EGR Valve: Service and Repair

EGR VALVE REPLACEMENT





Removal of Engine Cooling Fan
^ Remove / Disconnect:
- Cover above Throttle Body (TB) pulley.
- Upper charge-air pipe from Charge Air Cooler (CAC).
- Air intake and intake hose from Air Cleaner (ACL).
- The two screws attaching the EVAP valve to the engine cooling fan shroud.
- Engine cooling fan shroud mounting screws (four).
- Air duct to ECM box.
- Bend back the cover a little, pull out the relay holder and separate the connectors for the fan; place the relay holder across the intake manifold.
- Fan shroud spacers.
- Fan and shroud.
^ Protect radiator with shield, P/N 9995474.





Release the Hoses and Couplings
^ Remove the lower CAC pipe.
^ Disconnect the EGR temperature sensor and withdraw the sensor's connector from the holder.





Remove EGR Valve
^ Undo the vacuum hose from the EGR valve.
^ Disconnect gas recirculation pipe from valve.
^ Remove valve mounting screws, valve and gasket.
^ Remove EGR temperature sensor from original EGR valve. Clean sensor carefully.





Install EGR Valve
^ Install EGR temperature sensor in new EGR valve.
^ Reconnect gas recirculation pipe to valve.
^ Mount valve on intake manifold using new gasket.
^ Tighten valve mounting screws.
^ Tighten pipe connection to 50 Nm (37 ft lb).
^ Connect the vacuum hose to the EGR valve.





Re-fitting Hoses and Couplings
^ Install:
- The lower CAC pipe.
- EGR temperature sensor connector in clip and reconnect sensor.





Install Engine Cooling Fan
^ Install / Reconnect:
- Fan and shroud.
- Shroud spacers.
- Relay shelf and FC connector.
- Fan shroud mounting screws (four).
- Air duct to ECM box.
- EVAP valve.
- Air intake and intake hose to ACL.
- Upper charge-air pipe to CAC.
- Cover above the TB pulley.