Two-Piece Valve

These valves have a detachable pintle and seat. They are identified by the lack of a weld spot at the center of the pintle when viewed from the bottom.

1. Remove EGR valve and discard gasket. Clean base surfaces of valve and visually inspect seat and base for 2 scribe alignment marks. See Fig 1 . This alignment must be maintained at reassembly.
   Fig 1: Two-Piece EGR Valve Assembly Note position of scribe marks.

   
2. Measure distance from the base surface down to shoulder on seal. Record this measurement for reassembly. Hold base of valve in vise and remove valve seat with wrench. Pintle is staked at factory and may need to be worked back and forth to remove it.
3. With valve held in an upright position, remove pintle with pliers. DO NOT locate pliers on sealing surface. Using correct size drill bit (No. 54 for 3.8L engines and No. 40 for 4.1L engines), slowly turn drill bit up into valve shaft opening approximately 1". See Fig 2 . Lightly tap on shaft to allow loose material to fall from shaft opening.
   Fig 2: Removing Seat From EGR Valve Seat is staked in place at factory.

   
4. Clean holes in pintle with a drill bit and compressed air. Place pintle over end of shaft and force down until a "lock-in" position is felt. Screw seat into base until seat is at the original position. Recheck depth measurement taken in step 2) and align scribe marks. Support valve at base and restake the seat at the 3 original staking locations.