Caravan Help

[RedRam1]

Any Dodge Techs out there who can help me with a Caravan problem?

I've got to get the annual emissions inspection on the wife's '98 grand caravan in a little over a month. Trouble is the 'service engine soon' light has been illuminated for a month or so, and you cannot pass emissions with the light on regardless of what's coming out the exaust pipe. The van still runs good as new. Autozone hooked it up to their scanner, and the fault diagnosis was "EGR circuit malfunction" or something like that - cannot remember the exact message, just that it pertained to the EGR.

I checked all the vacuum lines associated with the EGR, there was also a little black box beside the egr that had an electrical connector hooked to it along with a vacuum line that ran to the egr valve. All lines were tight with no visible damage, I dicconnected and cleaned the electrical connector going to the little black gizmo with contact cleaner, but the light still glows.

All I can think of to do is to remove & clean the valve or maybe take a shot in the dark and replace the little electrical gizmo, if it's not too expensive. Anyone have any ideas?

 

[RedRam1]

forgot to mention, it's a 3. 3L

 

[HoleshotHolset]

I don't know if the Chrysler ECM's look for this but here's a shot anyhow... .



Certain ECM's look for a corresponding drop in airflow across the MAF (Mass Air Flow sensor) anytime the ECM is calling for EGR flow. It makes perfect sense - if you have another source of airflow into the engine that isn't going through the MAF sensor, then the MAF should drop a bit when this happens.



So, the problem could be a dirty/malfunctioning MAF and have nothing to do with the EGR. Some folks have used electrical contact cleaner on the MAF with varying degrees of success. I used brake-kleen in the past and haven't had any issues.....



Or, the ECM could be calling for EGR flow and is not getting enough flow out of the EGR. Maybe the EGR itself is clogged with poo or the diaphragm can't open the valve far enough.



Hope this helps a little bit.....



Matt

 

[parcher]

If the code said "circuit malfunction" it is an electrical problem. The "black box" next to the egr valve is a pressure transducer, it is the most common item to fail on the Chrysler egr system, only way to get it is with a new egr valve, I'd bet a paycheck a new egr valve with transducer will fix your problem.



Gold certified Chrysler tech, ASE master automobile technician, if it matters.



P. S. NO Chrysler built vehicle EVER used a mass air flow sensor. Some of the Mitsu imports did but not the home grown stuff.

 

[Paul Herioux]

Ditto what the other Paul said.

On the EGR valve there is a sticker with a P/N on it, the number should start 4287***. Take this number to your local dealer and buy the right valve, they are a real pain to look up by application. Don't waste your time with aftermarket EGR valves, my experience is they have about a 90% failure rate.



Former Gold cert tech, now working on all brands and teaching kids.



Paul

 

[HoleshotHolset]

In that case... . nevermind what I said. haha :-laf



Besides, who cares if a gasser runs right?



Matt

 

[Briar Hopper]

I did have nearly the exact same problem, on a Mazda Protege', and it was the Mass Air Flow sensor, so Matt was technically correct, except of course, there's none on domestic Chrysler vehicles.

It turned out to have had the connector snapped off the plastic housing, and the Mazda dealer wanted $765. 00 for a new one ! I found one over the 'net, salvage yard in Texas, cost me $160.

 

[HoleshotHolset]

Briar: I noticed that same sort of high-priced parts problem on Mazda's that you have... .



It prevented me from buying a few low-dollar RX-7's.....



The most outrageous part price I have ever heard was an ignition module on a low #, low dollar gasser Benz - it was darn near $1200.....



Matt

 

[parcher]

Several year ago I priced out an exhaust system on a MB 190E..... FIVE THOUSAND DOLLARS!

 

[RedRam1]

Thanks a lot for all the help! Knew there had to be some DC Master Techs lurking around these parts! It also appears my seat of the pants diagnosis was correct, I suspected the black box, or the valve itsself, bummer that you can't buy separately. Guess I'll try to clean the valve first, even though I have an extrememy low level of confidence this will work. If not, I'll get the valve/transducer from DC. Any idea how much $$$$ we're talking for these parts?



Thanks,

Jim

 

[HoleshotHolset]

parcher: I came real close to buying a semi-beatup BMW 740i..... man what a nice car! I 'dated' the girl that owned it and she beat the snot out of it - so it needed a little work.



A distributor cap for that thing was $80 - that's when I threw in the towel and told her to keep it. If ignition tuneup parts are that much bread - I didn't want to know how much the other stuff was. ($1200 for cat-back AFTERMARKET non-OEM exhaust... . )



Jim: Keep us updated on the Caravan - hope you get it goin'.



Matt

 

[RedRam1]

Matt,



I'll let you know how the Caravan works out. I've got until my birthday (8-8) to get it emmissions tested & buy new plates, so there's no big rush. The thing runs as good as it ever did, so I just need allow enough time to do some additional troubleshooting in the event that the EGR/transducer does not kill the service engine light.



Jim

 

[HoleshotHolset]

Too bad you don't have a 'friend' at the inspection site.



My old truck was so foul on the emissions that the exhaust probe wasn't even in the tailpipe - and it still failed! ... . nothing that rolling in a brand new truck to take the 'pee test' won't solve... . haha :-laf



Matt

 

[RedRam1]

Matt,



Actually I do have a friend at the inspection site. Trouble is, the computers are so smart these days, he can't fool them. I would be surprised if the van flunked the test based on actual emissions, it has always passed with flying colors, it's just that you can't pass with the light on regardless of what's coming out the exhaust. I'm going to try cleaning the valve, then if that does not work, replaceing the EGR/transducer assy, and if that fails, I guess I will cave in and take it to the dealer.

 

[parcher]

You are wasting your time cleaning the valve, it's not goint to fix anything. The code was for the circuit=ELECTRICAL! Swap the valve and be done with it!

 

[RedRam1]

parcher,



OK, OK, I'll swap the valve, but I'm sending you a bill if that does not fix it! I'm kidding, of course, I really appreciate all the help.



Jim