Egr CHRYSLER VOYAGER 1996 Service Manual

REMOVAL
(1) Disconnect both cables from battery, negative
cable first.
(2) Remove 2 screws holding PDC to bracket,
swing out of way.
(3) Remove nut and clamp holding battery to bat-
tery tray (Fig. 5).
(4) Remove battery from vehicle.
(5) Disconnect two vacuum hoses at EVM (Fig. 6).
(6) Remove mounting screws of EVM.
(7) Remove the EVM to gain access to the EVM
electrical connector.
(8) Remove electrical connector at EVM.
INSTALLATION
(1) Install electrical connector to EVM.
(2) Install EVM and tighten mounting screws.
(3) Connect vacuum hoses.
(4) Install PDC to bracket and tighten mounting
screws.
(5) Install battery.
(6) Connect battery cables positive first.
SPECIFICATIONS
TORQUE CHARTÐ2.5L DIESEL
Description Torque
EGR Valve Mounting Bolts..............23N´m
(204 in. lbs.)
EGR Tube Mounting Bolts..............23N´m
(204 in. lbs.)
EVM (Electric Vacuum
Modulator) Mounting Bolt. . . . 2 N´m (20 in. lbs.)
Fig. 5 Battery ClampFig. 6 EVM Location
25 - 8 EMISSION CONTROL SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

EMISSION CONTROL SYSTEMÐ2.0L ENGINE
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION................. 9
POSITIVE CRANKCASE VENTILATION SYSTEM
(PCV) SYSTEMÐ2.0L ENGINE............ 9REMOVAL AND INSTALLATION
EGR TUBE............................ 10
EGRVALVE ............................ 9
TORQUE............................. 10
GENERAL INFORMATION
GENERAL INFORMATION
The emission control system for the 2.0L engine
functions the same as the systems for the 2.4/3.0/3.3/
3.8L engines. Refer to group 25 for more information
about Diagnostic Trouble Codes and other system
features.
POSITIVE CRANKCASE VENTILATION SYSTEM
(PCV) SYSTEMÐ2.0L ENGINE
The PCV System for 2.0L engines function the
same as PCV systems for 2.4/3.0/3.3/3.8L engines.
Refer to group 25 for more information.
REMOVAL AND INSTALLATION
EGR VALVE
If the EGR system operates incorrectly, replace the
entire EGR valve and transducer together. The EGR
valve and electrical transducer (EET) are calibrated
together.
REMOVAL
The EGR valve attaches to the rear of the cylinder
head (Fig. 2). EGR transducer is attached to the air
inlet duct.
(1) Remove EGR transducer from air inlet duct.
(2) Disconnect vacuum supply tube from EGR
transducer solenoid.
(3) Disconnect electrical connector from solenoid.
(4) Remove air inlet duct.
(5) Remove EGR tube to EGR valve screws.
(6) Remove EGR valve mounting screws. Remove
EGR valve and transducer.
(7) Clean gasket surfaces. Discard old gaskets. If
necessary, clean EGR passages.
Fig. 1 PCV SystemÐ2.0L
NS/GSEMISSION CONTROL SYSTEM 25 - 9

INSTALLATION
(1) Loosely install EGR valve with new gaskets.
(2) Finger tighten EGR tube fasteners.
(3) Tighten EGR tube fasteners to 11 N´m (95 in.
lbs.) torque.
(4) Tightening EGR valve mounting screws to 22
N´m (200 in. lbs.) torque.
(5) Install air inlet duct.
(6) Connect vacuum supply tube to solenoid.
(7) Attach electrical connector to solenoid.
(8) Install EGR transducer onto air inlet duct.
EGR TUBE
The EGR tube attaches to the intake manifold ple-
num below the throttle body and EGR valve.
REMOVAL
(1) Remove screws attaching EGR tube to intake
manifold (Fig. 3).
(2) Remove EGR tube to EGR valve screws.(3) Remove EGR tube. Clean gasket surface on the
EGR valve. Wipe clean the grommet on the intake
manifold.
INSTALLATION
The rubber grommet that seals the EGR tube to
intake manifold connection is reusable.
(1) Loosely install the EGR tube and fasteners.
(2) Tighten the EGR tube to intake manifold ple-
num screws to 11 N´m (95 in. lbs) torque.
(3) Tighten the EGR tube to EGR valve screws to
11 N´m (95 in. lbs.) torque.
TORQUE
Description Torque
EGR valve to cyl. head.......22N´m(200 in. lbs.)
EGR tube to EGR valve...........11(95in.lbs.)
EGR tube to intake manifold . . . 11 N´m (95 in. lbs.)
Fig. 2 EGR System
Fig. 3 EGR Tube Stud Bolts
25 - 10 EMISSION CONTROL SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)