Chrysler Town and Country P0404 P0406 fix EGR Valve Replacement How to

[4631027]

Thanks. I was able to do it without pulling the alt.

[briansmobile1]

@4631027 You bet!

[jeff27577]

well damn, the bottom bolt will not let go. looks like im pulling the alt. was hoping to not have to do that.

[robeldc]

Great video, and instructions!! Appreciate the help!!

[briansmobile1]

@robeldc You're welcome!

[wallydisneydad]

Brian (AKA briansmobile1), Thank you for the video. Saved me a lot of money. I ended up not taking off the alternator bolts and instead took the advice of one of your posters. I did however replace his pry bar with a piece of pine to pry with. For others taking shortcuts, the negative cable disconnect, is what clears the ODB code. Again, thanks.

[briansmobile1]

@wallydisneydad You're welcome! Way to go!

[dwayneemitchell]

This does not appear to be too difficult if you have the right tools...which I unfortunately do not. What would you expect to be a fair price to have a mechanic replace this?

[briansmobile1]

@dwayneemitchell More than what the tools would cost. And after you buy the tools you'll retain them.

[BrotherApps]

I am impressed, excellent video and instruction. I just changed it on my 2006 T&C and did not have to losen the alternator. I used jeffsmopar1 suggestion to use a prybar after removing the top bolt. Thank you very much gentlemen for the tips and savings.

[briansmobile1]

@BrotherApps You're welcome. Thanks for your gracious feedback!

[lbclocomotion]

Thank you for the information and all the details in this AWESOME VIDEO! God Bless You Brutha!

[mysticalmayra]

My mom owns a 2002 town and country V6. I tried to locate egr with diagrams and videos but no luck. Then I read someone else had same problem on internet, missing egr on same model, engine and year. I called local chrysler dealer and they said they had replacement egr for $150. They verified the vin and said it was needed. I then asked them to locate egr on pics of the engine. They said one was never installed and proceeded to tell me not to worry about it, that it was not needed.

[briansmobile1]

@mysticalmayra Right on.

[edanneberg]

Good vid and thanks for posting them, but you need to look up what these thngs do IF you are going to mention it....the ERG re-introduces exhasut gas into the intake to ulimately lower exhaust gas (by adding mass), so less NoX is produced. It's an emissions control device, not a gas-saving device.

[mrexecutive1]

Great video! just wanted to give your viewers a shortcut on this job. Alternator removal is not required and you can access bottom egr bolt with a 1/4" drive socket. saves a lot of time rather than removing panels belt alternator. also egr tube on top of intake removal not required. only 4 bolts needed for removal. the two egr mounting bolts and the two tube bolts on the egr. thanks again for all your great videos, hopefully theres more to come. Happy New Year.

[briansmobile1]

@mrexecutive1 Thanks- Happy New Year to you and yours!

[MrGILCORY]

@mrexecutive1 I need to remove the alternator. Do i need to remove egr to get it out on my 06? what is the best way to remove the bottom bolt facing the front of van on the alternator. looks like not enough room for wrench, but socket runs into a/c pipe? what scars me is snapping bolt off. do you wire brush the bolts after taking them out? Can i remove the egr if needed, after moving the alternator a bit forward and then egr take out so i can get alternator out?

[mrexecutive1]

@MrGILCORY here are instructions for alternator by the book. 3.3L & 3.8L Engines

Remove or disconnect the following:

Negative battery cable, Alternator harness connectors, Right front lower splash shield,

Accessory drive belt, Lower oil dipstick tube bolt and the wiring harness from the tube,

3 mounting bolts, Dipstick tube, Alternator.you may clean blts with brush if you would like. EGR does not need to be removed. Install in reverse order, Tighten to 40 ft. lbs. (54 Nm).

[MrGILCORY]

@mrexecutive1 Can I get alternator out without removing egr valve? What is best way to remove bottom bolt of alternator, the one facing the front of the van below manifold. What is best sequence remove all 3 bolts and then move forward the alt. and then find access to the lower egr bolt. Is it necessary to put in new egr gasket?

[snarfeater]

wrx owner friends

[snarfeater]

you are like a free college professor im backing up all your videos before you charge 45 dollars a video they are worth at least that tech manuals are hundreds of dollars and courses are too alldata costs a pretty penny but they charge for each car separately and that could run thousands of dollars you are doing a public service especially for some of my wrx owners who went through hell with those boxer engines , besides those knock allot i notice thanks again!

[snarfeater]

the EGR valve should be cleaned routinely. Excessive idling and poor fuel quality can clog the EGR valve 

[snarfeater]

no you are wrong the egr is for emissions it robs power and lowers gas milage by lowering combustion temps hence the heat energy driving the engine and on the hiway the engine is not running fast if you open the egr by hand the engine will stall the number one problem with the 6 liter powerstroke was the egr besides if your engine burns oil as most cars do then the egr is making your engine suck in all the smoke and garbage coming out everyone look at your intake its black this is one reason

[briansmobile1]

@snarfeater Truly fascinating!

