. Connect the engine wiring harness electrical connector (1) to the EGR valve.




8. Install the EGR cooler pipe hose to the EGR cooler tube and reposition the EGR cooler pipe clamp (1).




9. Connect the EGR cooler hose fitting (2) to the heater inlet pipe.
10. Install the heater inlet pipe bracket bolt (1).

Tighten the bolt to 25 N.m (18 lb ft).

11. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill).
12. Install the crankcase ventilation hose/pipe.
13. Install the right exhaust pipe.
14. Install the intake manifold tube.
15. Install the generator.