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Make a visual inspection of exhaust passages through the system to make sure the new EGR valve will work properly. On some vehicle models, you may need to remove the fuel injectors or the intake manifold to properly dislodge carbon buildup from passages. Consult your repair manual, if necessary. After you have removed the valve, use a dull or plastic scraper to remove any traces of gasket material off the base of the valve (if you're reusing the same valve), and the intake or exhaust mounting surface. To remove buildup, put on your goggles and chemical-resistant gloves and spray carburetor cleaner on it. If you are cleaning the valve itself, be careful not to let solvent reach the valve's diaphragm or electrical circuits or contacts. Let the carbon soak in the solvent and then use the scratch awl (or screwdriver or another similar tool) to scratch off carbon deposits from around ports and passages.
Be careful not to scratch the mounting surfaces, though. A stiff wire brush is an ideal tool for the job, but, often, carbon deposits can be hard as a rock to remove. Some newer engine models use multiple EGR ports. Sometimes it's necessary to remove the intake manifold to properly clean all the ports to avoid driveability problems. If you need to remove the intake manifold, you may need to replace the intake gasket as well. Consult your vehicle repair manual, if necessary. Check the throttle body bore and plate for carbon buildup and clean as necessary. Use the pipe cleaning wire brush and a shop rag to clean inside a pipe, port or intake as necessary. For more help with maintaining your new EGR valve and the EGR system exhaust passages, check this post: How to Clean an EGR Valve. The next video gives you some visual clues about how to clean the EGR valve. Installing the EGR valve is a simple process.
However, you need to make sure the valve is properly seated and tighten the bolts to the proper torque. Position the new valve against the pipe and thread the pipe's nut by hand, if yours comes equipped with it. Position a new gasket and start the valve's mounting bolts through the EGR and gasket by hand. Tighten the mounting bolts with the wrench — and the pipe, if equipped, with the adjustable wrench. Then, finish tightening the bolts with the torque wrench to prevent overtightening the bolts and damaging the gasket, or leaving the bolts loose and cause a leak. Check the bolts' torque specifications for your application in your vehicle repair manual. Plug in the valve electrical connector, reattach vacuum hoses, and replace the air cleaner duct and any other components you had to remove to gain access to the valve. Connect the negative (black) battery terminal. Start the engine and check that the EGR valve is working correctly and there are no vacuum leaks. In the next video, you can watch the installation of an EGR valve. Replacing a faulty EGR valve doesn't involve too much work, but removing carbon buildup from passages, ports, intake, and other places may take some effort. Removing buildup will help increase the valve's service life and help good engine operation. The main causes of carbon buildup are driving mostly short trips or within the city, and an increase in engine oil consumption due to wear and tear. If possible, make a quick check of the passages under the EGR valve every other year, and clean the system as necessary or about every 60 months to prevent driveability issues. Check your vehicle service manual for the maintenance intervals of the emission control system.
