The Neon--manufactured by Chrysler, sold by Dodge and Plymouth dealers, and powered by a Japanese-manufactured engine--captured the American compact car market with lively performance and eye-catching styling when it was introduced in 1994. The Neon, like most modern cars, is equipped with an exhaust gas recirculation (EGR) valve that returns unburned fuel to the combustion chambers. While the exhaust gas recirculation valve was not a component of the Neon known for failure, because it made little noticeable impact on performance, Neon exhaust gas recirculation valve service is often overlooked. You can replace your Neon's EGR valve on your own if you know what you're doing.
Park your Neon on a level surface. Turn off the engine. Open the Neon's hood. Let the Neon's engine cool. Remove the retainer nut that holds the air intake plenum (it's a housing shaped to route airflow) leading to the air filter housing. Remove the air filter, the air filter housing, and the flex hose leading from the housing to the throttle valve. Removal is primarily a snap-off-and-out process with the exception of loosening a hose clamp at the throttle valve.
Locate the exhaust gas recirculation valve, now exposed, by finding a small, curving pipe starting at the exhaust manifold and ending at the valve. Loosen two bolts attaching this pipe to the valve, using caution to save the heat-resistant gasket, which is often omitted as part of a replacement valve purchase.
Remove the two additional bolts holding the valve to the intake manifold. Remove the vacuum hose that is attached to the valve. Make sure there are no breaks in any of the vacuum hoses associated with the valve or the vacuum transducer, a round device with electrical wires and vacuum hoses attached, one of which should be connected directly to the valve. There is communication between this transducer and the vehicle main computer to regulate vacuum flow. Without this intact, the exhaust gas recirculation valve will not operate.
Install the new EGR valve and torque the two bolts, using care not to over-tighten them, stripping the aluminum threads. Install the vacuum hose, the supply pipe and gasket, and the air cleaner assembly.
