EGR System - Eliminated
NUMBER: 18-026-01GROUP: Vehicle Performance
DATE: Nov. 2, 2001
SUBJECT:
EGR System Elimination
OVERVIEW:
This bulletin provides technical details about the elimination of EGR valves.
MODELS:
2002 (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLE WITH A 3.3L OR 3.8L ENGINE (SALES CODES EGA, EGH, EGM).
DISCUSSION:
A running change to eliminate the EGR system is being made during the 2002 model year. The change will be made in steps. First, the EGR will be turned off in the calibration (PCM software), followed by the removal of the EGR valve. This left a period of time during which vehicles were built with a non-functioning EGR valve on the engine. The following information will help to identify and service a functioning versus non-functioning EGR valve:
^ Vehicles with functioning EGR valves
Vehicles built before September 18, 2001 (MDH 0918XX) at the Windsor Assembly Plant ("R" in the 11th position of the VIN) and September 14 (MDH 0914XX) at the St. Louis Assembly Plant ("B" in the 11th position of the VIN) will have functioning EGR valves. Normal diagnostic and service procedures apply.
^ Vehicles built with non-functioning EGR valves.
Vehicles built after the dates mentioned above through approximately the end of October, 2001 will have a non-functioning EGR valve on the engine and may or may not have an EGR vacuum harness. Vehicles built after approximately the end of October, 2001 will not have an EGR valve on the engine. In either case, the vehicle VECI label will identify the EGR valve "non-functional" and have a dotted line to the EGR valve.
For non-functional EGR equipped vehicles electronic diagnostics will not function, however, the electrical connection must be maintained if the vehicle has an EGR vacuum harness (the EGR solenoid must be energized to shut off vacuum flow to the EGR valve). If the vehicle does not have an EGR vacuum harness the electrical connector may or may not be disconnected and taped back to the harness.
If a non-functional EGR valve is diagnosed with a problem, the EGR valve must be removed and cover plates installed, per the following procedure:
PARTS REQUIRED
REPAIR PROCEDURE:
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES BUILT AFTER SEPTEMBER 18, 2001 (MDH 0918XX) AT THE WINDSOR ASSEMBLY PLANT ("R" IN THE 11TH POSITION OF THE VIN) AND SEPTEMBER 14 (MDH 0914XX) AT THE ST. LOUIS ASSEMBLY PLANT ("B" IN THE 11TH POSITION OF THE VIN) WITH NON-FUNCTIONING EGR VALVES AND AN EGR VALVE PROBLEM.
1. Remove the two screws holding the EGR tube to the upper intake manifold, and save for reuse (the silicone sealing ring will remain on the intake manifold).
2. Disconnect EGR vacuum connector from nipple on upper intake manifold (if present).
3. Remove the entire EGR valve assembly with adaptor base from the cylinder head including EGR tube.
4. Install EGR cover plate, p/n 04861623AA, onto upper intake manifold using the two screws saved in Step 1. Ensure that the words "THIS SIDE UP" are visible on the cover plate after installation. Tighten screws to 4 Nm (35 in.lbs.).
5. Install EGR cover plate onto the cylinder head, using gasket, p/n 05277723, and screws, p/n 06503692. Tighten to 28 Nm (250 in.lbs.).
6. Install cap, p/n 03580172, onto EGR vacuum nipple on upper intake manifold.
7. If the EGR electrical connector is not already taped back to the wire harness tape it to the harness.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE