EGR valve replaced, how-to with pictures

[InetDev]

Symptoms:

• No codes.
• Bucking, hesitation during acceleration.
• Loss of power, no sense of power between 1k-3k

Possible issue:

• EGR valve clogged

Possible causes:

• Running rich/unburnt fuel
• High mileage (mine has 131k)

Tools:

• 8mm socket with 4" extension
• Two 90-degree (right angle) pry bars, small (Harbor Freight item# 97387 works)

Recommendation:

• Replace with reconditioned/cleaned EGR valve
  *** OR ***
• Clean valve carefully with brake cleaner and replace o-rings

Procedure:

1. Locate the EGR Valve.
2. Disconnect wiring, there is a clip on side facing firewall.
3. Remove two 8mm bolts on side flanges.
4. Twist counter clockwise about a half inch or so, yell "By the Power of Greyskull!" furry underwear optional.
5. Place small pry bars under each flange.
6. GENTLY use pry bar leverage to lift straight up.
7. EGR valve will "pop" loose.
8. Check for gunk in EGR valve, opening where it came from.
9. Clean out that junk in the opening, vacuum/wipe whatever.
10. Place new/reconditioned EGR valve, align, push down.
11. Tap with gently baby smacks using a rubber mallet to properly seat.
12. Reinsert 8mm bolts, tighten, reconnect wiring harness.

I've never tried to clean one myself and figured it may be best to allow someone with more experience do it since there are so many things that can go wrong by allowing the brake cleaner to soak into unwanted places on the valve solenoid. The recondition kit that has the o-rings is about $10-12. I purchased my reconditioned EGR valve for $50 after core refund, well worth the extra piece of mind in my opinion since the shipping was absorbed by other parts in my order.

I grabbed the engine bay shot from someone's photobucket account and the pry bars from Harbor Freight. The EGR valve is my gunked up one.


Someone else's engine bay, mine looks the exact same, just dirtier. An aftermarket coolant filter is pictured in the bottom left. Well worth the extra insurance for your water pump. Search "coolant filter" for related threads.




Harbor Freight has this set for $6.50, even cheaper when on sale, they come in handy.



All gunked up.