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  1. #1
    Join Date
    Nov 2005
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    Mid-Michigan
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    Has anyone had an EGR Code P0406???

    I just got a check engine light this morning - Checked the code: P0406 - EGR Sensor A - Circuit High. Did a search - no luck. Just wondering if anyone has experienced this before, and if so - what's the fix? My warranty, it's expired - of course!

    Thanks guys.
    2005 Cool Vanilla SE - "Project RT6 SixPack"



  2. #2
    Join Date
    Sep 2004
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    Tulsa, OK
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    Hey, me too! Just the past couple of days. Mine first came on after I put in an FM modulator, so I just figured it was griping about having something disconnected, and it went out. Then I took the FM-mod back out (POS!) and it came back, I figured the same thing, it went out again. I'm hoping its just coincidence and I didn't do something (seems unlikely)

    Now its back on again (when I actually checked it). Doesn't seem to be running any differently. Of course the manual is so helpful, 4 out of the 8 or so diagnostics require either the starscan or a goofy pinout box for the PCM. :(

    I'll have to do the tests I can when I get a chance. Seems doubtful it'd hurt anything to let it go for a couple of days(?)

  3. #3
    Join Date
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    P0406-EGR Position Sensor Circuit High
    • When Monitored: With the ignition on. Battery voltage greater than 10 volts.
    • Set Condition: EGR position sensor signal is greater than 4.89. One trip Fault.
    Possible Causes
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO (F856) 5-VOLT SUPPLY CIRCUIT
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT OPEN
    (K900) SENSOR GROUND CIRCUIT OPEN
    EGR SOLENOID ASSEMBLY
    PCM


    most likely cause: EGR assembly
    Izzy pics

    Quote Originally Posted by Canadianknight
    I got it all straightened out with them guys. All good... feel bad for calling 'em a stealership now.

    Thanks Seven thanked for this post
    Likes Seven liked this post

  4. #4
    Join Date
    Oct 2007
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    Brooklyn, NY
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    How can I check for the items that you listed?

    Is the EGR an easy find on the 2005 Dodge Magnum SE?

  5. #5
    Join Date
    Apr 2005
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    2.7L EGR is located at the rear of the right cylinder head.



    1. EGR system components and location. Upper tube (2), EGR valve (1), and Lower tube (3).

    here is the complete diagnostic procedure:

    P0406-EGR POSITION SENSOR CIRCUIT HIGH




    For a complete wiring diagram Refer to Section 8W</B>.

    • When Monitored:
    • With the ignition on. Battery voltage greater than 10 volts.
    • Set Condition:</B> EGR position sensor signal is greater than 4.89. One trip Fault.
    Possible Causes</B> (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO (F856) 5-VOLT SUPPLY CIRCUIT (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE (K34) EGR POSITION SENSOR SIGNAL CIRCUIT OPEN (K900) SENSOR GROUND CIRCUIT OPEN EGR SOLENOID ASSEMBLY PCM
    </B>
    Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).</B>
    Diagnostic Test

    1. EGR POSITION SENSOR VOLTAGE ABOVE 4.5 VOLTS </B>

    Start the engine.
    With the scan tool, read the EGR Position Sensor voltage.

    Is the voltage above 4.5 volts?
    Yes
    • Go To 2
    No
    2. (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO THE (F856) 5-VOLT SUPPLY CIRCUIT </B>



    Turn the ignition off.
    Disconnect the EGR Solenoid harness connector.
    Disconnect the PCM harness connectors.
    Measure the resistance between the (K34) EGR Position Sensor Signal circuit and the (F856) 5-volt Supply circuit in the EGR Solenoid harness connector.

    Is the resistance below 100 ohms?
    Yes
    No
    • Go To 3
    3. (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE </B>



    Ignition on, engine not running.
    Measure the voltage on the (K34) EGR Sensor Signal circuit in the EGR Solenoid harness connector.

    Is the voltage above 0 volts?
    Yes
    No
    • Go To 4
    4. EGR SOLENOID ASSEMBLY </B>



    Turn the ignition off.
    Connect the PCM harness connectors.
    Connect a jumper wire between the (K34) EGR Position Sensor Signal circuit and the (K900) Sensor ground circuit.
    With the scan tool, monitor the EGR Position Sensor voltage.
    Ignition on, engine not running.

    Is the voltage below 0.5 of a volt?
    Yes
    No
    • Go To 5
    • NOTE: Remove the jumper wire before continuing.
    5. (K34) EGR POSITION SENSOR SIGNAL CIRCUIT OPEN </B>



    Turn the ignition off.
    Disconnect the PCM harness connectors.

    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 Position Sensor Signal circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

    Is the resistance below 5.0 ohms?
    Yes
    • Go To 6
    No
    6. (K900) SENSOR GROUND CIRCUIT OPEN </B>



    Measure the resistance of the (K900) Sensor ground circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

    Is the resistance below 30 ohms?
    Yes
    • Go To 7
    No
    7. PCM </B>

    NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

    Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.

    Were there any problems found?
    Yes
    No

  6. #6
    Join Date
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    Quote Originally Posted by Ripp View Post
    Seems doubtful it'd hurt anything to let it go for a couple of days(?)
    Mines been throwing this code for 6 or 7 months now.... Not a concern for me. Other than the annoying check engine light. One of these days I'll get it fixed.

    Stock catback, and stock drivetrain
    Typing from a tablet, excuse typos.


  7. #7
    Join Date
    Dec 2006
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    wilbraham, ma
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    Hate to dig up an old thread but do any of you know if this is covered under the emissions warranty?

