EGR Valve replacement?
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Senior Member
Joined: Oct 2004
Posts: 226
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From: Miami OK
EGR Valve replacement?
Anyone else had the displeasure of changing their Egr Valve? I had to do mine this last Sunday 12-3-05. Ws not all that fun. What should have been a 30 minute Job turned into a 2 day project. Why you ask? Becuase of a damn broken bolt. For those that haven't change EGR before 5 bolts and 1 flare nut have to come off to change. Three of the screws are to hold the plastic cover on, the one over the throttle body, 2 bolts hold on the Egr Valve and1 flare nut coming up from the exhuast manifold.
Well I broke lose the rear broke lose the rear most bolt no P. Broke front bolt lose, seemed overly tight, but did lossen after another 1/2 turn. Took lose the inverted flare fitting, and removed pipe from EGR, still attached to Exhaust manifold. I finish taking out rear most bolt no problems. Try to finish removing front bolt. 1/2 turn in th thing acts like I just tightened way up. Realizing I have a problem I turn it back in maybe 1.5 turns. Spray some penetrating lube on it. front and back. Work bolt back and forth in the "GOOD" area for some time. Try to take out again, no go. Running short on patience I try to horse it out.
Bad Idea, as you all know. It never did snap just slowly twisted off. By the time I realized it was breaking I was to far to just tighten back up. 
So, I spent the next 2-3 hours drilling out bolt while intake neck was still on truck, Bad Idea #2. Did not drill anywhere near center, but to my credit hole was small enough not to get into aluminum throttle neck/ elbow. 
At this point I had been up nearly 25 hours with no sleep and realized enough to leave and go to bed. (I work 3rd shift) 5p.m. when I went to bed, and I had to be at work at 10:00 with a 45 min. drive to get there. I make arrangement to barrow my Moms truck, God bless her. I did finally get the bolt out. Took and endmill A really good hand drill, and I had to remove the Intake neck/ elbow from truck. Had I been awake enough to realize this 24 hours before, I went to bed after work got up aroun 4:30p.m., I could remove that one piece, intake neck, I would have saved a ton of time. and would not have ended up wallering out the hole. Luckily hole was not so far goon as to need drilled and helicoiled or tapped bigger, but lets just say you don't wanna tighten that one bolt TOOOO much.
On the bright side Check engine light did go off. After about 3 blocks of driving after the change.
Apperently the people at AutoZone aren't that worthless. Of course they did sell me the wrong EGR valve the first time. LOL
Anyway thanks for letting me rant. I just had to off load some of this. This board is great I used search function to find ease of change. If I ever have to change this thing again I will wait til a warmer day. High here has been in the low 30's over night lows in the teens and wind chills under 0. Not the right time of year for this stuff to happen. Sorry for the long post.
Scotty
Well I broke lose the rear broke lose the rear most bolt no P. Broke front bolt lose, seemed overly tight, but did lossen after another 1/2 turn. Took lose the inverted flare fitting, and removed pipe from EGR, still attached to Exhaust manifold. I finish taking out rear most bolt no problems. Try to finish removing front bolt. 1/2 turn in th thing acts like I just tightened way up. Realizing I have a problem I turn it back in maybe 1.5 turns. Spray some penetrating lube on it. front and back. Work bolt back and forth in the "GOOD" area for some time. Try to take out again, no go. Running short on patience I try to horse it out.
Bad Idea, as you all know. It never did snap just slowly twisted off. By the time I realized it was breaking I was to far to just tighten back up. So, I spent the next 2-3 hours drilling out bolt while intake neck was still on truck, Bad Idea #2. Did not drill anywhere near center, but to my credit hole was small enough not to get into aluminum throttle neck/ elbow. At this point I had been up nearly 25 hours with no sleep and realized enough to leave and go to bed. (I work 3rd shift) 5p.m. when I went to bed, and I had to be at work at 10:00 with a 45 min. drive to get there. I make arrangement to barrow my Moms truck, God bless her. I did finally get the bolt out. Took and endmill A really good hand drill, and I had to remove the Intake neck/ elbow from truck. Had I been awake enough to realize this 24 hours before, I went to bed after work got up aroun 4:30p.m., I could remove that one piece, intake neck, I would have saved a ton of time. and would not have ended up wallering out the hole. Luckily hole was not so far goon as to need drilled and helicoiled or tapped bigger, but lets just say you don't wanna tighten that one bolt TOOOO much. On the bright side Check engine light did go off. After about 3 blocks of driving after the change.
Apperently the people at AutoZone aren't that worthless. Of course they did sell me the wrong EGR valve the first time. LOLAnyway thanks for letting me rant. I just had to off load some of this. This board is great I used search function to find ease of change. If I ever have to change this thing again I will wait til a warmer day. High here has been in the low 30's over night lows in the teens and wind chills under 0. Not the right time of year for this stuff to happen. Sorry for the long post.
Scotty
Senior Member
Joined: Mar 2001
Posts: 1,919
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From: Western Massachusetts
I agree, changing the EGR isn't as easy as it looks. I figure most anything I do to my truck, other than adding fuel, is going to take a while. There really is no alternative to sucess though, is there.