Help How to remove EGR assembly

[Saik]

Hey ya'll I'm trying to get fix a P0401 error code on my 04. I bought a new EGR assembly for $80, and when I tried to replace the current EGR I was baffled on how to remove it.

First there's a large metal pipe leading down to the bottom of the engine, and another pipe going inside the intake. Also none of my wrenches and sockets are able to reach the screws that hold the EGR in place.

Is there any tutorial or any tips and tricks you have to help me replace the EGR. Thank you!

 

[ImConfused666]

Did you ever get a response? I'm just about to remove the EGR on my wife's 2006 so I can bench test it. When I pulled the vacuum line and used a pump to pull a vacuum, I got no change in the engine idle speed so I'm assuming this is likely to be the problem. Just looking at it, I think it's going to be an aggravating job to remove/replace.

 

[ponkotsu]

I have the factory manual for 2003, but I doubt if 04 is any different. Looks pretty straightforward, but probably tough to get your hands in there. Spray down the exhaust fitting threads first. And work them back and forth until they are loose before completely removing if possible. That will make it much easier to reassemble. Manual says you need to remove both ends of the exhaust pipe, but maybe not necessary depending on how much clearance you have to get it out. Be careful not to damage the gasket.

Removal Order:

Remove Air cleaner outlet tube
1 EGR vacuum regulator solenoid electrical connector
2 Vacuum hoses
3 EGR vacuum regulator solenoid mounting nuts
4 EGR vacuum regulator solenoid
5 Differential pressure feedback EGR system electrical connector
6 Differential pressure feedback EGR system
7 EGR valve tube mounting nut
8 EGR valve tube mounting nut
9 EGR valve tube
10 Vacuum hose
11 EGR valve mounting bolts
12 EGR valve
13 EGR valve gasket
14 EGR valve bracket mounting bolts
15 EGR valve bracket

 

[makuloco2000]

Did you ever get a response? I'm just about to remove the EGR on my wife's 2006 so I can bench test it. When I pulled the vacuum line and used a pump to pull a vacuum, I got no change in the engine idle speed so I'm assuming this is likely to be the problem. Just looking at it, I think it's going to be an aggravating job to remove/replace.

you getting any codes why are you pulling it off? I can send you a exploded diagram of the removal process it literally bolts right on though.

 

[ImConfused666]

Yes. I'm getting a P0401.

Thanks.

 

[ImConfused666]

Well, thanks again. You're right that removal and replacement are straightforward. Hard to reach the danged bolts but... still straightforward. Now, I just have to do the testing to see if I need to spend the money to replace it.

Thanks again.

 

[makuloco2000]

Yes. I'm getting a P0401.

Thanks.

If you are getting a p0401 just change it out no testing required it is an egr "module" now so the dpfe, egr and egrvr are all one unit and sold as such. Here it is.

 

[ImConfused666]

Thanks. Seeing the layout before doing the job boosted confidence in how long it would take. It ended up only taking about an hour of actual labor. One of the key things is to do everything while the engine is cool. I forgot to tighten the flare nut on the exhaust line going to the valve. That sucker warms up quick.

Testing the EGR valve yielded dubious results. However, being able to compare it against the new one confirmed my initial diagnosis and the replacement seems to have fixed the problem.

Thanks again. It's good to be part of the Internet Community.

 

[makuloco2000]

Yeah its all inclusive like I said so it's replacement 98% of the time and wires or pcm 2% of the time.

 

[mmeriaux]

Time to buy a wrench for the exhaust tube nut (#3 in diagram above). Any verification on what size it is? Looks to be close to 26mm. Anyone can verify for me?

Edit: I found that 27mm fits well.

 

[JoshMcMadMac]

Time to buy a wrench for the exhaust tube nut (#3 in diagram above). Any verification on what size it is? Looks to be close to 26mm. Anyone can verify for me?

Edit: I found that 27mm fits well.

Be careful not to break the tube when disconnecting it. They get brittle, and it really sucks trying to remove the nut on the other end that goes into the manifold...ask me how I know