Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Exhaust Gas Recirculation (EGR) Cooler System
The exhaust gases are directed through the EGR cooler to lower the exhaust gas temperature before entering the intake manifold. Engine coolant reduces the exhaust gas temperature when the gases are directed through the EGR cooler by closing the EGR bypass valve.
The PCM controls the EGR cooler bypass valve by commanding the EGR cooler bypass solenoid duty cycle. When the EGR cooler bypass valve is commanded OFF (Transit), or 0% (all others), duty cycle, the exhaust gases pass through the EGR cooler to the intake manifold. When the EGR cooler bypass valve is commanded ON (Transit), or 100% (all others), duty cycle, the exhaust gases pass directly to the intake manifold without passing through the EGR cooler.
For additional information on the EGR cooler system components, refer to ENGINE CONTROL COMPONENTS .
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.