[snarfeater]

@snarfeater i also hate retro fail cars like the pt cruiser as it looks like a midget herse

[briansmobile1]

@snarfeater LOL!

[srikrana]

thanks very much,,that was a great deal of information...

[briansmobile1]

@srikrana You're welcome!

[ckempjr07]

Thanks guys!!! You do a good job.

[briansmobile1]

@ckempjr07 You're welcome man!

[linaeme46]

the mass air flow sensor (po172)has anything to do with the egr for a 2005 chrysler pacifica?

[briansmobile1]

@linaeme46 They're independent in function, but work in concert to manage air fuel mixture. The EGR works to manage NoX. The MAF meters or measures how much air is incoming so the computer can use that data to inject the right amount of fuel into the intake manifold.

[linaeme46]

@briansmobile1 Thank you. The mechanic stated that he change both pieces but the light still on. The car still in the same condition in not getting a right away speek, you can fell the bubble went you press the gas. Now the mechanic said that I need to change the catalitic converter $600.00 cost. I as if he clear the code but he could not answer me. Autozone machine indicated the same code still there. Do you thing I should look for a second oppinion?

[briansmobile1]

@linaeme46 You're mechanic is guessing instead of testing. Get another mechanic.

[briansmobile1]

@linaeme46 In my industry we call that "parts swapping" and it's the mark of incompetence..... bless his heart.

[linaeme46]

Do you can say the approximate labor cost?

[twain55]

Great video. Thanks for sharing.

[briansmobile1]

@twain55 You're welcome!

[kar9sk]

thanx dude im doing mine in a few days. im so thankful for guys like you on youtube who are kind enough to share your knowledge!

[briansmobile1]

@kar9sk You're welcome

[GerryJ08]

I'll try to get one done tomorrow. Cheers.

[GerryJ08]

Thanks but in looking at the images (can I send you a couple to show you what I mean?) it does not appear to be the valve cover gasket leak.

[briansmobile1]

@GerryJ08 a vid response would be great

[GerryJ08]

Hey Brin this is Gerry from BC, Canada, Great video as always. Question: My 2005 Dodge Grand Caravan 3.3 ltr has what looks like oil on the outside of the intake manifold by the gasket. Would replacing the EGR valve solve that problem or is it from something else? I can send you pics for clarification if needed. Cheers.

[briansmobile1]

@GerryJ08 It's more likely to be the Valve Cover Gasket that's leaking.

[MusicsMyOnlyEscape]

Thanks for your assistance. I was able to get the EGR valve in with out removing the alternator. Thank goodness because I counldn't get that third bolt on it to budge.

Now I have to look at the struts. They are starting to creek and make noises.

[briansmobile1]

@MusicsMyOnlyEscape Good job!  Way to go!

[MusicsMyOnlyEscape]

Thanks for everybody's help...here goes. check back later.

Todd

[Pms020992]

@briansmobile1 big question does the egr valve has anything to do with the rpm, my chrysler 300 is having some issues while driving it

[briansmobile1]

@Pms020992 It does

[deklon]

Just watched the video, read the comments, got the part and replaced it successfully. It is correct that you can easily get to the bottom bolt without removing the alternator. It is correct that after removing the top bolt simply move the valve toward you to reach the bottom bolt. Thanks to all of you who made those comments. I wouldn't have done it if I needed to remove the alternator and belt!

[Goodwrench496]

No problem,like to help where i can.

[briansmobile1]

@Goodwrench496 That's awesome. I can respect and get behind that.

[ndorowamwari]

Thank you. You saved me a lot of time and money

[briansmobile1]

@ndorowamwari You're welcome. Thank you so much for being awesome and taking on a challenge like that. YOU are the man!

[Goodwrench496]

Exhaust gas recirculation (EGR) systems were introduced in the early '70s to reduce an exhaust emission that was not being cleaned by the other smog controls. Oxides of nitrogen (NOx) are formed when temperatures in the combustion chamber get too hot. At 2500 degrees Fahrenheit or hotter, the nitrogen and oxygen in the combustion chamber can chemically combine to form nitrous oxides

[briansmobile1]

@Goodwrench496 Cool. I remember hearing that in my emissions training. Thanks for posting it.

[donaldstop]

thank you very much! because of this video I was able to replace my EGR. Mine is the 3.3 liter and I had to borrow a slim 1/2" drive to release the tention off the belt. The auto parts store let me use the serpentine belt tool kit for free.

[briansmobile1]

@donaldstop You're welcome- thank you!

