Mechanics

EGR VALVE

2002 Chrysler PT Cruiser

Engine Mechanical problem
2002 Chrysler PT Cruiser 4 cyl Front Wheel Drive Manual 240200 miles

Engine light is on, computer diagnosis indicates EGR Flow Insufficient. Looking for detailed instructions on how to remove and clean/replace EGR valve and hose.
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Jcmartin3@rocketmail.com
September 26, 2010.



REMOVAL
If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer are calibrated together.

Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
Remove the negative battery cable.

Fig.5 EGR Tube At Intake Manifold


http://www.2carpros.com/forum/automotive_pictures/12900_egr1_4.jpg



Loosen the bolts at the intake manifold
Remove EGR tube bolts at EGR Valve.

Fig.6 EGR Transducer Bracket


http://www.2carpros.com/forum/automotive_pictures/12900_egr2_3.jpg



Fig.7 EGR Transducer Bracket


http://www.2carpros.com/forum/automotive_pictures/12900_egr3_2.jpg



Unclip EGR transducer bracket, and remove from bracket.

Fig.8 Vacuum Hose


http://www.2carpros.com/forum/automotive_pictures/12900_egr4_1.jpg



Disconnect the vacuum supply hose to EGR transducer solenoid.

Fig.9 Electrical Connector


http://www.2carpros.com/forum/automotive_pictures/12900_egr5_1.jpg



Unlock the connector then disconnect the electrical connector from solenoid.
Remove the 2 bolt at EGR valve to cylinder head. Remove EGR valve and transducer.
Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages.

INSTALLATION
Connect vacuum supply tube to solenoid.
Attach electrical connector to solenoid.
Install EGR transducer into the bracket and snap closed.
Loosely install EGR valve with new gaskets.
Finger tighten EGR tube fasteners.
Tighten EGR valve mounting screws to 22 N.m (195 in. lbs.) torque.
Tighten EGR tube fasteners to 11 N.m (97 in. lbs.) torque.

NOTE: Make sure that the hoses are routed away from the hot EGR tube and Valve and clipped.

Install the negative battery cable.
Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.

http://www.2carpros.com/kpages/auto_repair_manuals_alldata.htm

Rasmataz
Sep 26, 2010.


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