EGR Valve: Service and Repair

Exhaust Gas Recirculation Valve Replacement

Removal Procedure

1. Remove the engine cover.
2. Remove the generator.
3. Remove the intake manifold tube.
4. Remove the exhaust gas recirculation (EGR) coolant hose.
5. Remove the right exhaust pipe.




6. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube.




7. Remove the EGR cooler tube bracket bolt.
8. Remove the crankcase ventilation hose/pipe.




9. Disconnect the EGR solenoid electrical connector.




10. Remove the EGR nut (1) and bolt (2).
11. Remove the EGR valve and EGR cooler tube as an assembly.




12. On the bench, remove the 2 EGR valve to EGR cooler tube bolts.
13. Separate the EGR valve from the EGR cooler tube.




14. If necessary, remove the EGR bracket bolt, nut, and EGR bracket.
15. Discard the EGR valve gasket.

Installation Procedure






Notice: Refer to Fastener Notice.

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

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




2. Position the EGR valve to the EGR cooler tube, using a NEW EGR valve gasket.
3. Install the 2 EGR valve to EGR cooler tube bolts.

Tighten the EGR valve to EGR cooler tube bolts to 20 N.m (15 lb ft).

4. Position the EGR valve and EGR cooler tube assembly in the vehicle.




5. Install the EGR nut (1) and bolt (2).

Tighten the EGR nut and bolt to 50 N.m (37 lb ft).




6. Connect the EGR solenoid electrical connector.
7. Remove the crankcase ventilation hose/pipe.




8. Install the EGR cooler tube bracket bolt.

Tighten the EGR cooler tube bracket bolt to 25 N.m (18 lb ft).




9. Compress the clamp and connect the EGR heater inlet hose/pipe to the EGR cooler tube.
10. Install the right exhaust pipe.
11. Install the EGR coolant hose.
12. Install the intake manifold tube.
13. Install the generator.
14. Install the engine cover.