[speedster29]

Great video. I have a 2005 Town and Country with 67,000 miles and got the P0404 code. I replaced the EGR valve today. If you are lucky and the bolts are not corroded, it is possible to wiggle out the lower bolt without moving the alternator, so I would suggest trying that first.

[briansmobile1]

@speedster29 Cool

[grawey77]

Same Engine size.

[grawey77]

Explain why some of these have no egr valve. I have an 04 with no egr valve.

[wheels152]

I changed this last weekend. I used a 1/4 ratchet and a cheap thin walled socket and I didn't have to take off the alternator. Much easier

[james08diaz]

I got a Chrysler T&C 2003, and would like to update the front bumper to 2005 with the headlights and grilles, does anybody knows if it works? or there are some complication issues if i try to do that? it fix? 'cuz the replacement it seems similar.

[briansmobile1]

@james08diaz Anything is possible with an angle grinder and a welder. Just ask gassolean

[jamesgel]

@briansmobile1

Thanxs for your help!

[briansmobile1]

@jamesgel  You bet.

[dbroncotroy]

@briansmobile1 - Thanks for the great video. I did the same thing as @jaser119. I losened the bottom 10mm with a socket and then pushed the EGR valve back and hand removed the bolt. It saved a ton of time rather than removing the alternator. Thanks again!!!

[briansmobile1]

@dbroncotroy You're welcome. Thanks for watching/posting!

[jaser119]

I am not great at working on cars but I did it! I did not have to remove the alternator on our 2006 T&C. I removed the top 10mm and then pushed the EGR valve back with my hand to loosen and get to the bottom 10mm. It was still a tight fit but it barely came out. It took me a little bit to get the new bolt started because of the tight space but I finally got it. Figured I saved a couple hundred $. Thanks for the video.

[briansmobile1]

@jaser119 Way to go! You're welcome

[Gardensynergy]

Very helpful! My van is the same as this one in your video. 2 weeks prior to the dash board light coming on and getting the code P0404, my van would die while in drive. No warning. It would just cut power. I would pull it over, put it back in park and restart it. It started up fine. Did it twice in one day. I have had this problem in the past. About 6 times in the four years I have owned it. My milage has always been between 12 - 16 MPG too. Does this problem have to do with the EGR valve too?

[briansmobile1]

@Gardensynergy It can be. Power loss off the line would be too.

[TheKuggy]

Watch your video...good job! But i have a 2002 chrysler town and country lxi and the egr valve is not located where the one in the video is. I noticed this one in the video was a 2005 did the move it? I am currently getting code p0403...Please help

[briansmobile1]

@TheKuggy Is yours a 3.0 liter? If so it may be on the back of the motor on the drivers side.

[TheKuggy]

@briansmobile1 Nope 3.8 v6 Vin 2c4gp54l42r696821 Thanks

[TheKuggy]

No 3.8 v6 Vin 2c4gp54l42r696821

[briansmobile1]

@TheKuggy For 2002 3.8l  They are located just above the alternator (pretty much in the same location.) If yours isn't there it may have been deleted by putting a plate to cover the hole in it's place.

[TheKuggy]

@briansmobile1 Ok, I have had this van for 3 yrs, never had an issue with this code. What would be the purpose of deleting this component and how can the code come up if it isnt there.

[briansmobile1]

@TheKuggy Has the computer been replaced or re flashed? There's a recall on some of them. If it wasn't equipped with one then your ECM is bug.

[TheKuggy]

@briansmobile1 Very good question. I have relplaced this with a refurished computer updated the same as the old one from a company in Florida.I have called them(with code) but they told me i need to take it to a garage to get put on a computer.

[briansmobile1]

@TheKuggy I bet that's the problem right there.

[TheKuggy]

@briansmobile1 No 3.8 v6 Vin 2c4gp54l42r696821

[nickbuol]

Thanks a TON. I just did this on our 2006 Grand Caravan. Your instructions were great. Of course leave it to Chrysler to change things from the 2005 T&C you show and the 2006 GC that I have. The 19mm or 3/4 inch wrench did no good since the tensioner pulley does not have a box end. I had to run to an auto parts store and get a loaner serpentine belt tool. Anyway, used the short bar connected to the pulley, and the long bar connected to the short one and it was cake. A lot of work for 1 bolt.

[briansmobile1]

@nickbuol Cool. You're welcome and thanks for posting here.

[Blockhead2231]

I just changed one on a 2006 T&C touring. Patience was the virtue and able to do so without manipulating the alternator. The part ranged from $62 to $100 from three different auto stores. I went middle of the road with O'Reilly at $80. Definitely worth the price since saving on the labor/shop charges! I didn't go frugal and attempt an EGR cleaning since the process is a little time consuming. I event went ahead and changed the plugs. Runs nice now. Thanks to briansmobile1!

[briansmobile1]

@Blockhead2231 Glad to hear it! Thanks for the update.

