Join Date: Apr 2003
Location: Summerville, SC
From the FSM. (edit I forgot you have a 3.5)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING EGR SYSTEM
A failed or malfunctioning EGR system could cause
engine spark knock, and possibly sags or hesitation,
rough idle, and stall the engine. To ensure proper operation
of the EGR system, all passages and moving
parts must be free of deposits that could cause plugging
or sticking. Ensure that the system hoses does
not leak. Replace leaking components.
Inspect hose connections between intake manifold,
EGR solenoid and transducer, and the EGR valve.
Replace hardened, cracked, or damaged hoses. Replace
TESTING ELECTRONIC EGR TRANSDUCER
(1) Ensure manifold vacuum flows to the electronic
Use the DRB scan tool’s Actuators screen to test
the solenoid on the electronic EGR transducer. Refer
to the appropriate Powertrain Diagnostic Manual.
(2) Disconnect the vacuum supply hose from the
transducer. Tee a vacuum gauge between the transducer
and hose. Start the vehicle. There should be a
minimum of 15 inches of vacuum supplied to the solenoid.
If vacuum is low, check for kinked or twisted
hoses and leaking hoses or hose connections.
(3) Actuate the solenoid using the DRB scan tool.
The solenoid should click when turned on and off. As
the solenoid cycles, it should shut vacuum to the
transducer on and off. Replace the EGR valve and
transducer/solenoid if the solenoid operates incorrectly.
If the solenoid operates correctly, test the
TESTING EGR TRANSDUCER—3.5L ENGINE
(1) Disconnect the vacuum hose and back-pressure
hose from the transducer. Disconnect the electrical
connector from the solenoid.
(2) Plug the transducer output port (Fig. 3).
(3) Apply 1 to 2 PSI of air pressure to the transducer
back-pressure port. Use a hand held air pump
or compressed air regulated to 2 PSI.
(4) Apply a minimum of 12 inches of vacuum to
the other side of the transducer. Replace the EGR
valve and transducer/solenoid if the transducer does
not momentarily hold vacuum then slowly bleed off.
TESTING EGR VALVE—3.5L ENGINE
(1) Remove the EGR valve from the engine. Refer
to EGR System Service.
(2) While applying at least 15 inches of vacuum to
the EGR valve diaphragm, check for movement of the
² If the stem does not move, replace the EGR valve
and transducer/solenoid as an assembly.
² If the stem moves approximately 3 mm (1/8 inch),
maintain vacuum supply to diaphragm. The valve
should remain open for approximately 30 seconds or
more. If the valve leaks, replace the EGR valve and
(3) If the EGR valve operates correctly, check for
blockage in the port on the rear of the cylinder head.
The port connects the EGR valve to the exhaust port
of rear cylinder. Also, check for blockage in the EGR
valve back-pressure tube (to transducer).
November 2011 COTM winner
R.I.P Kyle you will be missed.
Last edited by 95trep3.3; 02-25-2011 at 09:47 PM.