A Guide to Removing/Replacing EGR Valve
CerealKLR4u
08-10-2004, 01:58 PM
EGR Valve and Solenoid Removal/Replacement for 97 Neon Sport(should be same for similar models)
(note: EGR = EGR Valve...same thing...just varies in what i call it through here)
Ive read a bunch of stuff prepping myself for how to remove the EGR valve on a neon..so Ive decided to write up this little guide to how i did it...without dislocating my hand lol. Its actually quite simple.
Firstly, you wanna remove the EGR Solenoid, this is this is the plastic piece with two tubes and a
electric connecter on it, and its on the right side of the air intake connected to it with a plastic fastner. First disconnect the electrical clip on the back of the solenoid. then disconnect the hoses from the two tubes, they should come off fairly easily. They should be two differnt sizes, and easy to remeber which one goes where...Actually they can only go on one way comfortably. Next go to the ring-style clip holding it onto the air intake tube and disconnect it, it should now come out pretty easily. This part few people actually seem to have problems with removing. Now that you have that half of the package out of the vehicle you can move on to the actual EGR Valve itself.
Keep in mind if you do need to replace this, the solenoid and the egr valve come as a package deal so dont worry about saving one or the other if you replace, but keep them around just to make sure the parts you get are identical for obvious application purposes.
Now find the two tubes that you disconnected from the EGR Solenoid and follow them up to the *drumroll* EGR valve...they both go to the valve just different pipes. disconnect these two tubes and set them next to the solenoid you just took off. Now you should know at least where the mysterious EGR valve actually is (personally , i couldnt find it at first). Anyways there are two 10mm bolts mounting the EGR Valve to the block and a pipe connected to it with two 8mm bolts(could be slightly smaller, but my 8mm worked fine). I went ahead and took these bolts out first but before you can do that , theres a little prepatory work to be done so you can actually move around a little bit in there cause everything is so tight.
First thing to do to make some space is (if you have a stock air intake) is to move the air intake tube that the solenoid was connected to. This is very simple, theres two ring fasteners holding it on, one at the block, and one near the air cleaner.. loosen these and it almost pops off completely , i didnt bother taking off the tube connected to it and just pushed the whole thing aside on top of the block. Another good thing to do that made it easier was to release the clips on the fusebox near the battery and just move it out of the way for the time being. it wont go far but enough so you can manuever a ratchet in there. I also undid the negative terminal on the battery so the cables were out of my way. Now you should have good room in there to get into those bolts.
Now take your ratchet and work on removing the two 8mm bolts on the pipe connected to the egr...set these two bolts somewhere safe so you dont lose them. Now you just have the 2 10mm bolts mounting the egr to the block. It might be easier to now replace the fusebox to its original position which just clicks right back in (how conveinient). The top bolt shouldnt be too hard to figure out, but the bottom bolt is always the "tricky" one that alot of people seem to have problems with. No matter which way you attack it, it just doesnt seem like you can get the ratchet on it, at the right angle, enough to rotate ....unless....you read this...there should be a pair of rubber tubes in front of the egr that are blocking your way instead of trying to go around them.. I just went between them!...amazingly with the longest extensions on your ratchet it slides right between the two tubes and up onto the bolt (how simple!) now just work on loosening that last screw and your almost home free. Be warned there is a gasket on the back of the egr so make sure it doesnt fall when you release it...grab the gasket , catch the screws, and pull out the EGR Valve. And there you have it...a nice clean quick EGR Valve removal.
From here you have two options: try and clean out your old one if its not blown, or buy a new one which usually runs for about 75 bucks (Autozone price). Regardless of what you do with the valve make sure to clean out the two small rubber tubes you removed, clear out any carbon buildup and blow through them to make sure they are clean, if they are brittle, cracked, or too gunked up to fix, just go buy some new ones. Personally i dont know how to clean the EGR Valve itself out yet, Im still working on the best way to go about taking out all the carbon. So if you know, then go for it, (and tell me) if not its up to you what to do..To put the new one (or the old now clean one) back on just follow this procedure in reverse and things should go smoothly.
