My '05 Caravan SXT reached 98,xxx miles and I got the first CEL/MIL to come on. Pulled the code and it was an EGR high value (specific number I'd need to remember). It had poor (surging) driveability during the warm up cycle when cruising (steady, partial throttle) between 35 -50 MPH suggesting to me a lean mixture. Removed the electrical connector, checked for corrosion, applied cleaner - code returned, so based on the string of EGR failed notes...

But the short cut in changing the EGR valve is not to remove the alternator (and the right front wheel etc.) if possible.

DISCONNECT the battery! I kept the serpentine belt on and loosened two of the bolts (the lower "belt side" and the rear "block bolt" and removed the third bolt "top belt side" just below the EGR valve which permitted me enough displacement (approx 1/4 inch) of the alternator to permit a socket and extension to reach the lower EGR to cylinder head mounting bolt. Then reverse everything (making sure all three Alt bolts are installed and torqued, reconnect all wiring/battery.

Found this out once my box head wrench hit the alternator body before the lower bolt was disengaged! The 2-hour job would have been done in 30 minutes if I knew this trick up front.

With the new EGR valve in, runs great with no surging.

Hope this quick outline helps - remember all safety precautions!

 

Great information. Thank you