Emissions Control System: Removal & Installation Dodge Caravan IV

REMOVAL

The solenoid attaches to a bracket near the radiator on the passenger side of vehicle. (Scheme 17) The solenoid will not operate unless it is installed correctly.

Scheme 17

1. Disconnect electrical connector from solenoid.
2. Disconnect vacuum tubes from solenoid.
3. Remove solenoid from bracket.

INSTALLATION

The solenoid attaches to a bracket near the radiator on the passenger side of vehicle. The solenoid will not operate unless it is installed correctly.

The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly.

1. Install solenoid on bracket.
2. Connect vacuum tube to solenoid.
3. Connect electrical connector to solenoid.

1. Install NVLD valve to the bracket. see scheme 7
2. Install valve and bracket to the vehicle. see scheme 6
3. Install the 2 mounting bolts and tighten.
4. Install the electrical connector and lock.
5. Install the 2 hoses and lock the clamps.
6. Lower vehicle.

Scheme 18

Scheme 19

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove 3 hoses. (Scheme 18)
4. Remove the electrical connector. (Scheme 19)
5. Remove the 3 screws and remove LDP pump.

1. Install LDP.
2. Install the 3 screws and tighten. (Scheme 19)
3. Install the electrical connector.
4. Install the 3 hoses. (Scheme 18)
5. Lower vehicle.
6. Connect the negative battery cable.

REMOVAL - FRONT EVAP CANISTER

1. Raise and support the vehicle.
2. Remove the 2 hoses. see scheme 16
3. Remove bolt.
4. Pull canister rearward to remove.

Scheme 20

Scheme 21

1. Raise and support the vehicle.
2. Remove the 3 hoses.
3. Remove bolt. (Scheme 21)
4. Pull canister rearward to remove.

REMOVAL - REAR EVAP CANISTER

1. Raise and support the vehicle.
2. Remove 3 hoses. see scheme 17
3. Remove the bolt.
4. Pull rearward to remove canister.

Scheme 22

1. Install canister arrow heads into the rubber grommets. (Scheme 22)
2. Install bolt and tighten.
3. Install hoses.
4. Lower vehicle.

Scheme 23

1. Install canister arrow heads into the rubber grommets. (Scheme 23)
2. Install bolt and tighten.
3. Install hoses.
4. Lower vehicle.

Scheme 24

1. Install canister arrow heads into the rubber grommets. (Scheme 24)
2. Install bolt and tighten.
3. Install hoses.
4. Lower vehicle.

REMOVAL - 2.4L

1. Remove EGR tube attaching bolts at intake manifold.
2. Remove EGR tube attaching bolts at EGR valve.
3. Check for signs of leakage or cracked surfaces on either the manifold or tube. Repair or replace as necessary.

INSTALLATION - 2.4L

1. Loose install EGR tube and gasket with attaching bolts at intake manifold.
2. Loose install EGR tube and gasket with attaching bolts at EGR valve.
3. Tighten bolts to EGR valve to 11.9 N.m (105 +/-20 ins. lbs.).
4. Tighten bolts to Intake manifold to 11.9 N.m (105 +/-20 ins. lbs.).

Note. Procedures for EGR valves on 3.3L and 3.8L engines not available from manufacturer.

The EGR valve and Electrical EGR Transducer are serviced as an assembly. see scheme 23

1. Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage.
2. Remove electrical connector from solenoid.
3. Remove EGR tube bolts from EGR valve.
4. Remove EGR valve from cylinder head adaptor.
5. Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary.

Note. Procedures for EGR valves on 3.3L and 3.8L engines not available from manufacturer.

The EGR valve and Electrical EGR Transducer are serviced as an assembly. see scheme 23

1. Assemble EGR valve with new gasket onto the cylinder head adaptor.
2. Loose assemble the bolts from EGR valve to EGR tube.
3. Loose assemble the bolts from EGR valve to cylinder head.
4. Tighten bolts from EGR valve to cylinder head to 22.8 N.m (200 +/-25 in. lbs.) torque.
5. Tighten bolts from EGR valve to EGR tube to 11.9 N.m (105 +/-20 in. lbs.) torque.
6. Reconnect vacuum hose and electrical connector to electrical EGR transducer.