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.
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HOMESERVICE MANUALSPLYMOUTH1994GRAND VOYAGER BASE, 31THREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS - TESTS W/CODES - 3.8LSELF-DIAGNOSTIC TESTSTEST TC-25A - EGR SYSTEM FAILURE (DTC 32)
1994 Plymouth Grand Voyager Base, 31TH
Test TC-25A - EGR System Failure (DTC 32)
1994 Plymouth Grand Voyager Base, 31THSECTION Test TC-25A - EGR System Failure (DTC 32)
NOTE:
For connector terminal identification, see CONNECTOR IDENTIFICATION
in this article. For wiring diagram, see WIRING DIAGRAMS
.
- Start engine. Allow engine to idle for at least 2 minutes. Disconnect vacuum supply hose from Exhaust Gas Recirculation (EGR) solenoid. Connect a vacuum gauge to end of disconnected hose. If vacuum gauge indicates less than 10 in. Hg, repair vacuum supply to EGR solenoid. Perform TEST VER-2 .
- If vacuum gauge indicates more than 10 in. Hg, reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to end of disconnected hose. While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM.
- If vacuum gauge indicated less than 5 in. Hg while throttle was opened, replace EGR valve assembly. Perform TEST VER-2. If vacuum gauge indicated more than 5 in. Hg while throttle was opened, remove vacuum gauge.
- Connect a vacuum pump to EGR valve. With engine idling, slowly apply vacuum to EGR valve. If engine idle became rough as vacuum was applied, go to next step. If engine idle did not become rough, remove EGR valve and inspect manifold and EGR backpressure tube for restrictions. If restrictions are present, clean as necessary. Perform TEST VER-2. If no restrictions are present, replace EGR valve assembly. Perform TEST VER-2.
- Turn ignition off. Apply vacuum to EGR valve. Observe vacuum gauge. If vacuum was not held for at least 10 seconds, replace EGR valve assembly. Perform TEST VER-2.
- If vacuum was held for at least 10 seconds, condition required to set trouble code is not present at this time. EGR SYSTEM FAILURE trouble code sets when Powertrain Control Module (PCM) performs a test of EGR system and monitors oxygen sensor signal for a change, but does not detect any change in oxygen sensor signal. Possible causes are: EGR valve not opening, EGR backpressure tube blocked or EGR passages in manifold blocked. Go to next step.
- Inspect all related vacuum hoses and connectors, and repair as necessary. Perform TEST VER-2. If no problems were found with vacuum hoses and connectors, see INACTIVE TROUBLE CODE CONDITION in this article. Perform TEST VER-2.
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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.