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Old 01-09-2010, 11:25 PM
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How To: Install a new EGR

My 05 WK has been stalling lately, and i got a CEL with 0406 for a DTC code which is high EGR input voltage, so I figured Id swap it out. I paid 72 plus tax at my stealership along with a new hood prop.

Knowing what I know now, this is a 30 minute job, maybe a little less for those with a CAI. Ive tried to cut this process down to the bare essentials. I did a few other things like install a new hood prop, remove all the stock intake stuff getting ready for my Airaid, I also messed with serp belt and alternator, which is not needed for this.

First remove the intake components, which includes a 10mm bolt my the TB, a ring clamp on the TB, and I also took out the complete airbox, and stock intake plumbing by the headlight. I also unbolted the radiator overflow tank to make it easier to move, its just 1 bolt. Once you get all that out, you see this...

...to uplug it, you slide a small red piece in and to the right then unplug it.

new one, comes with a metal gasket and 2 bolts.


Then use a 8mm socket to undo the vent tube (circled in red above) that goes to the TB, it just slides out of the TB with little effort. Be careful with this little guy, its a small rubber gasket used to seal off the inlet of the TB. I tried to slide mine, but it was stuck to the tube, so of course it tore. I had to reuse it or else the tube is loose, so now I get a hiss where its leaking. Gotta pick up one at the Jeep place on monday.


Next use a 10mm socket to remove the bolts on the EGR. The inside one will come all the way out, the outer one will go until it hits the alternator. I tried all I could to move the alternator and it wont move far enough. I then used a dremel to cut the bolt between the EGR and head, be careful. Make sure the bolt is lose enough so you can turn it by hand or with pliers once the EGR is off.


Cut...I covered the hole up so no dust or metal shavings would get in there.


Then reinstall using the metal gasket that comes with it. I used a new bolt that was included, and a M8 x 1.25, 16mm bolt fomr Lowes. Another member said use a 20mm, but I bought both and the 16mm fit perfect, mine had a 13mm hex head.


Once its installed, reinstall the vent tube with the 8mm bolts, dont forget the paper gasket at the EGR and the small rubber gasket up at the TB.


Jeep really screwed up on this. There is literally less than 2 threads holding this thing on, all they had to do was make it 2-3mm shorter and it would be much easier.


Hope that helps anybody that might try to do this themselves. I really enjoy working on cars. I havent done much to my Jeep but Im about to start doing some stuff so Ill post up some more threads when I do them. I posted my 2 previous projects that i had before the Jeep. I did pretty much all the work on them except the engine build.

My turbod G35 coupe. Started out with a vortech supercharger then went with a GT35R single turbo, full coilover suspension with upgraded control arms, fully customized big brake kit F&R, several different sets of rims, and different stereo setups, pretty much my fav car. I won 1st place at nopi nationals 2 years in a row with it.




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Old 01-10-2010, 12:19 AM
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Re: How To: Install a new EGR

Great write up man!!!!
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Old 01-10-2010, 12:26 AM
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Re: How To: Install a new EGR

+rep!
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Old 01-10-2010, 11:36 AM
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Re: How To: Install a new EGR

after driving 50 miles today. ive noticed a few things that are wierd.

1. i dont get the dead spot that i used to get when accelerating, the throttle response is crisp.

2. i dont get the hard clunk i used to get when letting off the gas at around 40mph. it used to feel rough on downshifts.

3. i dont get an erratic idle when slowing down to a stop. the rpms used to drop around 500 and was unstable. now it just goes to 700 and stops.

im not claiming the EGR fixed those things, but i didnt change anything else. ill report back in a week with another update.
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Old 01-15-2010, 05:42 PM
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Re: How To: Install a new EGR

well, after about 300 miles it still runs perfect. not one single stall or stutter, no hard shifts, and no dead spots. unbelievable. all this time it ws the EGR causing all those problems.
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Old 07-04-2010, 01:40 PM
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Re: How To: Install a new EGR

On the bolt that hits the alternator, It only takes a few minutes to take the belt off, and unbolt the alt to move it out of the way. For those like me that don't have a good way to cut that bolt off.
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Old 07-04-2010, 01:58 PM
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Re: How To: Install a new EGR

Quote:
Originally Posted by tig488 View Post
well, after about 300 miles it still runs perfect. not one single stall or stutter, no hard shifts, and no dead spots. unbelievable. all this time it ws the EGR causing all those problems.
X2. No issues in 4 weeks since EGR valve was renewed. Gas mileage back up to original levels.

If there are engine performance issues driving you nuts, no codes, and >40K miles on the odometer, change it. It's the hidden mechanical gremlin.

Dealer didn't believe me; I shamed them into changing it. Sometimes, the entire world of knowledge is not in the StarScan tool.
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Old 04-21-2011, 06:38 PM
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Re: How To: Install a new EGR

Ok yea getting the EGR off is a BEEYATCH!!! The bottom bolt was a PITA. I didnt have to cut it, though. I did wiggle it out (without screwing up the head thread) and it was fun putting the new bolt on. I ended up shaving down the new bolt a few threads and she went on nice n smooth! Now I gotta throw on my CC and I'm good to go at 56k! Hopefully my MPGs will go up, although I need some new spark plugs on my Hemi! Thanks for the write up, +rep for you!
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Old 04-21-2011, 07:08 PM
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Re: How To: Install a new EGR

saw how far back it was on the 4.7 and decided to have my mechanic do it. $55 and a lot easier on me haha
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Old 04-21-2011, 07:13 PM
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Re: How To: Install a new EGR

Quote:
Originally Posted by SvenskaJeepGuy View Post
saw how far back it was on the 4.7 and decided to have my mechanic do it. $55 and a lot easier on me haha
Damn much cheaper than the $400 my stealership quoted me!
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Old 04-21-2011, 07:52 PM
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Re: How To: Install a new EGR

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Damn much cheaper than the $400 my stealership quoted me!
and the part was only $28 from autozone
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Old 04-21-2011, 08:19 PM
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Quote:
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and the part was only $28 from autozone
Nice! Mine was $52 I think. Hemi parts like to be more expensive. Lol
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