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Zoban
04-16-2008, 08:15 PM
Got an engine light today so checked for codes and these two popped up..

DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

DTC P0406 Exhaust Gas Recirculation Sensor A Circuit High

Mag is a 2006 3.5 RWD.

Any pointers on what I need to check/fix.

Car was in for an oil change yesterday but everything top side of the engine looks in place.

Thanks in advance.

klarmie
04-16-2008, 09:20 PM
most likley gonna need the EGR valve...kind of common..many post in the past with members having the same problem

P0406-EGR POSITION SENSOR CIRCUIT HIGH


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a6f444.gif

</B>


When Monitored:

With the ignition on and battery voltage greater than 10.4 volts.
Set Condition:</B> The PCM detects that the Exhaust Gas Recirculation Valve input voltage is above the maximum acceptable value.Possible Causes</B> INTERMITTENT DTC (F856) 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE (K34) EGR SIGNAL CIRCUIT SHORTED TO VOLTAGE (K34) EGR SIGNAL CIRCUIT SHORTED TO THE (F856) 5 VOLT SUPPLY CIRCUIT (K34) EGR SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE (K900) SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE EXHAUST GAS RECIRCULATION VALVE POWERTRAIN CONTROL MODULE (PCM)
</B>
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.</B>
Diagnostic Test

1. DTC IS ACTIVE </B>

Start the engine and allow it to reach normal operating temperature.

WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in personal injury or death.


NOTE: Diagnose and repair any system voltage or sensor supply voltage DTCs before continuing with this test.

With the scan tool, select View DTCs.

Is the status Active for this DTC?
Yes

Go to 2 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#gf9dd7ba3aa34177b528d5e9d8fc6c3a)No

Refer to the *CHECKING FOR AN INTERMITTENT DTC Diagnostic Procedure.2. (F856) 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819a202a.gif
Turn the ignition off.
Disconnect the Exhaust Gas Recirculation Valve connector.
Disconnect the Powertrain Control Module (PCM) connector.
Turn the ignition on.
Measure the voltage of the (F856) 5 Volt Supply circuit in the Exhaust Gas Recirculation Valve harness connector.

Is there any voltage present?
Yes

Repair the (F856) 5 Volt Supply circuit for a short to voltage.
Perform the PCM Verification Test.No

Go to 3 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#h16f569fd84745548d660cfc83b2074d)3. (K34) EGR SIGNAL CIRCUIT SHORTED TO VOLTAGE </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819a2149.gif
Measure the voltage of the (K34) EGR Signal circuit in the Exhaust Gas Recirculation Valve harness connector.

Is there any voltage present?
Yes

Repair the (K34) EGR Signal circuit for a short to voltage.
Perform the PCM Verification Test.No

Go to 4 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#p15855484a214b12a49d91370bf269d9)4. (K34) EGR SIGNAL CIRCUIT SHORTED TO THE (F856) 5 VOLT SUPPLY CIRCUIT </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819a2033.gif
Measure the resistance between the (K34) EGR Signal circuit and the (F856) 5 Volt Supply in the Exhaust Gas Recirculation Valve harness connector.

Is the resistance below 100 ohms?
Yes

Repair the (K34) EGR Signal circuit for a short to the (F856) 5 Volt Supply circuit.
Perform the PCM Verification Test.No

Go to 5 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#k3320234fee0481cb1cbbde88b0cb908)5. (K34) EGR SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819a2152.gif
Turn the ignition off.

CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals, resulting in poor terminal to pin connection. Install Miller Special Tool #8815 to perform diagnosis.

Measure the resistance of the (K34) EGR Signal between the Exhaust Gas Recirculation Valve harness connector and the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?
Yes

Go to 6 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#l628de81cf1f451689897105ab8f4726)No

Repair the (K34) EGR Signal for an open circuit or high resistance.
Perform the PCM Verification Test.6. (K900) SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819a215b.gif

CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals, resulting in poor terminal to pin connection. Install Miller Special Tool #8815 to perform diagnosis.

Measure the resistance of the (K900) Sensor Ground circuit between the Exhaust Gas Recirculation Valve harness connector and the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?
Yes

Go to 7 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#i08fa64ac85a4550bf610db7f765fcdb)No

Repair the (K900) Sensor Ground circuit for an open circuit or high resistance.
Perform the PCM Verification Test.7. EXHAUST GAS RECIRCULATION VALVE </B>


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/819aa98e.gif
Turn the ignition off.
Connect the Powertrain Control Module (PCM) connector.
Connect a jumper wire between the (K900) Sensor Ground circuit and the (K34) EGR Signal circuit in the Exhaust Gas Recirculation Valve harness connector.
Turn the ignition on.
With the scan tool, read the Exhaust Gas Recirculation Valve signal voltage.

NOTE: The sensor voltage should be approximately 0.0 volts (plus or minus .1 volt) with the jumper wire in place.


