Question about 1994 Dodge Caravan

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My 94 caravan runs perfect when I remove the EGR, but when I replace the EGR it starts and then stalls. what could be it's problem.

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  • Dodge Master
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The EGR Valve has a vacuum leak in it.

Posted on Aug 19, 2010

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The vacuum line on top of the EGR is required for propper vehicle operation. The vacuum line is what opens the valve when the solenoid is comanded on. As for the MAP sensor check the injector/MAP sensor harness right by the driver side corner of the rear head. The harness tends to melt and cause rough running conditions and misfires. So would the EGR which is a common issue and yes the the whole assembly should be replaced.

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If your vehicle has one, and I think it does, check your EGR system. If the egr valve is full of carbon, it can be partially open, creating a vacuum leak. If the egr valve solenoid is bad, it could be opening the valve at the wrong time, also creating a vacuum leak. Unplug the egr vacuum hose, plug the open end of the hose and start it and see what it does. A picture of the egr is below.
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Try replacing your Idle Air Control valve. I am a former Ford tech and have two LTC's a 94 and a 96. I have had to do this job on both. When they get up in miles, the IAC valve gets carboned up and can't adjust the air/fuel intake mixture under load. If you still have a stalling issue after that, then you will probably have to replace the EGR valve as well. But it is very important that you start the engine with the old EGR valve removed so you can blow any carbon balls out of the EGR passage before installing the new EGR valve. Otherwise you will just end up plugging and ruining the new EGR valve and have the same stalling issue. Good luck!

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To check the egr yourself you will need a hand held vacuum pump. To perform the test start the van and let it warm-up, then remove the top vacuum hose from egr valve and attach hand vacuum pump to egr valve. Apply about 5 in-hg vacuum to the egr valve. With the engine at idle speed and vacuum applyed the engine idle speed will drop or stall. If not then the egr valve is faulty and will need to be replaced. If the engine didi change idle speed and or stalled the egr valve is good. Hope this will help you.

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if it stalls and start right away without long crank time more likely you have ignition spark cutting out.this vans are notorious for ecm failing to ground contorol.if it is a 3.3 or 3.8 V6 very common problem. check for spark at a plug wire when stalles and if no spark replace ecm.i hope i was helpful. please rate me.

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