If you’ve got a higher-mileage Crossfire and you’re getting an intermittent or intermediate EGR fault, don’t automatically assume the EGR valve itself is bad.

A couple things to check first:
1. Vacuum lines
The small vacuum lines connected to the EGR valve can dry out, crack, or leak over time. Swap those out first — they’re cheap and often the real culprit.

2. Breather port clog
On the passenger side, locate the breather tube on top of the valve assembly. Remove the hose and shine a flashlight inside. You should see a tiny pin-sized hole.
If you can’t see it, it’s probably clogged.
Use a small pick or fine wire to carefully clear the obstruction. Make sure the hole is completely open.

3. Electronic portion only
In many cases, you don’t need to replace the entire EGR valve. The electronic component on the back of the valve can be replaced separately and is much easier to access. You don’t even need to remove the intake elbow to do it.
If you do decide to remove the entire valve, you’ll need a 24mm crow’s foot wrench.

After repairs:
Clear the codes
Run a few proper drive cycles
Check I/M readiness on your scanner
You should see everything ready except possibly A/C and HTD catalyst depending on conditions. Once monitors are set, you should be good for smog.

Hope this helps someone save time and money.

Additional note: You can also check the strength of the valve by running a little vacuum pressure. You know the valve is working properly if the engine sounds like it's about to like bog down or shut off just release the vacuum.