Hi,
I apparently have a bad FCV based on a mil code. I would like to replace it but cannot find out how to do it by searching the factory service manual. Every search of FCV in the FSM yields EGR airflow control valve.

Is the FCV coupled to the EGR? If so, can it be replaced separately (anybody with a part number?).

Thanks, my wife really wants the MIL gone and I would also like it to disappear if we decide to sell the CRD or trade it in.

I can turn a wrench and am a decent backyard mechanic but turbo diesel vehicles make me clueless.

Drew

Hi, Drew. The FCV is immediately downstream from the output side of the intercooler (in fact, the other end of the hose is attached to it). I does operate in conjunction with the EGR, but is not part of it. In addition to "ballancing" the input air when the EGR operates, it also shuts the intake on engine shutdown to avoid dieseling. On a properly operating unit, you'll hear it open back up about 30 seconds after shutdown. It's just a circular butterfly on a servo in the air stream.

I've taken mine out before just to clean it and it took maybe 20 minutes (including figuring out where all the fasteners are, etc.) Here's what you need to do:
- Remove hose from output side of intercooled and FCV. This is a good time to soak it in some mild degreaser if you've run without the EHM or filter mods. It'll be oily.

- Disconnect and remove the battery. You don't HAVE to, but it makes getting under the FCV a lot easier.

- Disconnect the electric plug on the FCV and disassemble the accessory mounting bracket that's just above it and attached to the head. This'll make removal a little easier.

- Remove the 4 allen bolts from around the perimeter (the bottom ones can be a bear if you have big hands) and slide the whole assembly out. It'll likely by oily since that seems to be what kills them. You may want to inspect the unit to see if it really is broken or just gummed-up. You may say some money by simply cleaning if with some MAF cleaner, etc. Of course, if you heard a clicking sound while it was in, it's probably done-for. That's the servo gear skipping because it's partially broken.

- Assembly is the reverse of removal. Be sure you rinse the hose out well if you were soaking it. A compressor or leaf blower do a good job of drying it out

Dan

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2005 Silver CRD Limited
245/75R16 GoodYear Duratracs
Fumoto drain | ProVent CCV Filter
Stanadyne FM100 filter | Cummins fuel pump
GDE Eco | SEGR | BoulderBars | FrankenLift | Frankenskids

FCV - (AIR) Flow Control Valve, or AFV, or FCV, or AFCV, etc - spring-loaded in open position, ECM adjusts opening based on EGR requirement and MAP (Boost) at the time - also used to throtte off the intake at shutdown like a gasser (patooie!) so the KJ CRD engine stops smoothly like a gasser (ditto!) - remove the inlet hose, plate should be at 90* angle to tube - you should be able to force it closed, and it will spring back to wide open if all is copasetic - replacement is up around 300bucks

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

Thanks for describing where it is. Anybody have a part number? I still can't find this FCV by name in the factory service manual

So, what fails in these? Does the motor burn out? Does a gear strip? Can it fail and be repaired with simple cleaning?

Now that you folks have mentioned it, I don't hear any of the noise that I typically do when I shut down.

THANKS AGAIN. YOU ALL HAVE BEEN A GREAT HELP!

Mine got reall noisey, stripping gear sound, then quieted down satripping gear sound. I don't think it's working and don't have a cell. I saw a cross section of one somewhere and besides gears it has a sensor on it's position. I believe my gears are stripped after the sensor because I have no cel

I found my hard copy of the cross section I printed out It's definetly from the VM site and it looks like all you need to remove is the side cover to expose the gears

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)