Chrysler Stratus Convertible. Manual — part 169

(12) Remove push pin from bracket for EVAP can-

ister (Fig. 24). Remove canister.

INSTALLATION

(1) Install EVAP canister to bracket install push

pin.

(2) Install hoses and lines.
(3) Raise the fuel tank on the transmission stand.

(4) Connect the purge and vent lines.
(5) Connect LDP and fuel pump electrical connec-

tor.

(6) Raise tank into position and install tank

straps.

(7) Install the fuel filler tube and tighten the

clamp.

(8) Lower vehicle.
(9) Connect the battery cable.
(10) Fill fuel tank. Use the DRB scan tool to pres-

surize the fuel system. Check for leaks.

PROPORTIONAL PURGE SOLENOID

REMOVAL

(1) Remove the negative battery cable.
(2) Remove solenoid from bracket by pulling up on

solenoid.

(3) Disconnect electrical connector from solenoid.
(4) Disconnect vacuum tubes from solenoid.

INSTALLATION

The top of the solenoid has TOP printed on it. The

solenoid will not operate unless it is installed cor-
rectly.

(1) Connect vacuum tube to solenoid.
(2) Connect electrical connector to solenoid.
(3) Install solenoid on bracket.
(4) Install the negative battery cable.

Fig. 22 Fuel Line

1 – FUEL PUMP MODULE
2 – FUEL LINE
3 – FUEL FILTER

Fig. 23 Evap Components

1 – LDP FILTER

Fig. 24 LDP and EVAP Canister

1 – LDP
2 – LDP FILTER
3 – EVAP CANISTER

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EMISSION CONTROL SYSTEMS

25 - 31

REMOVAL AND INSTALLATION (Continued)

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

REMOVAL AND INSTALLATION

EGR VALVE AND TRANSDUCER—2.5L . . . . . . . . 33

EGR TUBE—2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 33

SPECIFICATIONS

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

DESCRIPTION AND OPERATION

EXHAUST GAS RECIRCULATION (EGR)
SYSTEM

DESCRIPTION

The EGR system consists of (Fig. 1), and (Fig. 2):
• EGR tube

• EGR valve

• Electric EGR Transducer

• Connecting hoses

OPERATION

Refer to Monitored Systems - EGR Monitor in this

group for more information.

The EGR system reduces oxides of nitrogen (NOx)

in engine exhaust and helps prevent detonation
(engine knock). Under normal operating conditions,

engine cylinder temperature can reach more than
3000°F. Formation of NOx increases proportionally
with combustion temperature. To reduce the emission
of these oxides, the cylinder temperature must be
lowered. The system allows a predetermined amount
of hot exhaust gas to recirculate and dilute the
incoming air/fuel mixture. The diluted air/fuel mix-
ture reduces peak flame temperature during combus-
tion.

The electric EGR transducer contains an electri-

cally operated solenoid and a back-pressure trans-
ducer (Fig. 3). The Powertrain Control Module (PCM)
operates the solenoid. The PCM determines when to
energize the solenoid. Exhaust system back-pressure
controls the transducer.

Fig. 1 EGR Control Valve—2.5L

1 – VACUUM INLET
2 – EGR SOLENOID
3 – EGR BACK PRESSURE TRANSDUCER
4 – VACUUM OUTLET TO EGR VALVE
5 – BACK PRESSURE HOSE

Fig. 2 EGR Valve—2.5L

1 – EGR VALVE SCREW (2)
2 – THERMOSTAT HOUSING
3 – EGR TUBE
4 – EGR VALVE

25 - 32

EMISSION CONTROL SYSTEMS

JX

When the PCM energizes the solenoid, vacuum

does not reach the transducer. Vacuum flows to the
transducer when the PCM de-energizes the solenoid.

When exhaust system back-pressure becomes high

enough, it fully closes a bleed valve in the trans-
ducer. When the PCM de-energizes the solenoid and
back-pressure closes the transducer bleed valve, vac-

uum flows through the transducer to operate the
EGR valve.

