EGR Valve - Popping/Knocking/Chattering Noise

NO: 25-02-97

GROUP: Emissions

DATE: Jul. 25, 1997

SUBJECT:

Popping/Knocking Noise
in Engine Compartment

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 25-01-96, DATED APR. 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL YEAR CHANGES.

MODELS:

**1995 - 1997** (FJ) Avenger/Sebring

NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE.

SYMPTOM/CONDITION:

Popping, knocking or chattering noise from the engine compartment during vehicle operation.

DIAGNOSIS:

Drive the vehicle with a warm engine between 1600 and 1800 RPM. If the noise is heard, stop the vehicle, disconnect the EGR vacuum line and plug it. Re-test the vehicle as listed above. If the noise goes away, perform the Repair Procedure.

NOTE:
THE VEHICLE MUST BE DRIVEN TO PERFORM THIS DIAGNOSIS.

NOTE:
UNPLUG THE VACUUM LINE AFTER THE TEST

PARTS/EQUIPMENT REQUIRED:

1 **05010162AA** Valve, EGR
1 04300297 Gasket, EGR
**AR (1) MD323103 Bracket (For early built 95 models with original EGR
Valve p/n 4287791 )**

REPAIR PROCEDURE:

This repair involves replacing the EGR valve with an improved part.

1. Remove the existing EGR valve and replace it with p/n 50101 62AA. Use a new gasket when replacing the valve.

NOTE:
IF THE ORIGINAL EGR VALVE'S P/N IS 04287791, THE BRACKET P/N MD323103 WILL BE REQUIRED FOR PROPER MOUNTING.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 25-01-45-92 0.5 Hrs.

FAILURE CODE: P8 - New Part