Cleaning EGR Valve

The EGR Valve should be visually inspected and cleaned if there is an active Diagnostic Trouble Code (DTC) associated with the EGR Valve. Cleaning the EGR valve restores the initial position, relative to the valve seat, eliminates the DTC, and allows the engine to remain emissions compliant. Important Notice: Once the DTC for the EGR Valve Out of Range is active, the EGR valve is electronically disabled, and YSAD Active Control cannot be used to open a disabled valve. A disabled EGR valve must be first opened using a TK Service Parts Tool (either 2042998 or 2042980) then cleaned to remove deposits from between the valve and seat, according to the EGR Valve Cleaning Notes.

Use Active Control in YSAD to open the EGR valve after removing it from the engine as shown in the following drawing. See “Using YSAD to Connect to ECU” for more information about connecting YSAD.

Important Notes About Cleaning the EGR Valve:

• Do not dismantle the EGR valve to clean it. The valve may not function properly when reassembled.

• Do not use liquid solvent to soak the valve, or spray liquid solvent into the valve. If liquid enters the valve motor it may be damaged and will not function properly.

• Use a soft or plastic brush. Do not use a metal brush. A metal brush will scratch the valve face and valve seat, which will cause the valve to leak when fully closed. This will reduce engine performance.

• Use a soft or plastic brush to remove carbon from valve face and valve seat. Carbon deposits on the valve face and valve seat will cause the valve to leak when fully closed. This will reduce engine performance.

EGR Service Tool Kit 2042980

This EGR Service Tool Kit includes a EGR 12V Opener Tool (2042980) and a EGR Mechanical Opener Tool. These tools will aid the technician in safe and effective cleaning of the EGR valve

The EGR 12V opener tool is the primary tool recommended by Thermo King for opening the EGR valve for cleaning. This tool allows the technician to evenly drive the EGR valve open electrically while having both hands free to handle and clean the EGR assembly. The opener can be connected directly to the unit battery or to a separate 12V power source.

In the event the EGR valve assembly is locked up in the fault mode, the EGR mechanical tool (2042998) can be used to safely and evenly push open the EGR valve plate manually so that it may be cleaned.

Using Active Control to Open EGR Valve

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1. Attach YSAD to the ECU/engine harness.

2. Check and clear any Diagnostic Trouble Codes (DTC) as required.

   1. Click on Diagnostic Codes to view any active DTCs.

      
      

      Check for Active DTCs

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   2. Clear the active DTCs as shown below.

      
      

      Clear Active DTCs

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3. Detach the EGR valve from the collector, but keep the EGR valve connected to the harness.

4. Use YSAD Active Control to open the EGR valve for inspection and cleaning as shown below.

   
   

   Use YSAD Active Control to Open EGR Valve

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   YSAD Showing EGR Valve Opened with Active Control

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5. Using a soft or plastic brush, remove stubborn deposits (e.g., carbon) from the surfaces of the EGR valve, valve seat, and housing as shown below. Do not use a metal brush or scraper or damage will result. Visually inspect the EGR valve

   
   

   Removal of Stubborn Deposits

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6. Once the deposits are removed from the EGR valve, wipe the valve and seat interface clean using a shop rag dampened with brake parts cleaner or similar solvent. Do not soak the valve guide and valve shaft interface, and do not spray the EGR valve with parts cleaner or damage will result.

7. Dry the EGR valve and return it to service by reattaching it to the collector.

8. Use YSAD to stop Active Control of the EGR valve as shown below.

   
   

   Use YSAD to Stop Active Control of EGR Valve

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9. Close and disconnect YSAD, and reassemble the EGR system components.

1. Attach the 4-pin female connector to the EGR assembly.

2. Place the tool’s toggle switch in the CLOSE position.

3. Connect the red positive (+) lead to a positive power source or unit battery.

4. Connect the black negative (-) lead to a negative power source or unit battery.

5. Place the toggle switch in the OPEN position. The EGR valve should open fully within 1 to 3 seconds. The EGR valve is now ready to be cleaned.

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6. Use a plastic brush to remove stubborn deposits from the EGR valve, then visually inspect it. Do not use a metal brush or scraper; otherwise, damage will result.

7. Once deposits are removed from the EGR valve, wipe the valve and seat interface clean using a shop rag dampened with brake parts cleaner or similar solvent. Do not soak the valve guide and valve shaft interface, and do not spray the EGR valve with parts cleaner; otherwise, damage will result.

8. Place the tool’s toggle switch in the CLOSE position. The EGR valve should close fully within 1 to 3 seconds.

9. Disconnect the 4-pin connector from the tool to the EGR assembly.

10. Reinstall the EGR assembly onto the engine and reconnect the 4-pin connector harness.

11. Return the unit to service.

1. With the EGR valve assembly removed from the unit, insert the tool into the side opening as shown. Ensure the valve stem is perfectly centered between the opener’s two pins.

2. Firmly press down on the tool handle towards the body of the EGR. This will open the EGR to allow for cleaning.

Note NOTE: The EGR valve is a spring loaded valve, therefore downward pressure must be maintained on the tool handle to keep the valve open while cleaning.

3. Use a plastic brush to remove stubborn deposits from the EGR valve, then visually inspect it. Do not use a metal brush or scraper; otherwise, damage will result.

4. Once deposits are removed from the EGR valve, wipe the valve and seat interface clean using a shop rag dampened with brake parts cleaner or similar solvent. Do not soak the valve guide and valve shaft interface, and do not spray the EGR valve with parts cleaner; otherwise, damage will result.

5. Reinstall the EGR assembly onto the engine and reconnect the 4-pin female connector harness.

6. Return the unit to service.

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