TownAndCountry 2008

Exhaust Gas Recirculation System

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EGR Valve



Operation

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

The Exhaust Gas Recirculation (EGR) system is used to reduce nitrogen oxide emissions. EGR works by recirculating a portion of the engine's exhaust gas back to the engine cylinders. The exhaust gas increases the specific heat capacity of the mix lowering the peak combustion temperature. The EGR is controlled by the PCM for maximum efficiency.

Removal & Installation
3.3L & 3.8L Engines

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
The normal operating temperature of the Exhaust Gas Recirculation (EGR) valve and tube is very high. Therefore, never work around or attempt to service any engine component until it is completely cooled.


NOTE
It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired. Disconnecting the battery for at least 2 minutes will remove all power from the controller and reset these cells to normal default values.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable at the battery.
  4.  
  5. Disconnect the electrical connector (1) from the Exhaust Gas Recirculation (EGR) valve (5).
  6.  
  7. Remove the bolts (3), gasket, and EGR tube (2) from the EGR valve (5).
  8.  
  9. Remove the bolts (4), gasket, and EGR valve (5) from the cylinder head.

    Click image to see an enlarged view

    Fig. Exhaust Gas Recirculation (EGR) valve location-3.3L and 3.8L engines

  10.  

To install:

  1. Install a new EGR valve gasket to the EGR valve.
  2.  
  3. Install the EGR valve (5), gasket, and bolts (4) to the cylinder head. Tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the EGR tube (2), gasket, and bolts (3) to the EGR valve (5). Tighten to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the electrical connector (1) to the EGR valve (5).
  8.  
  9. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  10.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
The normal operating temperature of the Exhaust Gas Recirculation (EGR) valve and tube is very high. Therefore, never work around or attempt to service any engine component until it is completely cooled.


NOTE
It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired. Disconnecting the battery for at least 2 minutes will remove all power from the controller and reset these cells to normal default values.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable at the battery.
  4.  
  5. Remove the EGR tube bolts (3) at the Exhaust Gas Recirculation (EGR) valve (1).
  6.  
  7. Remove the EGR tube (5) from the EGR valve (1).
  8.  
  9. Remove and discard the gasket located between the EGR valve (1) and the EGR tube (5).
  10.  
  11. Disconnect the electrical connector (6) at the EGR valve (1).
  12.  
  13. Remove the EGR valve mounting bolts.
  14.  
  15. Remove the EGR valve from the cylinder head.
  16.  
  17. Remove and discard the gasket located between the EGR valve and the cylinder head.

    Click image to see an enlarged view

    Fig. Exhaust Gas Recirculation (EGR) valve location-4.0L engine

  18.  

To install:

  1. Install a new EGR valve gasket to the EGR valve.
  2.  
  3. Install the EGR valve (1), gasket, and bolts (3) to the cylinder head (2). Tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Install a new gasket, EGR tube (5), and bolts (3) to the EGR valve (1). Tighten to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the electrical connector (6) to the EGR valve (1).
  8.  
  9. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  10.  

Testing

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn all accessories OFF.
  4.  
  5. Start the engine and allow it to reach operating temperature.
    CAUTION
    When the engine is operating, do not stand in direct line with the fan. Do not put hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in personal injury or death.

  6.  
  7. With the scan tool, perform the EGR System Test.
  8.  
  9. Select OPEN to open the EGR valve.
  10.  
  11. The engine should run rough or stall when the valve is opened during the system test at idle speed.
  12.  
  13. If the engine runs rough or stalls without the EGR commanded OPEN, disconnect the EGR electrical connection and check if the engine idle becomes smooth.
  14.  
  15. Replace the EGR valve assembly if found to be faulty-stuck open, stuck shut, or non-responsive.

    Click image to see an enlarged view

    Fig. Related Diagnostic Trouble Codes

  16.  

 
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