MBE 4000 – Section 7.5 EGR Control Valve, Gas Outlet Pipe, and Gas Mixer

Section 7.5
EGR Control Valve, Gas Outlet Pipe, and Gas Mixer

The EGR control valve controls the quantity of exhaust gas returning back to the intake manifold.‪

Section 7.5.1
Removal of EGR Control Valve, Gas Outlet Pipe, and Gas Mixer

Remove the EGR control valve, gas outlet pipe, and gas mixer as follows:‪

1. Remove the EGR control valve cover mounting bolts attached to the front lifter bracket and to the rear of the EGR valve. See Figure "Removal of EGR Control Valve Cover" .
   

   1. EGR Control Valve Cover Mounting Bolts‪

   Figure 1. Removal of EGR Control Valve Cover

2. Loosen the wiring harness terminal from the back cover mounting bracket by punching the push-mount cable tie out of the drilled hole in the mounting bracket. Remove the two mounting bolts attaching the back cover bracket to the control valve. See Figure "Removing the Back Control Valve Cover Bracket" . Remove back bracket.
   

   1. EGR Control Valve Back Mounting Bracket‪

   2. Push-Mount Cable Tie‪

   Figure 2. Removing the Back Control Valve Cover Bracket

3. Remove the two bolts from gas outlet pipe attaching the pipe to the gas mixer. See Figure "Removal of EGR Gas Outlet Pipe" .
   

   1. Gas Outlet Pipe Flange‪

   2. Gas Outlet Pipe Mounting Bracket‪

   Figure 3. Removal of EGR Gas Outlet Pipe

4. Remove the metal gasket.
5. Remove the three bolts that attach the gas outlet pipe mounting bracket to the intake manifold and to the outlet pipe. See Figure "Removal of EGR Gas Outlet Pipe" .
6. Pull outlet pipe away from mixer and from the EGR control valve, exposing the membrane in the control valve. See Figure "Removing the Symmetric Membrane on Gas Outlet Pipe Side" .
   

   1. Membrane‪

   2. EGR Temperature Sensor‪

   Figure 4. Removing the Symmetric Membrane on Gas Outlet Pipe Side

7. Remove membrane from the EGR control valve.
8. Disconnect wiring harness terminal from valve connector. See Figure "Removal or Installation of EGR Control Valve" .
9. Remove the four bolts attaching the EGR control valve to the thermostat housing. See Figure "Removal or Installation of EGR Control Valve" .
   

   1. EGR Control Valve Mounting Bolts‪	3. EGR Control Valve‪
   2. Wiring Harness Terminal‪	4. EGR Temperature Sensor‪

   Figure 5. Removal or Installation of EGR Control Valve

10. Pull the EGR control valve out of the reed valve housing flange.
11. Remove symmetric membrane from the housing flange. See Figure "Removing the Symmetric Membrane on Gas Outlet Pipe Side" .
12. Pull the gas mixing pipe and metal gasket out of the air inlet pipe of mixer. See Figure "Removal of Gas Mixing Pipe" .
    

    1. Intake Manifold‪	3. Gas Mixing Pipe‪
    2. EGR Gas Mixer‪	4. Metal Gasket‪

    Figure 6. Removal of Gas Mixing Pipe

13. Remove the air temperature/pressure sensor attached to the gas mixer.
14. Remove the four bolts that attach the air intake pipe to the gas mixer. Remove the metal gasket as well. See Figure "Removal of EGR Gas Mixer" .
    

    1. EGR Gas Mixer Mounting Bolts (2 qty.)‪	3. Air Inlet Pipe‪
    2. EGR Gas Mixer‪

    Figure 7. Removal of EGR Gas Mixer

15. Remove the two bolts that attach the EGR gas mixer to the intake manifold. See Figure "Removal of EGR Gas Mixer" . Pull gas mixer off of four long studs away from intake manifold.
16. Unscrew the four studs from intake manifold.
17. Remove the metal gasket.

Section 7.5.2
Installation of EGR Control Valve, Gas Outlet Pipe, and Gas Mixer

Install the EGR control valve and gas outlet pipe as follows:‪

1. Insert a symmetric membrane into the reed valve housing flange using industrial petroleum jelly. See Figure "Removing the Symmetric Membrane on Gas Outlet Pipe Side" .
2. Insert the EGR control valve onto this membrane using petroleum jelly.
3. Install the back two bolts of the EGR control valve (M8 x 90 mm). Install the front two bolts (those closest to the front lifter bracket) of the EGR control valve (M8 x 40 mm). Torque all bolts to 25 N·m (18 lb·ft).
4. Using two bolts, install the back control valve bracket that holds the wiring harness terminal in place. Torque to 25 N·m (18 lb·ft).
5. Connect wiring harness terminal to valve connector.
6. Insert a second membrane into the right side of the EGR control valve housing using industrial petroleum jelly.
7. Taking the EGR gas outlet pipe in hand, fit component manually onto symmetric membrane, using petroleum jelly.
8. Install the four gas mixer mounting studs into the intake manifold.
9. Install metal gasket over studs.
10. Fit gas mixer over mounting studs and push on as far as possible.
11. Install the gas mixing pipe into the air inlet pipe of mixer using a new metal gasket. See Figure "Removal of Gas Mixing Pipe" .

    NOTICE:
    To avoid any engine damage, ensure that the gas passage of the mixing pipe is turned towards the intake manifold.‪

    Note: Due to its awkward shape, gas outlet pipe must be mounted to gas mixer before the gas mixer can be firmly attached to intake manifold.

12. Mount gas outlet pipe to gas mixer using a new metal gasket and two M8 x 16 mm bolts. Adjust gas mixer if necessary to accommodate the gas outlet pipe. Torque to 25 N·m (18 lb·ft).
13. Position support bracket in place for gas outlet pipe. Install bracket using three M8 x 16 mm bolts. Torque to 25 N·m (18 lb·ft).
14. Install the air inlet pipe to the gas mixer using four nuts. Torque to 50 N·m (37 lb·ft). See Figure "Removal of EGR Gas Mixer" .
15. Install the turbo boost/air intake temperature sensor to the gas mixer.