Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

EGR Valve Position Sensor

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Operation



The Exhaust Gas Recirculation (EGR) valve consists of 3 major components:



The pintle, valve seat, and housing which contains and regulates the gas flow
 
The armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects to the 2 connectors in the connector assembly
 
The third major component senses pintle position and is connected to the 3 connectors in the electrical connector.
 

The EGR flow is determined by the engine controller. For a given set of conditions, the engine controller knows the ideal EGR flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The engine controller adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct position.

Removal & Installation



2.4L Engine

The Exhaust Gas Recirculation (EGR) valve is to be replaced as an assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner box.
  6.  
  7. Remove the 2 bolts attaching the EGR tube to the EGR valve.
  8.  
  9. Remove the 2 bolts attaching the EGR valve to the cylinder head.
  10.  
  11. Disconnect the electrical connector from the EGR solenoid.
  12.  
  13. Remove the EGR valve as an assembly.
  14.  
  15. Clean the gasket surfaces. Discard the old gasket. If necessary, clean the EGR passages.

    Click image to see an enlarged view

    Fig. Exhaust Gas Recirculation (EGR) valve assembly-2.4L engine

  16.  

To install:

  1. Clean the surfaces of the cylinder head and the EGR tube where the EGR valve interfaces.
  2.  
  3. Install a new gasket between the EGR valve and the transducer to the cylinder head and loosely install the bolts.
  4.  
  5. Install the 2 bolts from the EGR tube to the EGR valve.
  6.  
  7. Tighten the EGR valve to the cylinder head bolts to 17 ft. lbs. (23 Nm).
  8.  
  9. Tighten the EGR tube to the EGR valve bolts to 97 inch lbs. (11 Nm).
  10.  
  11. Connect the electrical connector to the EGR transducer.
  12.  
  13. Connect the vacuum hose to the EGR transducer.
  14.  
  15. Install the air cleaner box.
  16.  
  17. Connect the negative battery cable.
  18.  

Testing



  1. Turn the ignition on. With the DRBIII®, read DTC-s and record the related Freeze Frame data. Is the Good Trip displayed and equal to zero-
    1. If yes, go to step 2.
    2.  
    3. If no, verify and correct any DTC conditions before continuing. Perform POWERTRAIN VERIFICATION TEST VER-5.
      NOTE
      If the vehicle is running rough at idle (DRBIII® is not actuating), follow the yes path to continue.

    4.  

  2.  
  3. Turn the ignition ON. Turn all accessories OFF. Start the engine. Allow the engine to reach normal operating temperature. With the DRBIII®, enter Engine System Test, then EGR System Test. Monitor the MAP Sensor voltage on the DRBIII® while actuating the FLOW function in the EGR System Test.
    NOTE
    When the EGR valve is commanded open, the MAP sensor voltage will shift with the induced vacuum leak.

    1. Was there a MAP sensor voltage shift when the EGR valve was opened-
    2.  
    3. If yes, go to step 3.
    4.  
    5. If no, got to step 7.
    6.  

  4.  
  5. Turn the ignition OFF. Disconnect the EGR Solenoid Assembly harness connector. Start the engine. Attempt to allow the engine to idle. Does the engine run rough or stall-
    1. If yes, inspect the EGR tube assembly.
    2.  
    3. If the tube is OK, replace the EGR valve. Perform POWERTRAIN VERIFICATION TEST VER-5.
    4.  
    5. If the engine idles smoothly, go to step 4.
    6.  

  6.  
  7. Inspect the EGR Assembly for the following:

    Gasket(s) for leaking
     
    Damage and/or holes in the EGR tube(s)
     
    Carbon build-up on or near the EGR pintle and passage ways
     
    Obstruction in the EGR tubes
     

    1. Were any problems found-
    2.  
    3. If yes, repair or replace the EGR Assembly as necessary. Perform POWERTRAIN VERIFICATION TEST VER-5.
    4.  
    5. If no, go to step 5.
    6.  

  8.  
  9. Turn the ignition OFF, disconnect the EGR Solenoid harness connector, and turn the ignition ON.
    1. Measure the voltage on the EGR Solenoid Control circuit in the EGR Solenoid connector.
    2.  
    3. Is the voltage above 1.0 volt-
    4.  
    5. If yes, repair the short to voltage in the EGR solenoid control circuit. Perform POWERTRAIN VERIFICATION TEST VER-5.
    6.  
    7. If no, go to step 6.
      NOTE
      Before continuing, check the Powertrain Control Module (PCM) harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

    8.  

  10.  
  11. If there are no possible causes remaining, replace and program the PCM. Perform POWERTRAIN VERIFICATION TEST VER-5.
  12.  
  13. Turn the ignition ON. Turn all accessories OFF. Disconnect the EGR Solenoid harness connector.
    1. Using a 12-volt Test Light, jumper across the EGR Solenoid harness connector.
    2.  
    3. With the DRBIII®, actuate the EGR solenoid.
    4.  
    5. Does the 12-volt test light flash ON and OFF-

      If yes, inspect the tube(s) for obstructions and damage, repair as necessary.
       
      If the tubes are OK, replace the EGR Solenoid Assembly. Perform POWERTRAIN VERIFICATION TEST VER-5
       
      If no, go to step 8
       

    6.  

  14.  
  15. Turn the ignition OFF. Disconnect the EGR Solenoid harness connector. Using a 12-volt test light connected to battery voltage, probe the EGR Solenoid ground circuit in the EGR Solenoid harness connector. Does the 12-volt test light illuminate brightly-
    1. If yes, go to step 9.
    2.  
    3. If no, repair the open in the EGR Solenoid ground circuit. Perform POWERTRAIN VERIFICATION TEST VER-5.
    4.  

  16.  
  17. Turn the ignition OFF, disconnect the PCM harness connector, and disconnect the EGR Solenoid harness connector.
    1. Measure the resistance between a good ground and the EGR Solenoid Control circuit at the EGR Solenoid harness connector.
    2.  
    3. Is the resistance below 100 ohms-

      If yes, repair the short to ground in the EGR Solenoid Control circuit. Perform POWERTRAIN VERIFICATION TEST VER-5
       
      If no, go to step 10
       

    4.  

  18.  
  19. Turn the ignition OFF, disconnect the PCM harness connector, and disconnect the EGR Solenoid harness connector.
    WARNING
    Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal-to-pin connection. Install Miller Special Tool #8815 to perform diagnosis.

    1. Measure the resistance of the EGR Solenoid Control circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool # 8815.
    2.  
    3. Is the resistance below 5.0 ohms-
      NOTE
      Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.



      If yes, go to step 11
       
      If no, repair the open in the EGR solenoid control circuit. Perform POWERTRAIN VERIFICATION TEST VER-5.
       

    4.  

  20.  
  21. If there are no possible causes remaining, replace and program the Powertrain Control Module (PCM). Perform POWERTRAIN VERIFICATION TEST VER-5.
  22.  

 
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