CM870 and ISX Engines – 019-372   EGR Valve Position Sensor

Disconnect the air intake pipe from the turbocharger. Refer to the OEM service manual.

Remove the alternator, if necessary. Refer to Procedure 013-001 in the Troubleshooting and Repair Manual, Signature, ISX and QSX15 Engines, Bulletin 3666239.

CAUTION  Do not use connector grease on the EGR valve position sensor connector. Use of connector grease can cause damage to the EGR valve and low engine performance.

Disconnect the wiring harness connector from the Exhaust Gas Recirculation
(EGR) valve position sensor connector.

There are two types of position sensors. The original position sensor has the connector molded into the sensor (as shown). the new hull effect sensor has a pigtail harness connected to the sensor.

Loosen and remove the two capscrews securing the EGR valve position sensor to the EGR valve actuator housing.

Discard the two position sensor capscrews and washers, if present.

Pull the position sensor away from the EGR valve actuator housing.

CAUTION  Make sure the EGR valve position sensor is properly aligned with the EGR sector shaft before installing. Misalignment upon installation can damage the sensor.

Inspect the position sensor for a damaged or missing o-ring and damaged or broken connector pins.

Guide pins, Part Number 3165138, are necessary for proper alignment between the position sensor and the housing. Improper alignment will result in damage to the sensor.

Insert alignment pins into the capscrew holes in the housing.

CAUTION  Do not allow any of the solution to get inside the sensor. Damage to electrical components can occur.

Use a cotton swab to lubricate the sensor o-ring with a mild soap and water solution.

Install the position sensor over the guide pins.

Press the sensor into the bore until the o-ring is fully engaged.

The external locating tab on the sensor must align with the hole in the housing.

When the position sensor is fully seated against the housing, remove the alignment pins and install the two M4 capscrews.

CAUTION  Do not apply any type of lubricant or grease on the position sensor connector or position sensor wiring harness connector. Lubricant or grease can cause inaccurate voltage signals due to insufficient connector engagement, which are then sent to the Electronic Control Module (ECM).

Connect the engine harness connector to the sensor. Push the connectors together until they lock.

Inspect the wiring harness and connector for excessive tension.

If excessive tension is present, determine the source and relieve the tension on the circuit.

Install the alternator. Refer to Procedure 013-001 in Troubleshooting and Repair Manual, Signature, ISX and QSX15 Engines, Bulletin 3666239.

Connect the air intake pipe to the turbocharger. Refer to the OEM service manual.