  8. #8
    Join Date
    Feb 2006
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    Batavia, IL
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    I have an EGR assembly for the 5.7L, if anyone wants it.

  9. #9
    Join Date
    May 2006
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    my check engine light just came on yesterday. went to auto zone and EGR came up on the test. does this have to do with gas? i just put some gas in my car about 10 minutes before the check engine light came on.

  10. #10
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    Quote Originally Posted by GROUNDED View Post
    Hate to dig up an old thread but do any of you know if this is covered under the emissions warranty?
    not sure about USA but here in Canada, the only things covered by the extended emissions warranty are the catalysts and the PCM.

    Quote Originally Posted by fasho24 View Post
    my check engine light just came on yesterday. went to auto zone and EGR came up on the test. does this have to do with gas? i just put some gas in my car about 10 minutes before the check engine light came on.
    totally unrelated.

  11. #11
    Join Date
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    Quote Originally Posted by GROUNDED View Post
    Hate to dig up an old thread but do any of you know if this is covered under the emissions warranty?
    While the Feds require a 2 year emissions warranty, the 3 year factory warranty is actually better/longer. So our emissions are covered for 3 years, except for the cat converter and PCM which is 8 years.
    If you live in California the rules are different, and more favorable.

    This is copied from the 2006 Warranty manual.

    5. Emission Warranties Required By Law
    5.1 Federal Emission Warranty
    A. Parts Covered for 2 Years or 24,000 Miles
    Federal law requires DaimlerChrysler Motors
    Company LLC ("DaimlerChrysler") to warrant the
    following emissions parts for 2 years or 24,000
    miles, whichever occurs first. DaimlerChrysler
    covers all of these parts under the Basic Limited
    Warranty for 3 years or 36,000 miles, whichever
    occurs first.
    • Air system controls;
    • distributor and its components;
    • electronic fuel injection system, including injector;
    • evaporative-emission canister and controls;
    • exhaust manifold;
    • exhaust gas recirculation valve and control system;
    • exhaust pipes (between exhaust manifold and catalyst);
    • fuel cap and tank assembly, pump, and fuel lines;
    • ignition coil and ignition module;
    • intake manifold;
    • on-board diagnostic-system components;
    • oxygen sensors;
    • positive crankcase-ventilation (PCV) valve or orifice;
    • secondary ignition wires;
    • spark plugs;
    • throttle body;
    • transmission-control module;
    • vacuum hoses, clamps, and fittings, as well as tubing used for these components;
    • vacuum, temperature, altitude, speed, timesensitive valves, sensors, and switches used in these components and systems


    B. Parts Covered for 8 years or 80,000 miles
    If your vehicle has one of the following parts, this
    Federal Emission Warranty covers that part for a
    period of 8 years or 80,000 miles, whichever occurs first.
    These limits are counted from the time when your
    Basic Limited Warranty begins under 2.1(E). The
    covered parts are:
    • catalytic converter; and

    • powertrain control module.
    Last edited by sidetrack; 06-01-2008 at 12:10 AM.

  12. #12
    Join Date
    May 2006
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    Fultonville NY (Upstate)
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    Quote Originally Posted by fnkychkn View Post
    P0406-EGR Position Sensor Circuit High
    • When Monitored: With the ignition on. Battery voltage greater than 10 volts.
    • Set Condition: EGR position sensor signal is greater than 4.89. One trip Fault.
    Possible Causes
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO (F856) 5-VOLT SUPPLY CIRCUIT
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
    (K34) EGR POSITION SENSOR SIGNAL CIRCUIT OPEN
    (K900) SENSOR GROUND CIRCUIT OPEN
    EGR SOLENOID ASSEMBLY
    PCM


    most likely cause: EGR assembly
    How many trips to clear? This came up on my 5.7L today.

    Jay
    Last edited by karfreek; 04-16-2012 at 06:25 PM.
    2013 Honda Accord EX - 2.4L/6-Speed Manual

    2004 Chrysler Pacifica AWD-Everything but the kitchen sink.
    2011 Dodge Challenger R/T Classic - Redline 3-Coat Pearl, 6-speed - Gone
    2005 Dodge Magnum RT-Can you say...HEMI? - Gone
    1989 WS6/L98 Trans Am-Got Torque? - Gone

  13. #13
    Join Date
    Dec 2009
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    NC, from LI,NY
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    I think they get clogged up and stick. Mine was running pretty rough while I had the code, I tried to get the dealer to cover it under warranty but no go. I was past the 24k mark which seemed silly to me, its a failed part, no? Anyway, they wanted $340.... new valve($35) and clean throttle body($5). I just laughed them off...see you guys next time, I can do that myself, thanks. I actually wound up getting a used 1 from a member that did the EGR delete, funny thing was, his looked rougher than mine(rust and what not) but worked great. So, the cost was a $5 can of carb. cleaner for the throttle body and I paid shipping and through Nick a few extra bux for his troubles! Gotta love this place!! If you plan on doing this, just a heads up on the bottom mounting bolts, you'll need a small 10mm socket(1/4" inch short socket) and probably a longer one too, couple tight spots under there, but simple enough. I think some guys have even gotten away with removing the jammed EGR valve and knocking it loose...I didn't even bother. ANYWAY, I plan on an SRT header/exhaust upgrade and EGR delete, so I'll have a high milage but functional valve up for grabs(pay for shipping)

  14. #14
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    Fultonville NY (Upstate)
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    Cool, thanks. It went off after two drive cycles so I am just going to wait and see. A new one is $54 on rockauto.com

    Jay

  15. #15
    Join Date
    May 2006
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    Fultonville NY (Upstate)
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    This came back again. How do you change it on a 5.7L?

    Jay

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