How to Replace an EGR Valve in a 2001 Pontiac Bonneville

The Exhaust Gas Recirculation (EGR) valve works by regulating measured amounts of fuel and exhaust (oxygen) that enter the engine combustion chamber (pistons). It was introduced in the early 1960s, as a device to improve automotive fuel efficiency and reduce smog forming emissions that enter the atmosphere. A malfunctioning EGR valve will remain open, signaled by the check engine light coming on, allowing too much fuel versus oxygen to enter the chambers. This can cause premature combustion (explosion) and result in the engine overheating. Replacing the fairly inexpensive EGR valve in your 2001 Pontiac Bonneville is a moderately easy repair to perform.

Removing the EGR valve

• 1

  Raise the hood, put on your safety glasses and locate the EGR valve, which is mounted onto the intake manifold near the firewall. The intake manifold is attached to the engine block and located on the left side, when facing the engine.

• 2

  Remove the tube leading to the air-intake cover to allow for better access to the EGR valve. Disconnect the single-prong electrical terminal connection and rubber vacuum tube that plugs into the EGR valve. Inspect these connections for excessive wear and replace them as needed.

• 3

  Take out the two mounting bolts located on either sides of the EGR valve. Detach the old valve from the manifold by gently tapping it, using a small hammer to break the seal. Carefully scrape off the old gasket and built up debris from the manifold using a razor.

Installing the EGR valve

• 1

  Apply a thin bead of gasket adhesive to the replacement gasket and then place it onto the manifold opening. Align the bolt holes so that the new EGR valve will seat correctly. Apply another bead of adhesive to the top side of the gasket.

• 2

  Insert the new replacement EGR valve into the manifold opening. Secure the replacement valve in place with the two mounting bolts. Reattach the electrical wire and vacuum hose connections. Reconnect the air-intake tube.

• 3

  Disconnect both of the battery cables and leave them disconnected for a minimum of six hours. This will reset the electrical system and check engine light indicator. After six hours, reconnect the battery and test drive the vehicle. Check to see if the check engine light comes on.