Procedures

CLEANING





1. Remove EGR valve Exhaust Gas Recirculation (EGR) Valve - Removal.
2. Remove the four screws (4) from EGR valve motor (3).






NOTE: The original EGR valve motor and its shim must be reinstalled onto the original EGR valve housing.

3. Remove the valve motor (6) and shim (5) from EGR valve housing (1). Motor (6) and shim (5) must be kept for reassembly.





4. Use two fingers to press down on valve spring retainer (3) to unlock two valve keepers (2). If valve keepers will not release using finger pressure, locate a 5/8" deep socket to the spring retainer (3). Gently tap on the socket with a small hammer to release keepers, then use two fingers and press for keeper removal.





5. Remove the valve spring retainer (3) and valve spring (2).





6. Lightly press on valve stem (1) about 3/8" to force valve faces from valve seats.
7. Using a small steel wire bristled brush, brush away loose soot from EGR valve housing.





8. The EGR valve shaft assembly (1) is comprised of two poppets (2), two seats (3), and a lower soot guard (4). An upper soot guard (5) is pressed into the housing.
9. Using the same steel wire bristle brush, clean the soot from both poppets (2) and both seats (3); Ensure there is metal to metal contact between both poppet/seats interfaces so that the valve is fully closed.
10. Using the same steel wire bristle brush bend to a 45 degree angle or 90 degree angle, clean the soot between the lower soot guard (4) and the upper soot guard (5) interface while rotating the shaft.
11. Completely submerge valve housing using a mixture of hot tap water and MOPAR(R) EGR System Cleaner (ESC). Mix cleaning solution 1 part ESC and 4 parts water. Allow the valve to soak in the cleaning solution for 1 hour, and occasionally agitating the shaft or moving it up and down through its full stroke.
12. Remove the valve assembly from cleaning solution. Completely remove remaining soot from shaft assembly (1), poppets (2), seats (3), and between the lower soot guard (4) and upper soot guard (5) using the wire bristle brushes.
13. Dispose of cleaning solution per local governmental regulations.
14. Rinse EGR valve housing in hot tap water until all cleaning solution is rinsed clean. Using shop air, blow dry the EGR valve completely.





15. Assemble valve spring (2) and retainer (3) to housing.





16. Position valve keepers (2). Press down on retainer (3) until groves on valve keepers lock into valve stem (1).





17. Install original shim (5) and original motor (6) to housing. Motor is not indexed. Rotate motor until its electrical connector is pointed towards front of vehicle. Install four mounting screws (7).
18. Install EGR valve Exhaust Gas Recirculation (EGR) Valve - Installation.