Skip to main content ↑ ↓
Topic: EGR Valve Replacement (Read 786 times) previous topic - next topic

EGR Valve Replacement

I'm getting a check in light on my Cummins ISM 500 and the code indicates SPN2791 EGR Valve Control, FMI 7 Mechanical System Not Responding or Out of Adjustment.  QuickServe tells me it means the valve is stuck open.  Replacement looks to be straight forward and I found the steps for the job in the service manual - just gotta raise the bed and pick out a comfortable spot on the aluminum frame.

I did an EGR valve job on a Ford 6.0 years ago, that seems a lot more complex than this since it felt like I had to remove the top half of the engine (turbo, oil cooler, intake manifold) - that one was the last big job I did and I kinda swore off trying anything like again.  I don't think I'm in over my head on this one, I guess we'll see...

Anyway - who is your go-to for Cummins parts?  Reman is fine, part number is 4955421RX, but prices are all over the place.  I just want a reliable vendor.

Re: EGR Valve Replacement

Reply #1 –
We have a 2005 U320, and we just had it replaced with our mechanic at home. Sending you our parts list of all the parts we needed, just to be safe we ordered extras. And on our 05 the EGR valve is at the top left of the motor. You have 3 bolts going to the exhaust manifold and 2 coolant lines. Make sure you have a way to cap these off, where you don't lose too much antifreeze. And if the exhaust manifold bolts have not been taken off before, you will need to spray them a couple of days before. Here is my part list and  remember we bought a few extra just in case :

Cummins V Band Clamp - 3683144
Part #3683144
Quantity 1
Unit price $72.48

Cummins Hexagon Flange Head Cap Screw - 3102043
Part #3102043
Quantity 3
Unit price $14.45

Cummins Grommet Seal - 3682826
Part #3682826
Quantity 4
Unit price $4.58

Cummins Kit,Egr Valve - 4955421RX
Part #4955421RX
Quantity 1
Unit price $2,372.41

Core VALVE, EGR (ISM02) - 3102745D
Part #3102745D

Re: EGR Valve Replacement

Reply #2 –
What was the first year for the EGR valve on the ISM? Disregard 2003 was the design year and started installing in 2004?

Re: EGR Valve Replacement

Reply #3 –
Had mine replaced last fall.

Re: EGR Valve Replacement

Reply #4 –
You feel handy?  The EGR valve may be able to be cleaned and returned to service.

Re: EGR Valve Replacement

Reply #5 –
Quote from: krush –
You feel handy?  The EGR valve may be able to be cleaned and returned to service.
I was thinking I would keep the old one as a spare, get it cleaned up and ready to go for the next time. It seems that some people have this issue with the ISM every 20 or 30,000 miles

Re: EGR Valve Replacement

Reply #6 –
Update - finally got some time and worked on it yesterday.  It was straight forward except for the v-band clamp - I was able to back the nut off, but the band itself wouldn't budge.  PB Blasted the crap out of it and left for the day.

Came back today and used my newly acquired rotary hammer in chisel mode.  Applied some light pressure and the band came off after about 5 or 10 sec.  Reinstall went smooth except for the elbow for the coolant line needed to be clocked slightly to get the nut to grab the threads.

I really thought I could figure out a way to block the coolant lines without draining the coolant.  This was more laziness than anything, so I have mess to clean up underneath - then top the coolant back off and test it.

All in all, I'm glad I tackled it - it is definitely something that I could do in 1/3 of the time next time, and I learned a bit about where the systems are on the engine.

Pics -
    • EGR out
    • new and old EGR side by side
    • pic of old valve - seems ok but maybe it wouldn't completely close or the position sensor was bad
    • EGR back in

Edit - added one more pic to show removal - there are 2 wiring harnesses not shown.  Disconnect coolant lines, disconnect v-band clamp, remove lower 3 bolts.  There's a gasket for the bottom and at the v-band.  Use high-temp anti-sieze on the bolts and flange.

Re: EGR Valve Replacement

Reply #7 –
Nice job!

Quote from: stevej –
PB Blasted the crap out of it and left for the day
When I know I will be working in an area , I do the same, let it sit for a day.  Sometimes I'll go back the next day and hit it again as an excuse to not work on it that day :D 
 

Re: EGR Valve Replacement

Reply #8 –
Actually learning when to walk away is a crucial skill. When we get away it gives the subconscious a time to work on the problem, it lowers frustration and the resultant costly mistakes of impatience, it brings a "fresh eye" to the problem when you start again, and it lowers the risk of personal injury. I have learned to make myself stop and walk away as part of the process. Even an experienced mechanic will forget a key skill they have learned in the past and when walking away will remember how this problem was solved in the past or a tool buried deep in the tool chest that will do the trick.

The first time is always a learning experience that can be painfully slow. Congratulations!