Here's a general guide. Specific steps and difficulties may vary slightly depending on the exact engine (2.0L or others) in your Neon. Always consult a repair manual specific to your vehicle's year and engine for precise diagrams and torque specifications.
Tools you'll likely need:
* Socket wrench set (metric)
* Phillips head screwdriver
* Flathead screwdriver
* Wire brush (small, preferably brass)
* Brake cleaner (or carb cleaner – use in a well-ventilated area!)
* Rags or shop towels
* Container for catching fluid
* Gloves
Steps:
1. Locate the EGR Valve: This usually sits on the intake manifold, near the back of the engine. Consult your repair manual for the precise location on your specific Neon. It will likely have a vacuum line connected and possibly some electrical connectors.
2. Disconnect Vacuum Line(s) and Electrical Connector(s): Carefully disconnect any vacuum lines and electrical connectors attached to the EGR valve. Take note of how they are connected to reassemble correctly.
3. Remove the EGR Valve: Depending on your Neon, the EGR valve may be held in place by bolts or screws. Use the appropriate socket wrench or screwdriver to carefully remove these fasteners. The valve itself may be somewhat stiff, so gentle but firm pressure might be needed.
4. Clean the Valve: Once removed, inspect the valve. You'll likely find carbon buildup on the valve itself and in the passageways. Use a wire brush to carefully remove as much carbon as possible. Pay attention to the valve seat, ensuring it's clean and free from debris. Spray brake or carb cleaner into the valve's passages and onto the valve itself, letting it soak for a few minutes. Then, use the brush again to scrub away loosened carbon. Repeat this process until the valve is relatively clean.
5. Clean the EGR Valve Passageway (Important): The passageway on the intake manifold where the EGR valve sits can also build up carbon. Use the brush and cleaner to clean this area as thoroughly as possible. This is often the most important part of the cleaning process.
6. Inspect the Valve: Once cleaned, inspect the valve's diaphragm or moving parts for damage or wear. If damaged, replacement is necessary.
7. Reassembly: Carefully reinstall the EGR valve, ensuring it's seated correctly. Reconnect the vacuum line(s) and electrical connector(s), matching them to their original positions. Tighten the bolts or screws to the manufacturer's specified torque (found in your repair manual).
8. Reconnect Battery Cable: Reconnect the negative battery cable.
9. Test Drive: After reassembly, take the Neon for a test drive to assess if the cleaning improved its performance.
Important Considerations:
* Caution with Brake Cleaner: Brake cleaner is highly flammable and should only be used in a well-ventilated area, away from sparks or open flames.
* Repair Manual: A repair manual specific to your 1997 Dodge Neon is highly recommended. It will provide detailed diagrams, torque specifications, and other important information.
* Professional Help: If you're uncomfortable performing this task yourself, it's best to take your Neon to a qualified mechanic. Improper cleaning or reassembly could damage your engine.
This is a general guide; specific details may differ for your Neon. Always prioritize safety and consult your vehicle's repair manual for precise instructions.
