How to replace a faulty EGR valve?

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Replacing a faulty EGR Valve:

Please follow the below steps to exchange or replace a faulty EGR valve.

  1. First, remove the engine cover.
  2. Then loosen the line on the valve and take away the electrical connections and/or vacuum lines, checking for signs of injury.
  3. Remove the fastening screws and check the valve for damage, corrosion, or carbon build-up.
  4. Clean the EGR valve mounting surface thoroughly and fit the new valve and gasket. Remove any loose carbon from the EGR supply port too.
  5. Line up the EGR valve with the bolt holes and gasket and reattach to the housing.
  6. Tighten all fasteners to the recommended torque settings.
  7. Once firmly seated, reconnect the vacuum lines and/or electrical connections.
  8. Finally use a diagnostic scan tool to reset the engine management light and check for the other errors. Make certain the malfunction indicator has been extinguished, then do a test. Many vehicles now require the EGR valve to be reset under adaptations. This simply allows the ECU to be told the stop position at the open and closed points. Failure to try to do this could cause the valve to interrupt and comprise the manifold.


Common EGR fault codes:

On late model EGR valves the subsequent fault codes are common:

    1. P0400: EGR flow malfunction
    2. P0401: EGR insufficient flow detected
    3. P0402: EGR excessive flow detected
    4. P0403: EGR circuit malfunction
    5. P0404: EGR circuit range/performance
    6. P0405: EGR sensor A circuit low
    7. P0406: EGR sensor A circuit high
    8. P0407: EGR sensor B circuit low
    9. P0408: EGR sensor B circuit high
    10. P1403: EGR solenoid low
    11. P1404: EGR system – closed valve pintle error
    12. P1405: EGR solenoid high
    13. P1406: EGR system pintle position error

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