De-energizing the solenoid, but not fully closing the

transducer bleed hole (because of low back-pressure),
varies the strength of vacuum applied to the EGR
valve. Varying the strength of the vacuum changes
the amount of EGR supplied to the engine. This pro-
vides the correct amount of exhaust gas recirculation
for different operating conditions.

This system does not allow EGR at idle.
A failed or malfunctioning EGR system can cause

engine spark knock, sags or hesitation, rough idle,
engine stalling and increased emissions.

REMOVAL AND INSTALLATION

EGR VALVE AND TRANSDUCER—2.5L

If the EGR system operates incorrectly, replace the

entire EGR valve and transducer together. The EGR
valve

and

electrical

transducer

are

calibrated

together. The EGR valve attaches to the front
exhaust manifold. The transducer/solenoid attach to
the front cylinder head.

REMOVAL

(1) Remove the negative battery cable.
(2) Disconnect vacuum supply from solenoid.
(3) Disconnect electrical connector from solenoid.
(4) Remove screws holding transducer to bracket.
(5) Remove screws holding Transmission Control

Module (TCM) to bracket (Fig. 4). Swing TCM up to
allow access to EGR screws (Fig. 5).

(6) Remove screws holding EGR tube.
(7) Remove EGR valve mounting screws. Remove

EGR valve and transducer.

(8) Clean gasket surfaces. Discard old gaskets. If

necessary, clean EGR passages.

INSTALLATION

(1) Loosely install EGR valve with new gaskets.
(2) Finger tighten EGR tube fasteners.
(3) Tighten EGR valve mounting screws to 22 N·m

(200 in. lbs.) torque.

(4) Tighten EGR tube fasteners to 11 N·m (95 in.

lbs.) torque.

(5) Install transducer to bracket.
(6) Connect vacuum supply to solenoid.
(7) Attach electrical connector to solenoid.
(8) Install the negative battery cable.

EGR TUBE—2.5L

The EGR tube attaches to the intake manifold ple-

num behind the throttle body and to the EGR valve.

Fig. 3 Electric EGR Transducer

1 – DIAPHRAGM
2 – PISTON
3 – SPRING
4 – EGR VALVE ASSEMBLY
5 – VACUUM MOTOR
6 – VACUUM MOTOR FITTING
7 – VACUUM OUTLET FITTING TO EGR VALVE
8 – EGR VALVE CONTROL ASSEMBLY
9 – ELECTRIC SOLENOID PORTION OF VALVE CONTROL
10 – VACUUM INLET FITTING FROM ENGINE
11 – BACK-PRESSURE HOSE
12 – TRANSDUCER PORTION OF VALVE CONTROL
13 – ELECTRICAL CONNECTION POINT
14 – EGR VALVE BACK-PRESSURE FITTING
15 – EXHAUST GAS INLET
16 – STEM PROTECTOR AND BUSHING
17 – BASE
18 – MOVEMENT INDICATOR
19 – POPPET VALVE
20 – SEAT
21 – EXHAUST GAS OUTLET

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EMISSION CONTROL SYSTEMS

25 - 33

DESCRIPTION AND OPERATION (Continued)

REMOVAL

(1) Remove the negative battery cable.
(2) Remove the air cleaner cover and hose.
(3) Remove screws attaching EGR tube to intake

manifold (Fig. 6).

(4) Remove EGR tube to EGR valve screws (Fig.

7).

Fig. 4 TCM Removal

1 – TRANSMISSION CONTROL MODULE (TCM)
2 – ATTACHING SCREWS

Fig. 5 EGR Removal

1 – EGR VALVE SCREW (2)
2 – THERMOSTAT HOUSING
3 – EGR TUBE
4 – EGR VALVE

Fig. 6 EGR Tube at Intake Manifold

1 – EGR TUBE BOLTS
2 – SUPPORT BRACKET BOLT
3 – EGR TUBE

Fig. 7 EGR Tube at EGR Valve

1 – COOLANT FILL NECK
2 – EGR TUBE BOLTS (2)
3 – EGR TUBE

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EMISSION CONTROL SYSTEMS

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REMOVAL AND INSTALLATION (Continued)