Chrysler Repair: 99 2.5L: CODE P0403, screwdriver blade, exhaust gas recirculation valve

Question
I just failed the emissions test and was given this code.  What is it for and What repair needs to be made.  Thank you.

Answer
Hi Amanda,
That code is about a pollution reduction device called the exhaust gas recirculation valve. It it inclined to fail due to getting gummed up and not responding when requested to do so by the engine computer. And when it failts to do so, a fault code is set. While the list of possible causes includes many other things my suggestion is as follows:
The first thing I would do is check the mechanical function of the egr valve which is located along a small diameter pipe that runs from the left exhaust manifold (on the side of the engine facing the front of the car) to just below the intake manifold area (where the incoming air in the large rubber tube enters the throttle). That valve is metal and has a round fitting with a vacuum hose attached, mounted on the top of the valve, and the round part is attached to the main body of the valve by a sort of saddle.  Inside the open saddle you will see a metal rod (with a slot) that connects the round top fitting to to the valve body. That rod is a stem on the valve and it is supposed to go in and out in response to the engine vacuum which varies with RPM and throttle opening (gas pedal position). Take a spray can of WD-40 or other penetrating lubricant and spray the stem where it enters the valve body and then use a regular screwdriver blade tip inserted in the slot to lever the valve in and out to try and free up its motion. Also check all the rubber vacuum hoses associated with the valve and a nearby vacuum solenoid valve. If the valve seems to open (against the built-in action of a spring) and close firmly by the spring action when using the screwdriver blade to facilitate the motion, then you should be able to pass the emissions test. To test it, start the engine and get it idling, then have a friend pump the gas paddle so the engine races up to over 2,000 rpm and back down while you watch the slot of the valve stem. It should move back and forth in synchrony with that revving action. If that doesn't work, then there are some other measures that require checking the inside of the valve and all the wires, hoses/pipes associated with the system. But most often it is the valve action being gummed up that causes the problems with it.
Roland