If you have any questions or comments, PM me or post here, im sure either I or someone else can help you out.
(note: EGR = EGR Valve...same thing...just varies in what i call it through here)
Ive read a bunch of stuff prepping myself for how to remove the EGR valve on a neon..so Ive decided to write up this little guide to how i did it...without dislocating my hand lol. Its actually quite simple.
Firstly, you wanna remove the EGR Solenoid, this is this is the plastic piece with two tubes and a
electric connecter on it, and its on the right side of the air intake connected to it with a plastic fastner. First disconnect the electrical clip on the back of the solenoid. then disconnect the hoses from the two tubes, they should come off fairly easily. They should be two differnt sizes, and easy to remeber which one goes where...Actually they can only go on one way comfortably. Next go to the ring-style clip holding it onto the air intake tube and disconnect it, it should now come out pretty easily. This part few people actually seem to have problems with removing. Now that you have that half of the package out of the vehicle you can move on to the actual EGR Valve itself.
Keep in mind if you do need to replace this, the solenoid and the egr valve come as a package deal so dont worry about saving one or the other if you replace, but keep them around just to make sure the parts you get are identical for obvious application purposes.
Now find the two tubes that you disconnected from the EGR Solenoid and follow them up to the *drumroll* EGR valve...they both go to the valve just different pipes. disconnect these two tubes and set them next to the solenoid you just took off. Now you should know at least where the mysterious EGR valve actually is (personally , i couldnt find it at first). Anyways there are two 10mm bolts mounting the EGR Valve to the block and a pipe connected to it with two 8mm bolts(could be slightly smaller, but my 8mm worked fine). I went ahead and took these bolts out first but before you can do that , theres a little prepatory work to be done so you can actually move around a little bit in there cause everything is so tight.
First thing to do to make some space is (if you have a stock air intake) is to move the air intake tube that the solenoid was connected to. This is very simple, theres two ring fasteners holding it on, one at the block, and one near the air cleaner.. loosen these and it almost pops off completely , i didnt bother taking off the tube connected to it and just pushed the whole thing aside on top of the block. Another good thing to do that made it easier was to release the clips on the fusebox near the battery and just move it out of the way for the time being. it wont go far but enough so you can manuever a ratchet in there. I also undid the negative terminal on the battery so the cables were out of my way. Now you should have good room in there to get into those bolts.
Now take your ratchet and work on removing the two 8mm bolts on the pipe connected to the egr...set these two bolts somewhere safe so you dont lose them. Now you just have the 2 10mm bolts mounting the egr to the block. It might be easier to now replace the fusebox to its original position which just clicks right back in (how conveinient). The top bolt shouldnt be too hard to figure out, but the bottom bolt is always the "tricky" one that alot of people seem to have problems with. No matter which way you attack it, it just doesnt seem like you can get the ratchet on it, at the right angle, enough to rotate ....unless....you read this...there should be a pair of rubber tubes in front of the egr that are blocking your way instead of trying to go around them.. I just went between them!...amazingly with the longest extensions on your ratchet it slides right between the two tubes and up onto the bolt (how simple!) now just work on loosening that last screw and your almost home free. Be warned there is a gasket on the back of the egr so make sure it doesnt fall when you release it...grab the gasket , catch the screws, and pull out the EGR Valve. And there you have it...a nice clean quick EGR Valve removal.
From here you have two options: try and clean out your old one if its not blown, or buy a new one which usually runs for about 75 bucks (Autozone price). Regardless of what you do with the valve make sure to clean out the two small rubber tubes you removed, clear out any carbon buildup and blow through them to make sure they are clean, if they are brittle, cracked, or too gunked up to fix, just go buy some new ones. Personally i dont know how to clean the EGR Valve itself out yet, Im still working on the best way to go about taking out all the carbon. So if you know, then go for it, (and tell me) if not its up to you what to do..To put the new one (or the old now clean one) back on just follow this procedure in reverse and things should go smoothly.
If you have any questions or comments, PM me or post here, im sure either I or someone else can help you out.
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