Commander 2006-2007

Exhaust Gas Recirculation System

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EGR Valve Position Sensor



Removal & Installation
3.7L & 4.7L Engines
  1. Remove the exhaust gas routing tube mounting bolts.
  2.  
  3. Remove the tube from the EGR valve and slip the opposite end out of the intake manifold.
  4.  
  5. Remove the gasket between the EGR valve and tube.
  6.  
  7. Disconnect the EGR valve electrical connector.
  8.  
  9. Remove the EGR mounting bolts and remove the solenoid assembly from the engine.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connector (3) and mounting bolts (2) to remove the EGR valve-3.7L Engine shown

  10.  

To install:

  1. Clean the gasket area at the rear of left cylinder head where it joins base of EGR valve.
  2.  
  3. Clean the EGR tube where it joins the EGR valve.
  4.  
  5. Position a new gasket between the EGR valve and cylinder head.
  6.  
  7. Position the EGR valve to the cylinder head. Tighten the two bolts to 80 inch lbs. (9 Nm).
  8.  
  9. Position a new gasket between the EGR tube flange and EGR valve assembly.
  10.  
  11. Position the EGR tube to side of EGR valve and then into the intake manifold. Tighten the two bolts to 8.5 ft. lbs. (11 Nm).
  12.  
  13. Connect the electrical connector to top of the EGR valve solenoid.
  14.  

5.7L Engine
  1. Disconnect the electrical connector from EGR solenoid.
  2.  
  3. Remove the two bolts connecting EGR tube to valve assembly.
  4.  
  5. Remove the gasket located between EGR tube flange and EGR valve assembly.
  6.  
  7. Remove the two mounting bolts.
  8.  
  9. Separate the valve assembly from the cylinder head.
  10.  
  11. Remove and discard the metal gasket located between cylinder head and valve assembly.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connector (4) and remove the mounting bolts (2) to remove the EGR solenoid (3) from the cylinder head (1)-5.7L Engine

  12.  

To install:

  1. Position a new metal gasket between cylinder head and valve assembly. Tighten the two mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Clean the EGR tube where it joins the EGR valve.
  4.  
  5. Position a new gasket between the EGR tube flange and EGR valve assembly.
  6.  
  7. Install the two bolts connecting the EGR tube to the valve assembly and tighten bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Connect the electrical connector to the EGR solenoid.
  10.  

Testing
  1. Using a diagnostic scan tool, check for the presence of any Diagnostic Trouble Codes (DTCs). Record and address these codes as necessary.
  2.  
  3. Refer to any Technical Service Bulletins (TSBs) that may apply.
  4.  
  5. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set.
  6.  
  7. With the engine running at normal operating temperature, monitor the scan tool parameters related to the DTC while wiggling the wire harness. Look for parameter values to change and/or a DTC to set. Turn the ignition off.
  8.  
  9. Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. Perform a voltage drop test on the related circuits between the suspected inoperative component and the PCM.
    CAUTION
    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 No. 8815 to perform diagnosis.

  10.  
  11. Inspect and clean all PCM, engine, and chassis grounds that are related to the most current DTC.
  12.  
  13. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits.
  14.  
  15. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation.
  16.  
  17. For intermittent Evaporative Emission trouble codes perform a visual and physical inspection of the related parts including hoses and the Fuel Filler cap.
  18.  
  19. Use the scan tool to perform a System Test if one applies to failing component. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions.
  20.  
  21. With the use of scan tool, perform the EGR System Test. Select OPEN to open the EGR valve. If the engine continued to run rough, repair or replace the EGR valve as necessary.
  22.  

 
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