Cart
No items added
Customer Login Register Free

EGR Valves Step by step replacement guide

Diagnostics, testing, removal and installation of EGR valves should always be carried out by suitably qualified persons.

Refer to the owner's handbook or manufacturer’s workshop manual for vehicle specific information.

Ensure you follow all safety precautions when working on or under the vehicle. Make sure engine is cold and the vehicle is in gear or park, the handbrake is on, and the ignition is off.

Step 1 Locate your vehicles OBDII diagnostic plug.

 
(Click to enlarge)

Step 2 Scan for trouble code using suitable OBDII Code Reader. Always Verify trouble codes by testing circuits at fault using vehicle manufacturers recommendations. See EGR Valve Diagnostics. If you need a suitable code reader Check our accessories page – AutoLink AL301 Code Reader

 
(Click to enlarge)

Step 3 Locate your EGR Valve. Before you start we recommend using a digital camera to record how the existing EGR valve wiring loom and other parts that have to be removed are located to remove and refit the new EGR valve. We have information and photographs of several makes and models on our On-vehicle location photo guide page. Be sure to keep track of all components handled during the process in order to properly return the EGR valve.


(Click to enlarge)

Step 4 Carefully remove the EGR valve electrical connectors.


(Click to enlarge)

Step 5 Remove any nuts or bolts holding the existing EGR Valve in place.


(Click to enlarge)

Step 6 Remove the old EGR Valve. DO NOT discard the existing EGR Valve till the new replacement is fitted and tested.


(Click to enlarge)

Step 7 Check that new EGR Valve is the same as old unit, same configuration, bolt holes align etc. It is extremely important that you get the correct replacement EGR valve for your vehicle application. Two Exhaust Gas recirculation valves may look identical but be calibrated differently.


(Click to enlarge)

Step 8 Remove old gaskets if applicable

WARNING - Check the gasket on the EGR valve. If the gasket appears worn or damaged in any way, replace the gasket with a new one. Usually new EGR valves DO NOT come with a replacement gasket so be sure not the damage your original gasket if possible, or you may need to purchase a new EGR Valve gasket from your dealer.


(Click to enlarge)

Step 9 Clean the surface for new EGR valve gasket if applicable. Once the old EGR valve is removed check all exhaust gas recirculation flow passage ways to and from the EGR valve are clear, if they are dirty be sure to clean and unblock before fitting the new EGR Valve.


(Click to enlarge)

Step 10 Fit new EGR Valve gasket if applicable.


(Click to enlarge)

Step 11 Fit the new EGR Valve and tighten to manufactures specifications.


(Click to enlarge)

Step 12 Reconnect EGR Valve electrical connector plug.


(Click to enlarge)

Step 13 The new EGR Valve should now be fitted securely and the connector plug firmly in place. Be sure to check your work to ensure you have not routed wires or hoses where they may be burnt by hot exhaust or the EGR valve or similar.


(Click to enlarge)

Step 14 Scan for trouble codes again, and then clear any displayed codes.  Start vehicle to check operation and check that trouble codes have not returned.


(Click to enlarge)

After fitting the new EGR Valve we recommend driving the vehicle to ensure that all operates as expected and that no further action is required. Your new EGR Valve should give you at least as much trouble free service as your original unit, unless the underlying issues that caused your premature EGR Valve failure have not been addressed.

Important

Search

Ignition Leads O2 Sensors