How to Install an EGR Valve on a 2000 Chrysler Voyager 2.4

Written by alibaster smith
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How to Install an EGR Valve on a 2000 Chrysler Voyager 2.4
Change the Voyager's EGR valve to prevent exhaust problems. (exhaust fulmes image by bilderbox from

The exhaust recirculation valve (EGR valve) on your 2000 Chrysler Voyager 2.4 recirculates the exhaust gases back into the engine so that they can be burnt again. This lowers engine temperatures during normal engine operation and reduces engine emissions. Because the valve is constantly exposed to exhaust gases, carbon can build up on it, causing the EGR valve to stick or preventing it from opening at all. When this happens, your Voyager can have problems idling, but you'll mostly likely notice a significant "bucking" problem when you try to accelerate.

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Things you need

  • Socket wrench
  • Socket set
  • Nylon brush
  • Carburettor cleaner

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  1. 1

    Open the bonnet of the vehicle and locate the EGR valve on the intake manifold, at the back of the engine. The valve is circular in shape and has a tube running down to a separate portion of the component with an electrical power connector.

  2. 2

    Locate the plug on the EGR valve. The EGR valve for the Voyager, unlike many EGR valves, has the plug located off to the side of the actual valve. Squeeze the power connector tabs and disconnect the power running to the valve.

  3. 3

    Unbolt the two mounting bolts located at the base of the valve and remove the valve.

  4. 4

    Clean the mating surface of the intake with carburettor cleaner and with a nylon bristled brush. This will provide a good mating surface for the new valve.

  5. 5

    Position the new valve into place on the intake manifold and align the mounting holes on the valve with the holes on the manifold.

  6. 6

    Secure the valve to the manifold, using the factory mounting bolts and a socket wrench.

  7. 7

    Plug the electrical connector back into the EGR valve. Make sure the connector is secure and locks into place.

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