How to Replace an EGR Valve on Cars

by Contributing Writer; Updated June 12, 2017

The EGR valve, or exhaust gas recirculation valve, in your Mustang car is essential to its being able to pass emissions tests, maintain good fuel mileage and smooth idling speeds. The valve passes exhaust gas back into the engine to cool gasses, prevent a buildup of nitrogen gas and burn up any remaining fuel. During the life of your car, you will have to replace the EGR valve on a Mustang car several times as they are prone to becoming dirty and blocked. Fortunately, not only is the valve inexpensive, it is easy to replace.

Under The Hood:

 How to Replace an EGR Valve on a Duramax

Disconnect the cable on the negative terminal of the battery.

Locate the exhaust manifold on the engine. The manifold will be on the right side, or driver's side, of the engine, but its location will vary slightly depending on the particular Duramax model.

Locate the metal tubing that is connected to the exhaust manifold. Follow the tubing to its other end, which will be connected to the EGR system.

Unplug the wiring harness that is connected to the EGR system by first pressing in on the release tab to unlock it.

Unplug the metal exhaust tubing by loosening the clasp that holds it into place. Remove the EGR valve from the engine by removing the Torx bolts that secure it.

Place the new EGR valve into the same position as the old one and secure it with bolts.

Reattach the exhaust tubing and secure it by tightening the clasp, and reattach the wiring harness by snapping it into place. Reconnect the cable to the negative terminal of the battery.

Start the engine, and make sure the EGR valve is functioning properly. If you don't hear moving air or a vacuum sound coming from it, the EGR valve is on correctly.

Items you will need

  • Socket set

  • Torx screwdriver

 How to Replace the EGR Valve on a Lincoln Town Car

Unplug the low-pressure sensor on the air-conditioning line at the accumulator so it doesn't get broken. Disconnect the hose from the coolant reservoir, using a pair of pliers to take the clamp off, to give more room to work.

Look down the passenger side of the engine between the exhaust manifold and the fender well to see the EGR pipe connection. Loosen and remove the 1-inch nut that is threaded onto the manifold, using a wrench.

Follow the metal pipe up to where it is connected to the EGR valve. Loosen and remove the connection to the valve, using a wrench. Remove the two vacuum lines and extract the pipe from the vehicle. Remove the two bolts securing the EGR to the intake manifold, using an 8 mm socket. Pull the EGR away from the manifold and retain the gasket.

Clean the hole in the intake manifold if it is blocked with carbon, using a screwdriver. Check the BPFE hoses that run to the EGR pipe. They are notorious for blocking and causing the EGR to malfunction and set a code stating "EGR valve has insufficient flow." To do this, pull the two hoses off the valve itself and look into the hoses for buildup. Remove the hoses, clean them out and then replace them.

Spread anti-seize compound on the pipe connections. Install the new EGR and components in reverse order of removal.

Items you will need

  • Pliers

  • 1-inch standard wrench

  • Large adjustable wrench

  • ¼-inch drive ratchet

  • Set of ¼-inch drive sockets

  • Common screwdriver

  • Anti-seize compound

 How to Change the EGR Valve on a Chevy Impala

Locate the Impala's EGR valve. The EGR valve is located on the driver's side of the engine bay towards the rear, regardless of whether the vehicle is equipped with the 3.4 or the 3.8-liter engine.

Use the pliers to remove the rubber tubes connected to the EGR valve. There will be one tube in the rear and one in the front. Be careful not do damage the tubing when you are sliding it off.

Use the socket wrench to remove the two bolts connected to the base of the EGR valve. If you feel a strong resistance, you may want to spray some anti-seizing compound on the bolts to help loosen them.

Remove the EGR valve and the gasket from the mount. Once the valve is removed, the gasket should slide right off. Set the items aside.

Place the new gasket over the mount, and then place the new EGR valve on top of it. Make sure they are properly lined up. Re-install the bolts and connect the tubing.

Items you will need

  • Pliers

  • Socket wrench

  • Replacement EGR valve (Delphi brand is recommended)

  • Replacement EGR gasket

 How to Replace the EGR Valve for a Dodge RAM

Locate the EGR valve in the engine bay. The year and make of the Dodge vehicle determine where the valve is located. This is on the front of the engine block, next to the timing belt in model-year 2005 and newer trucks. In older vehicles you will typically find the valve behind the engine, near the firewall.

Unclip the exhaust tube from the side of the valve. You can do this by hand. Shift the tube from side to side until it slides off.

Use a flat-head screwdriver to remove the EGR valve from the exhaust tube. There is a screw on each side of the tube.

Disconnect the harness from the EGR valve. Use your hand to pull up on the tab and slide the harness from the valve.

Use a flat-head screwdriver to remove the two screws that secure the EGR valve to the cylinder head. Remove the EGR valve and clean the surface of the cylinder.

Attach the new EGR valve to the cylinder head and tighten it down with the same screws that were previously installed.

