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HOMESERVICE MANUALSPLYMOUTH1990VOYAGER SE, 2.5 J, AUTOMATICREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMENGINE CONTROLS - SYSTEM/COMPONENT TESTSEGR SYSTEM OPERATIONAL CHECKEXHAUST GAS RECIRCULATION (EGR) SYSTEM OPERATIONAL CHECK
1990 Plymouth Voyager SE, 2.5 J, Automatic

Exhaust Gas RECIRCULATION (EGR) System Operational Check

1990 Plymouth Voyager SE, 2.5 J, AutomaticSECTION Exhaust Gas RECIRCULATION (EGR) System Operational Check
NOTE: To ensure proper EGR system operation all passages and moving parts must be free from restrictive deposits. Clean or replace components as necessary.
  1. Warm engine to operating temperature. Attach a tachometer to the engine. Run engine at idle in Neutral an additional 70 seconds.
  2. Accelerate the engine abruptly to 2000-3000 RPM and check EGR valve stem for movement. Repeat test to confirm stem movement, indicating EGR control system is functioning correctly.
  3. If EGR valve stem does not move, check for cracked, leaking, disconnected or plugged vacuum hoses. Verify correct hose routing. Disconnect hose harness from EGR valve/transducer and connect a vacuum pump to harness.
  4. Start engine and raise engine speed to 2000 RPM and hold. Apply 10 in. Hg. vacuum to EGR, while checking for EGR valve movement. If no movement occurs, replace EGR valve/transducer assembly.
  5. If valve opens approximately 1/8", hold vacuum constant and check for valve diaphragm leakage. Valve should remain open for at least 30 seconds. If leakage occurs, replace valve/transducer assembly. If valve is okay, check control system.
  6. If EGR valve stem did not move in step 2), but operates normally on external vacuum source, remove throttle body and check port in throttle bore for blockage. Use a solvent to remove deposits and check flow with light air pressure. Normal operation should be restored.
  7. If engine will not idle correctly or stalls, check for leaking EGR valve. With engine running, remove vacuum hose from EGR valve. If removing the vacuum hose does not correct rough idle, remove EGR valve/transducer assembly. Check valve for proper seating. Replace assembly as necessary.
  8. Also check EGR-to-intake manifold tube for leak. On 2.5L models, loosen tube and tighten to 25 ft. lbs. (34 N.m). On 3.0L models, remove tube and inspect gasket. Tube end should be uniformly indented on gasket, without signs of leakage.
  9. On all models, if there are signs of leakage, replace gaskets and tighten flange nuts to 17 ft. lbs. (23 N.m). If leak persists, replace EGR tube and gaskets.
NOTE: DO NOT use drills or wires to clean passages for EGR control system. Calibration of precision orifices could be altered, resulting in unsatisfactory vehicle operation.
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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.