Tip & How-To about Dodge Caravan
Here is an easier way to replace your exhaust gas recirculation valve on a non flex fuel 2005 3.3L. First off, the egr valve is located right above your alternator, it has 4 bolts in it, a pipe which goes from the top of the egr to the intake, and a plug in style wiring terminal. You'll need a 3/8 drive ratchet with a 9mm and 10mm socket, a 3/8 to 1/4 adapter, a 2 1/2 inch and 12 inch 3/8 drive socket extension, a small hammer, and a small 10mm open ended wrench to perform this repair. Also be sure you have the correct egr, there are 2 call the dealer with the last 9 digits of your vin to verify the one you need, I opted for the mopar replacement (100 after tax) parts store's have slightly cheaper aftermarket replacements. First, disconnect your wiring to the transducer, there is a plastic retainer (which locks the plug in place) you'll need to push it in to unlock it then press the back of the plug down and pull it out . Next remove the two 5/16 or 9mm bolts from the flange at the top of the egr where the recircirculation line goes back to the intake/throttle body. There are two 10mm bolts which hold the egr to the motor, the first is easy to remove, the second is blocked by the alternator. here is where some people have problems trying to figure out how to get to it. Don't remove the alternator, your serpentine belt, or anything else. I used a 12 inch 3/8 socket extension and a small hammer to tap the top flange (of the first two bolts you should have removed) towards the firewall as far back as you can get it. Now that you have a little bit of room to work with you can use a small 10mm wrench to remove the bolt. It is still a tight squeeze but you can do it. Once the old egr has been removed inspect the mating surface on the block where you will install the new one and make sure you have a clean surface for the new gasket. You'll need to obviously install the last bolt you removed first in the reinstallation process, then install the other bolts. You can also reuse the gasket from the recirc pipe if it is not damaged. Plug the wire in and lock it back with the retainer clip. Make sure all your tools have been picked up from the engine compartment and start your vehicle. Your engine light should go out now provided that was the only fault that triggered it. Good luck
Labor Operations: Click to display a list of Labor Operations associated with this procedure
The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head. An exhaust gas routing tube connects the EGR valve to the intake manifold.
5.
Disconnect the power brake booster vacuum hose (1) and the vapor canister purge hose (2) at the intake manifold.
6.
Disconnect the EGR valve solenoid electrical connector (1).
7.
Remove the EGR valve assembly retaining bolts (1).
8.
Remove the EGR valve and the EGR routing tube from the engine as an assembly.
9.
Remove and discard the metal gasket located between the cylinder head and the EGR valve assembly.
10.
Remove the EGR valve routing tube retaining bolts (1) at the EGR valve assembly
11.
Remove the EGR valve routing tube and discard the gasket.
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