Steps to replace the egr valve on 2004 dodge rame hemi?

Answer 1

The EGR valve is located in the front right of the motor, slightly below the alternator. It is about the size of a large bottle of pills with an attachment on it.

First, unlock the air filter cover and remove the air filter. Place a screwdriver in the ring sticking out above the air filter box below the windshield trim piece to hold up the air filter cover up and out of the way. The air filter box sits on three holders with rubber ends. Grasp the air filter box with both hands and lift straight up off the holders and out of the engine compartment. This will give you a clear view of the EGR valve and room to work as well.

Next, remove the wiring harness by sliding the red tab on the connector out of it's centered, locked position. Then remove the connector by pulling it away from the EGR valve.

The EGR valve has 4 bolts. 2 are 8mm and the other 2 are 10mm. Remove all 4 bolts, being careful not to drop or lose the gaskets on either end of the EGR valve. Removing these bolts is best done with a 1/4" ratchet with deep-well sockets or regular sockets and a small extension.

Remove the EGR valve and either replace with a new one or spray inside thoroughly with carbeurator cleaner or brake cleaner to free up the plunger action inside. This will break up the carbon on the inside, allowing the plunger that is in the valve to move freely, which is the likely cause if the problem. After soaking, it may be necessary to use a screwdriver to break free and exercise the plunger. Place the tip of screwdriver inside the opening in center of the EGR valve on move the plunger in and out. This may be difficult, so use spray liberally. Wipe carbon deposits off any area the will touch the gaskets and clean off excess spray.

Re-install EGR valve the same way it came off, making sure to reattach wiring and secure.

Note: If a check-engine light is on prior to replacing the EGR valve, disconnect the positive terminal on the battery and wait 30 seconds for the computer to reset itself. Reconnect the positive terminal and start engine. If problem persists, consult the dealer.

Addition-I took the two exhaust bolts off from the top but found it much easier to reach the two main housing bolts from below. I started all 4 bolts from underneath then tightened the exhaust again from the top. Make sure to wear safety glasses because carbon WILL fall into your face. Someone made the comment that the bolts will be tight and they were. I used an 18 inch length of pipe attached to the end of my ratchet for additional leverage.