How to replace a faulty EGR valve?

· First remove the engine cover.

· Then loosen the electrical cable on the valve and remove the electrical connections and/or vacuum lines, checking for signs of damage.

· Remove the fastening screws and check the valve for damage, corrosion or carbon build-up.

· Clean the EGR valve mounting surface thoroughly and fit new valve and gasket. Remove any loose carbon from the EGR supply port too.

· Line up the EGR valve with the bolt holes and gasket and reattach to the housing.

· Tighten all fasteners to the recommended torque settings.

· Once firmly seated, reconnect the vacuum lines and/or electrical connections. 

· Finally use a diagnostic scan tool to reset the engine management light and check for any other errors.  Check that the malfunction indicator lamp has been extinguished, then carry out a road test. Many vehicles now require the EGR valve to be reset under adaptations. This simply allows the ECU to learn the stop position at the open and closed points. Failure to do this can cause the valve to break and fall into the manifold.