Service Procedure

1. Open the hood.





2. Inspect the EGR valve mounting flange for the Certification Code "AR6000" or "AR6001" that is cast into the flange (Figure 1).

> If the certification code is "AR6000", continue with Step 3.

> If the certification code is "AR6001", the EGR valve does not require replacement. Return the vehicle to the customer, no further action is necessary.

3. For EGR valves with certification code AR6000: Inspect the top of the EGR valve for a "YELLOW" paint dot identification mark (Figure 1).

> If there is no paint dot on the valve or if there is any other color paint dot, the EGR valve must be replaced. Continue with Step 4.

> If a "YELLOW" paint dot is present, the EGR valve does not require replacement. Return the vehicle to the customer, no further action is necessary.

4. Attach one end of a hose to the radiator draincock and put the other end into a clean container.

WARNING:
Do not loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.

5. Remove the cap from the coolant recovery bottle.

6. Open the draincock and drain about two quarts of coolant from the radiator or until the coolant level is below the EGR valve level. Close the radiator draincock, remove the drain hose and save the coolant for later reuse.





7. Disconnect the EGR valve electrical connector (Figure 2).

8. Disconnect the EGR coolant hose (Figure 2).

9. Remove the EGR valve fasteners and then remove the EGR valve assembly (Figure 2).

10. Clean the intake manifold mating surface for the EGR valve gasket.

11. Position the new EGR valve onto the intake manifold with the provided gasket (Figure 2).

12. Install the EGR valve fasteners. Tighten the bolts evenly to 80 in-lbs (9 N.m).

13. Connect the coolant hose to the new EGR valve (Figure 2). Make sure the hose clamp is positioned behind the upset bead.

14. Connect the EGR valve electrical connector (Figure 2).

15. Fill the radiator to the top with the coolant that was drained from the radiator and fill the coolant recovery bottle to the COLD MINIMUM level.

16. With the heater control unit in the HEAT position, start and operate the engine with the recovery bottle cap in place.

17. After the engine has reached normal operating temperate, shut the engine off and allow it to cool. When the engine is shut down coolant will be drawn into the radiator from the recovery bottle.

18. Add coolant to the recovery bottle as necessary to raise the container level to the COLD MINIMUM mark. Use a 50/50 mixture of ethylene-glycol coolant and water if necessary.

19. Repeat Steps 15-18 two times to ensure all air has been purged from the system.