How to Install an EGR Valve on Vehicles

by Contributing Writer; Updated June 12, 2017

The Exhaust Gas Recirculation (EGR) valve on the Vehicles is an important part of the engine emissions system. The EGR valve allows a precisely metered amount of exhaust gas to be circulated back to the combustion chamber. This introduction of exhaust gas into the cylinder allows the engine to achieve combustion Vehicles a lower temperature, leading to the creation of fewer smog-related emissions. If the EGR valve is not functioning properly, it can lead to misfires, rough idle, stalling, and failed emissions tests. Fortunately, the EGR valve is easily replaced using basic hand tools.

Under The Hood:

 How to Install an EGR Valve on a 1997 Nissan Maxima

Mark the location of the vacuum lines running to the transducer and EGR valve using masking tape and permanent marker so that, when you reconnect the valve, you can be sure how the vacuum lines were originally routed. Then disconnect all of the lines from the transducer and the EGR.

Unbolt the tube nut fitting on the side of the EGR valve using a tube nut wrench and gently move the tube out of the way.

Unbolt the EGR mounting nuts and pull the EGR valve away from the intake manifold.

Remove the old EGR valve gasket.

Spray the mating surface on the intake manifold with carburetor cleaner. Then wiper the area clean and make sure it is free of debris.

Loosen the nut that secures the transducer solenoid and remove the transducer.

Secure the new EGR valve, gasket and transducer to the intake manifold with their respective mounting nuts. Tighten the EGR valve and transducer solenoid nuts to 12-14 ft.-lbs. using a torque wrench.

Reconnect vacuum lines that you removed in step 1. Then, reconnect the tube and tube nut to the fitting on the EGR valve using a tube nut wrench.

Items you will need

  • Tube nut wrench

  • Socket wrench

  • Socket set

  • Carburetor cleaner

  • Rag

  • Masking tape

  • Permanent marker

  • Torque wrench

 How Do I Install an EGR Valve a 2005 Dodge Durango?

Park the Durango and allow the truck to cool for a half hour. Open the hood to access the components.

Locate the current EGR valve. You will first have to remove the existing valve before installing a new one. On the 2005 Dodge Durango, the valve is located on the passenger side; look in the right-hand corner of the engine and you will see the valve.

Disconnect the current EGR by unscrewing the bolts securing the valve to the mount with a socket wrench. Pull the valve off the mount. You may need to use force to free the valve from carbon buildup. Discard the valve.

Clean the valve mount prior to installing the new EGR to ensure a clean connection. Spray the valve with carburetor cleaner and allow the cleaner to penetrate the stuck-on carbon for three minutes. Clean the carbon and debris off with a wire brush and rag.

Place the EGR valve onto the valve mount. Line up the holes on the valve to the holes on the mount. Replace the bolts and tighten with the socket wrench. The EGR is now installed.

Items you will need

  • Socket wrench

  • EGR valve

  • Carburetor cleaner

  • Wire brush

  • Rags

 How do I Install an EGR Valve in a 2003 Acura MDX?

Removing the Failed EGR Valve

Open the hood and detach the intake manifold cover from the top of the engine with a ratchet, short ratchet extension and socket. Start with the bolt on the center of the narrow end of the cover, and use a star pattern to loosen the bolts gradually and evenly. Put the cover aside in a safe place.

Look for the EGR valve. This is a small cylinder with an electrical connector on top and secured to the end of one of the intake manifolds by two mounting screws.

Remove the ignition coil cover to gain better access to the valve. The coil cover mounts on top of the coils, which mount over the spark plugs. Use a Phillips-head screwdriver.

Unplug the electrical connector from the top of the EGR valve and unfasten the two valve mounting bolts with a ratchet and socket. Lift the EGR valve and gasket out of the intake manifold.

Clean the mating surface on the intake manifold with a gasket scraper, if necessary.

Installing the New EGR Valve

Install the new EGR valve in position along with a new gasket.

Start the two valve mounting bolts by hand and then tighten the bolts with the ratchet and socket.

Plug the electrical connector to the top of the EGR valve.

Replace the ignition coil cover with the Phillips-head screwdriver.

Reinstall the intake manifold cover tightening the bolts gradually and evenly and following a star pattern. Use the ratchet, short ratchet extension and socket.

Items you will need

  • Ratchet

  • Short ratchet extension

  • Socket

  • Phillips-head screwdriver

  • Gasket scraper, if necessary

 How to Install an EGR Valve on a 2000 Ford Explorer

Park the Explorer on flat, level ground with the parking brake fully engaged. Raise the hood by pulling the release handle located under the steering column and then pulling up on the lever located under the center of the hood while lifting the hood. Disconnect the negative battery cable with a pair of pliers or open-ended wrench. The EGR valve is located above, and slightly in front of, the exhaust manifold on the driver's side of the engine. The EGR valve is a flat metal disc with a small rubber hose attached to the top and a larger metal pipe running from the bottom of the valve to the exhaust manifold.

Remove the small rubber hose from the top of the EGR by gently pulling straight up on the rubber fitting. Unscrew the metal pipe from the bottom of the EGR using an open-ended or adjustable wrench. Remove the two bolts holding the EGR valve to the engine. Remove the valve from the engine.

Clean any remaining gasket material from the EGR valve mating surface using a plastic putty knife.

Install a new EGR gasket on the mating surface using gasket sealer to hold it in place. Attach the new EGR valve to the engine using new bolts and tighten the bolts to 15 foot-pounds. Reconnect and securely tighten the metal pipe to the bottom of the valve and slide the rubber fitting back onto the top of the valve.

Reconnect the negative battery terminal and close the hood.

Items you will need

  • Pliers

  • Open-ended wrenches

  • Adjustable wrench

  • Plastic putty knife

  • New EGR gasket

  • Gasket sealer

  • Torque wrench