How to Change the EGR Valve on a Chrysler Town & Country

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The Exhaust Gas Recirculation (EGR) valve on your Chrysler Town and Country directs burned exhaust gases into the combustion chambers to help reduce oxides of nitrogen (NOx) emissions. Overtime, the stem or diaphragm in the valve may fail, keeping exhaust gases from entering the intake manifold. Before beginning disassembly, make sure your new valve is an exact replacement for your specific vehicle year and model.

Things You'll Need

  • Wrench or ratchet and socket
  • Soft brush
  • Clean shop rag or towel
  • Wire brush (if necessary)
  • New EGR valve gasket

Removing the EGR Valve

  • Open the hood and locate the EGR valve on the upper area of the engine, next to the valve cover. The valve resembles a thick mushroom with a round, metal hat. It mounts to the engine and connects to the exhaust system through a large metal pipe.

  • Unplug the vacuum hose from the top of the EGR transducer. This is a disc-shaped, plastic component attached to the EGR valve through a rubber hose and a metal line.

  • Unplug the electrical connector from the EGR transducer.

  • Unscrew the two pipe mounting bolts from the EGR valve, using a wrench or ratchet and socket.

  • Unscrew the two mounting bolts that hold the EGR valve to the cylinder head adaptor, using a wrench or ratchet and socket.

  • Remove the EGR valve/transducer assembly from the engine and valve gasket.

Installing the New EGR Valve

  • Clean the gasket-mounting surface on the cylinder head adaptor using a soft brush and a clean shop rag or towel. If necessary, remove carbon build up on the adaptor and pipe orifices using a suitable wire brush. Be careful not to damage the valve-mounting surface.

  • Install the new EGR valve/transducer assembly and new gasket in place. Then start the two cylinder head-adaptor mounting bolts by hand.

  • Install the pipe to the EGR valve and start the two pipe mounting bolts by hand.

  • Tighten the two cylinder head-adaptor mounting bolts using the wrench or ratchet and socket.

  • Tighten the two pipe mounting bolts using the wrench or ratchet and socket.

  • Plug the electrical connector to the EGR transducer.

  • Plug the vacuum hose to the top of the EGR transducer.

References

  • "Dodge Caravan/Plymouth Voyager/Chrysler Town & Country 1996 thru 2002 (Haynes Repair Manual)"; L. Alan LeDoux and John H. Haynes; 2001
  • Photo Credit Jupiterimages/Comstock/Getty Images
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