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Swapping a 2005 Chrysler T&C 3.8 without the EGR (California) for a 2005 EGR equiped motor out of a low mileage Caravan. Will I need to do more than remove the EGR and install the blank covers fro

I put a 2006 3.8 engine in my 2005 T&C van but it won't run over 2500 RPMs and is hard to start.... Pulling it back out and putting a 2005 3.8 EGR (California) motor in it's place. I still have my original 3.8 (non-EGR motor) to canabalize parts. As far as I can tell all I need to do is remove the EGR valve and install the blank covers from my old engine.... Is there anything else I need to do while I ahve the EGR motor on the ground???

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SOURCE: 2004 chrysler pt cruiser starter motor removal

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Posted on Feb 08, 2009

  • 1 Answer

SOURCE: Engine Light On - 2006 Chrysler 300 3.5 engine

I have a 2005 Chrysler 300. The engine light comes on from time to time -- sometimes it will stay on for a week or so and then go off for at most a day or two. I had the code read yesterday and the feedback was "EGR pressure flow is low." My car has about 65K miles. Is this a typical problem with this car? I was told replacing the EGR valve would fix the problem. How easy is it to replace an EGR valve on this vehicle? Once replaced, do I need to reset the computer --- if so how do I do this? If it is easy to fix, could you please provide step by step directions and show me location of the part in question that needs replaced?

Posted on Apr 10, 2009

  • 1 Answer

SOURCE: Code P0406

Where is the egr valve on my crystler 300?

Posted on Aug 17, 2009

Mustgo
  • 2359 Answers

SOURCE: 2005 Town and Country code P0404 egr

Check for

vacuum leaks on intake manifold,

the air tube between the air filter.

intake manifold vacuum hose.

===
clean throttle plate with Berryman carburator cleaner

SEE sample picture HERE
===

Also remove carbon built up behind the EGR valve and the EGR passage tube.

===

Vacuum leak WILL offset the intended 14.7 to 1 air fuel ratio.

More un-metered air (leaks) will lean out the fuel mixture.

Use small amount of Berryman carb clearer at potential air leak area will help you identify trouble spot.

At idle,just spray and listen for the RPM surge.

The in-rush of carb clearer will increase the RPM on the motor.

Record the problem spot(s) and address it later.

===

EGR carbon built up require 2+ hours to clean from start to finish.

You will need a new EGR base gasket before your start.

Locate and remove the EGR valve after the vehicle is cool down.

Carefully record the connector and vacuum line (for older vehicle) location by drawing an easily to follow diagram.

Remove the EGR valve.

Inspect the location of the carbon built-up inside the valve and the EGR passage tube.

SOAK these areas with WD-40 spary.

You will need a small screwdriver,cloth hanger and lot of newspaper and time to get this cleaning done right.

RE-SOAK the carbon and let it sit for over-night will also help.

One the last round,pass a shop vacuum of the EGR valve and the passage pipe.

Install the new EGR gasket and connectors.

Allow the vehicle to warm up outdoor to burn up any remaining WD-40.


Take it for a test drive.


Please rate my answer if it's useful to you.


Cheers,

Mustgo

Posted on Dec 19, 2009

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