Does the scan tool display the voltage as described above?
Yes

Replace the Exhaust Gas Recirculation Valve in accordance with the Service Information.
Perform the PCM Verification Test.No

Go to 8 (https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/81a3d078.htm#h974baab76544c5f89f0fe360e06e2bb)8. POWERTRAIN CONTROL MODULE (PCM) </B>

Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Exhaust Gas Recirculation Valve and the Powertrain Control Module (PCM).
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out or corroded terminals.
Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
Look for the data to change or for the DTC to reset during the wiggle test.
Refer to any Technical Service Bulletins that may apply.

Were any problems found?
Yes

Repair as necessary.
Perform the PCM Verification Test.No

Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information.
Perform the PCM Verification Test.

Zoban
04-16-2008, 09:26 PM
CRAP!!! Was afraid of that .. Just thought mighta been something simple due to timing of oil change being the last thing on way home last night and light popped on way to work.

Damn.

Magnum P.I
04-16-2008, 10:05 PM
if it still under warranty just take it in to the stealership,that should be covered.

Zoban
04-16-2008, 10:13 PM
Good point will slide by there tomorrow.

DA H.N.I.C.
04-16-2008, 10:17 PM
I've got the P0406 too. Think I'll take mine in to the dealership as well. Reload the factory flash from the handheld. Thanks for the info.

Zoban
04-17-2008, 04:49 PM
Appointment for first thing tomorrow morning .. Under Warranty YAY!!!

LOL.

DA H.N.I.C.
04-17-2008, 05:45 PM
Make sure to post the details!

Zoban
04-18-2008, 07:08 PM
In and out done like dinner .. Okay so took a lil over an hour but I had time to look at the other cars on the lots and bought a spring jacket..

EGR all fixed and no more light,.

While I was there I mentioned that my heat controls didn't have any of the lights working. He started to say that bulb replacement couldn't be covered under warranty but I chimed in that I had already looked at replacement bulbs and that they are soldiered in to the pcb.. "Oh in that case we'll replace the whole unit, let me check if we have one in stock"

They did and it's replaced now too ..

Was a really simple in out no issues and great to deal with..

glory1270
04-19-2008, 05:00 AM
does any idea what the cost is to fix the problem, if your car is not under Warranty.

Zoban
04-19-2008, 05:36 PM
The numbers on my paper work are as follows..

Labour Rate 99.95/hr

Starscan flat - 99.95
Valve- 85.85
Gasket- 3.80
Labour 1.5 - 149.93

Total for EGR if out of pocket.. 339.53 CDN plus 13% tax in Ontario = 383.67

The Heater control not that anyone cares..

Control Unit- 102.00
Labour .3 - 29.99

Total 131.99 CDN plus 13% tax in Ontario = 149.15 CDN

Grand Total that would have been my bill.

532.82 CDN.

I would say that I am happy to have bought the additional warranty.

tt_dexter
05-05-2008, 07:53 PM
There must be something in the air! I just got a 0406 DTC today and thought I'd check here for tips - thanks for the detailed information klarmie. It's much appreciated.

My Magnum SXT/AWD (3.5L) has 99k miles on it so I'll be doing the work and buying the part myself. I reset the code this afternoon and will wait to see if it reoccurs

klarmie
05-05-2008, 10:28 PM
heres the service info.....

3.5L


https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/813518fa.gif


Disconnect negative battery cable.
Remove purge solenoid from bracket.

https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/813518f7.gif
Relocate the purge solenoid.

https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/813768d0.gif
Unlock and disconnect the electrical connector from EGR valve.
Remove the wiper module, (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL (https://w05.dealerconnect.chrysler.com/service/mds2002/Dispatcher?SERVICE=SoftLink&SoftLinkId=889061370)) .
Remove shock tower brace and relocate.
Remove the upper intake manifold, (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL (https://w05.dealerconnect.chrysler.com/service/mds2002/Dispatcher?SERVICE=SoftLink&SoftLinkId=916001370)) .

https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/813768c3.gif
1 - TUBE 2 - EGR VALVE
EGR valve (2) and tube (1).

https://w05.dealerconnect.chrysler.com/service/mds2002/serviceInfo/en_US/813768cd.gif
Remove tube bolts (1) to EGR valve (3).
Remove tube (1) from intake manifold.
When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum.
Remove EGR valve mounting bolts (2).
Remove EGR valve from vehicle.
Clean mounting surface.

Nuclearjack
05-30-2008, 04:32 PM
The numbers on my paper work are as follows..

Labour Rate 99.95/hr

Starscan flat - 99.95
Valve- 85.85
Gasket- 3.80
Labour 1.5 - 149.93

Total for EGR if out of pocket.. 339.53 CDN plus 13% tax in Ontario = 383.67

The Heater control not that anyone cares..

Control Unit- 102.00
Labour .3 - 29.99

Total 131.99 CDN plus 13% tax in Ontario = 149.15 CDN

Grand Total that would have been my bill.

