Centinel System – Repair Manual – 011-022   EGR Valve

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulators.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Remove the water pump drive belt. Refer to Procedure 008-003 in Section 8.
• On some applications, removal of the alternator is required. Refer to Procedure 013-001 in Section 13.
• Remove the air intake pipe to the turbocharger. Refer to the OEM service manual.
• Remove the heat shield. Refer to Procedure 011-032 in Section 11.
• Disconnect the EGR valve motor and position sensor connectors from the harness.
• Remove the EGR valve coolant lines. Refer to Procedure 011-030 in Section 11.

NOTE: Brush away all loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

• Disconnect EGR temperature sensor. See the following procedure in the Troubleshooting and Repair Manual CM871 and CM876 Electronic Control System, ISX and ISM Engines, Bulletin 4021560.Refer to Procedure 019-378 in Section 19.
• Remove the front EGR connection tube from the EGR valve. Refer to Procedure 011-025 in Section 11.
• Disconnect the OEM fuel return hose from the integrated fuel system module. Refer to the OEM service manual. Or, loosen the fuel hose enough to position it away from the EGR valve mounting capscrew and tighten the fuel line.
• Remove the EGR valve heat shield. Refer to Procedure 011-032 in Section 11.
• Disconnect the OEM air compressor discharge line. Refer to the OEM service manual.

Loosen the v-band clamp connecting the EGR valve to the exhaust manifold.

Loosen the v-band clamp connecting the EGR valve to the EGR cooler connection.

Remove the EGR valve and v-band clamps.

Remove and discard the gaskets.

Disconnect the EGR valve electrical connector.

Make sure to support the EGR valve by hand before removing the mounting capscrews. If the EGR valve is not supported, it can fall off of the engine, causing damage to the EGR valve and actuator.

Loosen and remove the four EGR valve mounting capscrews.

Remove the EGR valve from the EGR valve support bracket.

The EGR valve will need to be moved at an angle forward and downward in order to disengage it from the EGR valve support bracket.

Use protective caps from the Air Handling Clear Care Kit to cover open points on the EGR valve and bracket.

NOTE: Be careful not to nick the EGR valve housing when removing the seal.

Remove the pipe seal from the EGR valve inlet port.

Pry the lip of the pipe seal up from the EGR valve with a small flat headed screwdriver.

Discard the pipe seal.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of injury.

Check to make sure the EGR poppet head is present. If the poppet head is missing, run a stiff wire through every port of the exhaust manifold to locate the missing poppet head.

Do not assemble the engine without finding the missing poppet head.

Clean the mounting surfaces with a shop towel wetted with a safety solvent to remove any deposits or debris.

Dry with compressed air.

Inspect the mounting surfaces for cracks, fretting, or other damage. Inspect the EGR motor and position sensor for damage.

Replace the valve if damage is found.

Inspect the v-band clamps for signs of overextension. The band must not be bent or cracked.

Inspect the v-band clamp threads for damage.

Replace the v-band clamp if damage is found.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the EGR valve mounting and sealing surfaces with a shop towel wetted with safety solvent to remove any deposits or debris.

Clean the accumulated soot from the EGR valve inlet port using a wire brush, then soaking with carburetor cleaner and cleaning again with a wire brush. Be sure the loose soot is removed from the EGR valve housing. This can be done by vacuuming the soot out of the EGR valve inlet port.

Dry with compressed air.

Inspect the mounting surfaces for cracks, fretting, or other damage.

Inspect the EGR valve poppets for a stuck open condition. If the EGR valve is stuck open, replace the EGR valve. Do not try to pry the poppets open or closed.

Inspect the EGR valve actuator for cracks or other damage. Replace if damage is found.

Inspect the EGR valve actuator connector for corrosion, worn pins, or other damage.

Replace the EGR valve assembly if corrosion, worn pins, or other damage is found.

Inspect the engine wiring harness EGR valve actuator connector for corrosion, worn receptacles, or other damage.

Replace the engine wiring harness EGR valve connector if corrosion, worn receptacles, or other damage is found.

Soot leakage at the EGR valve weep hole is normal and is to be expected. Do not replace the EGR valve if soot streaks are found at the EGR valve weep hole.

Inspect the EGR valve mounting bracket for soot leaks at the EGR valve joint. If a leak is found, replace the EGR valve seal.

Use a light coat of clean engine oil to lubricate the outer diameter of the EGR valve seal during assembly on to the EGR valve. Push the EGR valve seal into the EGR valve inlet port by hand. The EGR seal must remain square in the EGR valve inlet port during installation.

Hammer the EGR valve seal fully; use a flat piece of steel across the EGR valve seal. The EGR valve seal must be fully seated onto the EGR valve inlet port shoulder.

Before installing the v-band clamp, coat the clamping surface with high temperature anti-seize compound.

Install the smaller v-band clamp on the EGR cooler connection. Do not tighten.

Install the larger v-band clamp on the end of the EGR valve that connects with the exhaust manifold. Do not tighten.

Install a new gasket on the piloted end of the EGR cooler connection.

Install a new gasket on the piloted end of the EGR valve where it connects to the exhaust manifold.

Install the EGR valve. Position the EGR connection v-band clamp, as shown, and tighten.

Lubricate the EGR valve seal with clean engine oil.

Install the EGR valve onto the EGR valve mounting bracket.

Install the four mounting capscrews into the EGR valve mounting bracket.

Tighten the capscrews.

NOTE: The longest capscrew passes through the EGR valve and EGR valve mounting bracket and threads into the engine block.

Connect the EGR valve connector.

• Install the EGR valve coolant lines. Refer to Procedure 011-030 in Section 11.
• Connect the EGR valve motor and position sensor connectors to the harness (clean off the wiring harness and connector before connecting to the valve).
• Install the heat shield. Refer to Procedure 011-032 in Section 11.
• Install the air intake pipe to the turbocharger. Refer to the OEM service manual.
• Install the alternator, if removed. Refer to Procedure 013-001 in Section 11.
• Install the water pump drive belt. Refer to Procedure 008-003 in Section 8.
• Fill the engine cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for exhaust and coolant leaks.

• Install the EGR heat shield. Refer to Procedure 011-032 in Section 11.
• Connect the OEM air compressor discharge line. Refer to the OEM troubleshooting and repair manual.
• Install the front EGR connection tube. Refer to Procedure 011-025 in Section 11.
• Connect the OEM fuel return hose from the integrated fuel system module. Refer to the OEM troubleshooting and repair manual.
• Connect the EGR temperature sensor. See the following procedure in the Troubleshooting and Repair Manual CM871 and CM876 Electronic Control System ISX and ISM Engines, Bulletin 4021560. Refer to Procedure 019-378 in Section 19.
• Operate the engine and check for exhaust or coolant leaks.
• Verify active fault codes. If a failure resulted in coolant, oil, excessive fuel or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.