Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Exhaust Gas RECIRCULATION System: Description
All vehicles are equipped with an exhaust gas recirculation (EGR) system to reduce NOx emissions. With this system, exhaust gas is partially recirculated from an exhaust port of the cylinder head into a port located at intake manifold below the carburetor.
Exhaust gas flow is controlled by a vacuum operated dual EGR valve (single EGR valve on Federal 2.6L pickups) and a throttle operated sub EGR valve. Vacuum applied to the EGR valve is controlled by a single thermo valve on Federal 2.6L pickups, a dual thermo valve on all other pickups, a single and a dual thermo valve on Champ and Colt, and 2 dual thermo valves on Challenger and Sapporo.
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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