2008 3.8 EGR issues
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Registered User
Joined: Apr 2006
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2008 3.8 EGR issues
08 Caravan 3.8 is throwing CEL's to indicate the EGR is bad (80k miles).
I see a ton of info on EGR replacement on 01-07 Caravans that indicate the EGR is an easy job.
I see horror stories about EGR replacement on 07-09 Wrangler's with the 3.8
How hard is the EGR Valve replacement on the 08 Caravan? Does anyone have a step-by-step? How about a facory part number (Rockauto replacement lists 5 p/n's)?
Thanks in advance for the help!
I see a ton of info on EGR replacement on 01-07 Caravans that indicate the EGR is an easy job.
I see horror stories about EGR replacement on 07-09 Wrangler's with the 3.8
How hard is the EGR Valve replacement on the 08 Caravan? Does anyone have a step-by-step? How about a facory part number (Rockauto replacement lists 5 p/n's)?
Thanks in advance for the help!
Veteran
Joined: Apr 2010
Posts: 358
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On the 2008 and up 3.3 & 3.8 engines the EGR valve is located on the right side of the engine just behind the coil pack.
Here are the instruction I found somewhere online:
I chose to remove the EGR tube from the intake manifold as well, it made it easier to line everything up when reinstalling. Easy DIY job, took less than an hour.
George
Here are the instruction I found somewhere online:
Remove:
1. Disconnect and isolate negative battery cable at battery.
2. Disconnect electrical connector (1) from exhaust gas recirculate (EGR) valve (5).
3. Remove bolts (3), gasket and EGR tube (3) from EGR valve (5).
4. Remove bolts (4), gasket and EGR valve (5) from cylinder head.
Install:
1. Install new EGR valve gasket to EGR valve.
2. Install EGR valve (5), gasket and bolts (4) to cylinder head. Tighten to 30 N.m (22 ft. lbs.).
3. Install EGR tube (2), gasket and bolts (3) to EGR valve (5). Tighten to 15 N.m (11 ft. lbs.).
4. Connect electrical connector (1) to EGR valve (5).
5. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
NOTE: It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired.Disconnecting the battery for at least two minutes will remove all power from the controller and reset these cells to normal default values.
1. Disconnect and isolate negative battery cable at battery.
2. Disconnect electrical connector (1) from exhaust gas recirculate (EGR) valve (5).
3. Remove bolts (3), gasket and EGR tube (3) from EGR valve (5).
4. Remove bolts (4), gasket and EGR valve (5) from cylinder head.
Install:
1. Install new EGR valve gasket to EGR valve.
2. Install EGR valve (5), gasket and bolts (4) to cylinder head. Tighten to 30 N.m (22 ft. lbs.).
3. Install EGR tube (2), gasket and bolts (3) to EGR valve (5). Tighten to 15 N.m (11 ft. lbs.).
4. Connect electrical connector (1) to EGR valve (5).
5. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
NOTE: It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired.Disconnecting the battery for at least two minutes will remove all power from the controller and reset these cells to normal default values.
George
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Joined: Mar 2015
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EGR valve bolt sizes
What are the size and thread twist and length for the bolts that hold the EGR valve to the cylinder head on a 2008 dodge grand caravan SXT with a 3.8 liter engine. It is the one where the EGR valve is located on the right side of the engine behind and under the ignition module and behind the thermostat housing please let me know ASAP one of the bolts worked itself out while driving and now getting an exhaust leak, engine sounds like a cross between a lawn mower and motorcycle engine. There is black carbon scarring/build up next to where the missing bolt was and it is getting bad gas mileage. Should be between 18 and 24 mpg but it is only getting 14 to 15 mpg. Please let me know. Thank you
