Tools: 8 mm socket, 10 mm socket
Equipment: Replacement EGR Valve, Replacement EGR Gasket (metallic)
1. Disconnect the electrical fitting attached to the EGR valve. You will need to unlock it (red tab) and then depress the latch near the rear of the fitting before sliding it off.
2. Disconnect the vacuum tube connected to the top of the EGR valve using an 8 mm socket. It may be easier to remove the entire vacuum tube by diconnected it at the top of the engine as well (also 8 mm).
3. Using a universal socket joint (I found using a 1/4" drive was necessary to get the clearances around the alternator), remove the 2 bolts holding the EGR valves to the exhaust manifold of the engine using a 10 mm socket. The bottom bolt is a very tight clearance.
4. Remove the valve and gasket.
5. To install, reverse the steps using the new EGR Valve and EGR Gasket.
6. The 10 mm bolts should be torqued to 225 in-lbs
7. The 8 mm bolts that fasten the vacuum tube to the EGR valve should be torqued to 100 in-lbs.
Tip: I have found that if you loosen the alternator mounting bolts, you can get just a little more wiggle room to get a socket on the bottom bolt.
The 2002 Dodge Grand Caravan air conditioning recharge valve is located on the air conditioning compressor. The recharge valve will be labeled as such.
It does not have one.
Just replace it, the sensor on the top of it is usually what goes bad.
The 1998 Dodge Grand Caravan 3.8 liter engine EGR valve can be found on the top of the engine. The EGR valve will be near the back of the engine.
Usually you replace the egr valve.
It is part of the EGR valve.
Front passenger side of the engine.
replace egr valve.
On top of the intake cover on the right side.
Right front corner of engine, above alternater.
Trouble code P0401 means: EGR System Malfunction Replace the EGR Valve
Solenoid switch valve latched in the low/reverse position.It means that a valve is stuck in the valve body.
Front passenger side corner of the engine.
The cam sensor on a 2002 Grand Caravan is located on the top of the engine. It is at the top, just below the valve cover.
It might be that your pcv valve is plugged or the egr valve is sticking.
From my experience the original will fail by 50,000 miles.
Inside the trans, on the valve body. It is called a TRS.
Right front corner of engine, above alternater
yOU HAVE TO REMOVE THE VALVE BODY IT IS MOUNTED ON THE SIDE OF THE VALVE BODY UNDER THE TRANSMISSION OIL PAN. GOOD LUCK
The heater on a 1999 Caravan doesn't have a heater valve. The temp is regulated with a blend air door that is controlled by the body computer and climate controll head.
The PCV just slips out and slips in; no tools required in most cases.
The P1745 code in a Dodge Caravan is for high pressure in the transmission line. It is normally caused by a bad solenoid pack or a main regulator valve stuck in the valve body.