532.82 CDN.

I would say that I am happy to have bought the additional warranty.



For us non warranty folks is the Starscan flat part of the repair required?

Zoban
05-30-2008, 05:02 PM
Far as I know yep as they have to clear codes etc..

Think they stick you with a Starscan for just about anything electrical related.

Ripper
06-10-2008, 07:38 PM
Just got mine back today - after being away up north for the weekend coming home engine light came on and it ran a bit rough. Took it into the dealership and P0406 was the problem - covered under warranty so no out of pocket expenses....other than the inconvenience - but Eastway as usual was great and because they did some add'l repair work I got a rental for the day.....the Daykota was a treat but heavy one the gas!!!!! Now I know why i don't have a truck!

the hurse
07-21-2008, 12:32 PM
Grrr.... I had been getting that code for a while and the first time i took it to the stealership, they told me that they could not replicate the problem and that all of the codes had been cleared. Can ran fine for a few months and started doing it again. I took it back and was told that I needed to have the EGR valve replaced and some throttle body maintenance done. Ok i say, and 3 days and 480 buks later i get my car back. Then I drove her the next day and now its a lot of hesistation or stuttering and some real bad vibration. Shes back in the shop now and I am waiting on the verdict. I hope the mechanics didnt screw something up because she wasnt doing that when i before i took it to them.

Creek Rat
08-30-2008, 10:51 AM
I'm also getting the 0406 error. Is the EGR covered under the 7/70 Powertrain Warranty?

Norwood
11-01-2008, 11:10 AM
Good question, I got that code this past wed. at 69,500 miles and took it to the dealer this morning. The not very pleasent service writer (the guy was acting like he was doing me a favor just talking to me) told me that if the EGR was the problem that it iS NOT COVERED under 7/70 and that it would be $370.00 minus 15% for my dealer loyalty. I left to do some further investigation so her I am.....

Zoban
11-01-2008, 12:53 PM
Where you located ? I would find another dealer to check the Warranty status..

Norwood
11-01-2008, 04:11 PM
I am in the western burbs of Chicago. is the EGR covered under 7/70 or Emmisions warranty?

Zoban
11-01-2008, 05:42 PM
If I recall correctly emmissions are required to be covered by warranty ..

I could be wrong though..

fnkychkn
11-01-2008, 07:35 PM
EGR is not covered under the powertrain warranty or the extended emissions warranty. it is only covered by the 3 year/36,000 mile (60,000 km) basic warranty and certain service contracts.

Adrnlnjunky
03-25-2009, 11:46 AM
Can I get by with replacing the EGR myself and then taking it somewhere to get the code erased? Would that work or would just disconnecting the battery during the process be enough? Thanks!

fnkychkn
03-25-2009, 04:37 PM
Can I get by with replacing the EGR myself and then taking it somewhere to get the code erased? Would that work or would just disconnecting the battery during the process be enough? Thanks!
disconnecting the battery will erase the code.

Adrnlnjunky
03-25-2009, 08:13 PM
disconnecting the battery will erase the code.


Kewl. That's what I was thinking. Just wanted to be sure. Thanks.:loser:

Five Points
03-26-2009, 08:14 AM
I just paid $400 for my egr valve last week. not covered by my extended warranty.

Un4GivN
05-26-2009, 04:55 PM
I just did this install on the weekend. There are a couple of brackets that are stupid and very annoying to get off. I had to use a pry bar to get the 2 on the passenger side of the engine off so I could remove the intake! There is one mounted to the throttle body that seemed pointless so once it was time to put it back on, I neglected that part of the project.

Also, the EGR being behind the engine was so annoying to find the 2 holes where they went back into, maybe if I had one of those nifty cameras on a bendable fiber optic cable.

A note: once it's time to transfer the brass/copper tube onto the new EGR, you should mark it accordingly to the bracket so you have the right angle for it to be put back into the intake. I just guessed so HOPEFULLY I chose the right spot.

fuzzycali
05-26-2009, 05:29 PM
i just did this install on the weekend. There are a couple of brackets that are stupid and very annoying to get off. I had to use a pry bar to get the 2 on the passenger side of the engine off so i could remove the intake! There is one mounted to the throttle body that seemed pointless so once it was time to put it back on, i neglected that part of the project.

Also, the egr being behind the engine was so annoying to find the 2 holes where they went back into, maybe if i had one of those nifty cameras on a bendable fiber optic cable.

A note: Once it's time to transfer the brass/copper tube onto the new egr, you should mark it accordingly to the bracket so you have the right angle for it to be put back into the intake. I just guessed so hopefully i chose the right spot.

the 2 brackets on the pass. Side r easily removed if u loosed the 16mm bolts at the bottom of the bracket,no prying needed.
As far as the bracket on the throttle body. I would put that back on,if it was not needed the factory would have not put it on either.just my opinion.do it right the 1st time to save u time later..

RunningBull
05-26-2009, 05:45 PM
All major emission controls are coverd until 80,000miles