Installing EGR Valves

Typical EGR Valve

A Exhaust Gas Recirculation (EGR) system is an important part of the emissions control system in your car. A bad EGR valve may lead to several problems: rough idle, stalling and poor fuel economy. If the valve remains open, a lean mixture will be fed to the combustion chamber; if the valve remains closed or exhaust gases are unable to flow, detonation and knocking may be produced in the combustion chamber. Here is a simple guide to help you remove a failed valve and install a new one.

Things You'll Need

• Phillips screwdriver Ratchet and six-point socket set Screwdriver Scraper Solvent Clean shop rag

Instructions

1. Park your car in a safe place with enough space to work around the front of the vehicle.

2. Open the hood and locate the EGR valve. The valve is connected or mounted on the intake manifold. It has the shape of a round metal plate of about 3 inches wide and 1 inch thick, a thin vacuum hose attached on top and--depending on the vehicle model--an electrical connector as well.

3. Unplug the vacuum hose form the valve and the electrical connector--if equipped--from the top of the valve. Some valves come with a small sensor attached and may be taken off by removing two small screws using a Phillips screwdriver.

4. Remove the two nuts or bolts that attach the steel tube to the EGR valve--if equipped--using a ratchet and a six-point socket. Separate the tube from the valve--some tubes are attached to the valve with a large nut, which may be removed with a large wrench or adjustable wrench.

5. Remove the bolts or nuts securing the valve to its base using a ratchet and a six-point socket. If the valve seems to be stuck on its base after removing the bolts or nuts, use a small screwdriver and carefully pry the valve off its mounting base.

6. Remove the old gasket from the valve base and use a scraper to clean the gasket mating surface, being careful not to scratch the base. You may use carburetor cleaner or a similar strong solvent to clean the mating area.

7. Look inside and around the valve mounting base opening. If necessary, remove sludge, dirt and other residuals from the orifice using solvent and a small screwdriver, and wipe the mounting base clean with a clean shop rag. Make sure the base is completely clean and dry before proceeding to the next step.

8. Place the new gasket and EGR valve on the mounting base and install the screws or nuts by hand. Tighten the bolts or nuts using a ratchet, and torque them from 18- to 20-foot pounds (25 Nm) each.

9. Install and tighten the tube to the EGR valve, electrical sensor and plug the electrical connector, if equipped. Connect the vacuum hose to finish the valve installation.

Tips & Warnings

• Before working on any components inside the engine compartment of your car, make sure the engine and related parts are cold enough to the touch to avoid serious burns to the skin.