Reattach the harness and reattach the exhaust tube to the valve. Tighten the two flat-head screws that hold the tube to the valve.

Reattach the hose to the valve and use your hand to attach the clip to the hose.

Items you will need

  • Flat-head screwdriver

  • Shop cloth

 How to Replace the EGR Valve in a Villager

Let the engine in your Villager cool off for at least 30 minutes prior to beginning the procedure. Engine components can be very hot after the engine has been running.

Locate the EGR valve. The Villager's EGR valve is located on the driver's side of the engine bay, next to the intake manifold. Use the photo as a guide.

Use your hands to slip off the vacuum hoses. The EGR valve has two hoses, one for intake and one for output. Do not use pliers to help you remove the hoses; they are fragile and easily damaged.

Use your socket wrench to remove the mounting bolts for the EGR valve. Most EGR valves have three mounting bolts. Use a standard socket wrench to remove them.

Slip the EGR valve away from its mount and set it aside.

Remove the old EGR valve gasket; it cannot be reused. Clean the mounting spot with carbon cleaner and a towel.

Mount the new EGR valve and gasket. Tighten the bolts by hand to quickly secure the EGR valve, and then tighten them with the socket wrench.

Connect the two vacuum hoses. Start the engine and allow the diagnostic system to cycle for a few minutes. Your check engine light turn off shortly.

Items you will need

  • Socket wrench set

  • Liquid Wrench (optional)

  • Replacement EGR valve

  • Replacement EGR gasket

 How to Replace an EGR Valve on a Chevrolet Pickup

Removing the EGR Valve on a Chevrolet Pickup

Disconnect the ground cable from the negative battery terminal by loosening the retaining clamp, and pulling the clamp off the negative terminal.

Remove the air cleaner assembly, by removing the wing nut on top of the air cleaner lid and lifting the air cleaner housing off the carburetor.

Locate the EGR valve. It will be mounted to the intake manifold near the carburetor.

Disconnect the vacuum line from the EGR valve, by pulling it off.

Remove the bolts that connect the EGR valve to the intake manifold.

Remove the EGR valve from the intake manifold.

Installing an EGR Valve on a Chevrolet Pickup

Examine the passages in the intake manifold under the EGR valve. Remove any carbon deposits using a flat screwdriver. Vacuum the area with a portable vacuum to ensure none of the carbon gets sucked into the engine.

Clean the EGR valve mounting surface with a wire brush. Use a vacuum to clean the area and ensure no debris gets sucked into the engine.

Place a new EGR valve gasket into position on the intake manifold mounting surface.

Place the new EGR valve into position on the intake manifold.

Reinstall the bolts that connect the EGR valve to the intake manifold.

Reconnect the vacuum line to the EGR valve.

Place the air cleaner assembly into position above the carburetor. Reinstall the wing nut that secures the air cleaner assembly to the carburetor.

Reconnect the ground cable to the negative battery terminal.

Items you will need

  • Wrench set

  • Socket set

  • Flat-blade screwdriver

  • Pliers

 How to Replace the EGR Valve on a Mustang

Park your Mustang on a level surface and open the hood. Standing in front of the car, locate the EGR valve. It will be just behind and above the drive belts at the front of the engine. There will be several vacuum hoses attached to the valve and the valve itself has a silver in color disc like "hat" on it and a "L" shaped body.

Disconnect the vacuum hoses from the EGR valve. The hoses may have squeeze type hose clamps on the ends holding them in place, pinch the two tabs of the clamp together to open it and slide the hose off. Some hoses may be held in place by the force of the vacuum only, grasp the hose near where it connects to the EGR valve and pull the hose off.

Disconnect the exhaust vacuum line, which is a metal hose that is connected to the bottom left of the EGR valve. Use a wrench to unscrew the lock nut.

Remove the two bolts holding the valve onto the engine block using a 10 mm socket and socket wrench. To install the new valve, reverse these steps.

Items you will need

  • Crescent wrench

  • 10 mm socket

  • Socket wrench

 How to Replace the EGR Valve on an Acura

Unfasten the negative battery cable of the Acura from the battery post with an open end wrench before replacing the EGR valve. Locate the valve on the back of the engine at the top of the intake manifold.

Take the rubber vacuum hose off the side of the EGR valve, sliding it off the metal port by hand. Remove the electrical wiring harness from the socket at the top of the valve, unplugging the wiring harness by hand.

Loosen the bolts at the base of the EGR valve with a socket wrench and lift the valve off the intake manifold. Clean away any remaining gasket material with a putty knife from the top of the intake manifold where the valve was sitting.

Attach the new EGR valve and gasket to the intake manifold with bolts. Connect the electrical wiring harness to the top of the valve, plugging it into the socket by hand.

Slide the rubber vacuum hose onto the metal port on the side of the EGR valve by hand. Attach the negative battery cable to the Acura battery post with the open end wrench.

Items you will need

  • Open end wrench

  • Socket wrench set

  • Putty knife