EGR valve replacement guide - 3.3 V6 engine (minivans)

by Zach Isaacson • Also see our main minivan repairs page!

Here is a how-to guide to removing and replacing the EGR valve. The vehicle is a 2004 Grand Caravan with 3.3L engine. [Editor’s note: it probably applies to any vehicle with this engine, from a wide variety of years, and to similar V6 engines in the same vehicles.]

I purchased the valve from my local dealership. If I could have waited, I would have bought it from moparone.com.

Here is the location of the EGR valve. You need to start by unplugging the electrical connector on the top of the valve.
These are the first two bolts that you need to remove. They are 8mm or 5/16".
The second two bolts are behind the EGR (behind my fingers). They are 10mm bolts. To access them, you will either need a swivel or a combination of extensions (you will see what I used in a minute).
Here you can see the old, carbon filled valve with the new one.
Installation is the reverse of removal. Here I am putting the 10mm side bolts in. “ChryslerTech766” wrote, “Make sure to start the bolts by hand; they cross thread easily due to the tightness of the area given to work in, especially the bottom 10mm bolt.”
Make sure you remember to use a new gasket under the tube flange.
Tighten down the flange on the tube.
There you have it! Plug the connector back in and you are good to go!

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