[Blockhead2231]

Good video. Is there an EGR gasket? Thanks.

[briansmobile1]

@Blockhead2231 There is. It's a lead based exhaust type gasket.

[pattorminator]

Thanks for this video. It really helps to understand why it costs $45/hour to get this work done.

[Strtc28]

Great job! Would I also need to replace the egr valve sensor too?

[briansmobile1]

@Strtc28 Nope. It's one in the same. All one piece on this one.  Good luck! Thanks for stopping by.

[jcanivan]

Good job Thank you

You realy helped clarify what's involved in replacing an erg valve. Is a Dodge caravan 3.6 L erg valve easy to replace ?

[briansmobile1]

@jcanivan It's near impossible on a 3.6L because you just can't find one! On the 3.8 however it's not too bad.

[jcanivan]

Good job Thank you

You realy helped clarify what's involved in replacing an erg valve.

[smokinghull]

Thanks for your vid! Helped a lot. Had fun with the alternator...

[briansmobile1]

@smokinghull You're welcome

[bigmorg15]

Very handy. Its nice to say what sizes the bolts are instead of having to go through looking for the right size.

[kostyc123]

20min job. Easy. Thanks for this video it made things so easy. I also didnt need to take off the alternator.

[briansmobile1]

@kostyc123 You're welcome- way to go!

[bargidan]

good job on the vid. I did this though without messing with the alternator. 1/4" socket, extension, and 10 mm shallow was what I used to get to the bottom bolt. Removed top bolt rather easily. Then I just grabbed the valve and moved it back and forth a bit to loosen it up. Then the bolt loosend a bit so that it could be removed. If it wasn't for the bottom bolt this would be a very easy fix.

[briansmobile1]

@bargidan Cool. Way to go!

[good1charm]

Hey thank you very much. After watching this video everything went smooth. The only hard part was the short altenater bolt. So far no engine light. Looks like it worked.

[briansmobile1]

@good1charm Great job!

[hydraulix78]

Awesome vid man, thanks so much! Helped out a ton!

[briansmobile1]

@hydraulix78 You're welcome. Thanks for watching and commenting.

[sandra70hartford]

Hi I was wondering, I bought a used town and country just 3 weeks ago, today I had taken to bondys' ford where I purchaced it for the check engine light came on. now when I bought it they give me 3 months limited warranty except for carburetion components . My question is, Is this EGR valve part of their 3 month agreement or not? thank you

[briansmobile1]

@sandra70hartford Even if it is, it's up to them to interpret it. EGR is part of air fuel metering so probably not. I'm pretty skeptical about used car dealers and their worthless warranties.....

[MrJed234]

good job for mechanic helpers

[fjashby]

I strongly recommend you do NOT use a pry bar on this assembly - not surprized that came from a dealer tech!!

[fjashby]

Hello,

Good video! The bolts were VERY tight. I used penetrating oil and tapped the flanges of the bolts with a center punch and hammer lightly about 40 times to loosen them up.

On my 2005 3.3 TandC it did not require removing the alternator to get the bottom bolt. A 1/4 drive 10mm with a 1/4 extension, a 1/4x3/8 adapter and a 3/8 ratchet did the trick. Make sure you keep pressure on the bolts as they are easily stripped if you don't keep the socket seated all the way.

[ggariepy]

I was able to sneak a 10mm socket on a 3/8ths u-joint in under the valve to get to the lower bolt and loosen it without removing the alternator. Same '05 Town & Country 3.8L you were working on. It was a little touch and go but I did manage to do it. You can tighten the lower bolt the same way on reassembly. Part was $74.99 from Autozone. Tip: they list more than one for this application, you need the number that is printed on the plastic on the top of the valve. Great video!

[jeffsmopar1]

Hye Brian you can save alot of work on those by removing the top bolt of the egr then using a really ling prybar to push the egr valve towards the intake. Once it moves ahead you can remove that bottom bolt with a 1/4 drive 10mm shallow flex socket!

I've literally changed hundreds of them at the dealer and you need to do them fast working flatrate to make the time.

Nice vids man!

[briansmobile1]

@jeffsmopar1 Thanks Jeff- will do!~

[primitivethicket]

@jeffsmopar1 So this would alleviate the need to mess underneath & with the alternator? If so I would love a how to vid for this!! 

[primitivethicket]

@jeffsmopar1 So this would alleviate the need to mess underneath or with the alternator? if so I would love a how to video for this!

[jeffsmopar1]

@jeffsmopar1 @primitive thicket!

Yeah you don't need to remove the belt, alternator belt or any of that! Just push it ahead with a prybar so you can see the bolt, this often loosens the bolt enough then you can remove it with a flex socket like I said, reverse the order to reinstall it! I don't have a camera so they'll be no video coming but trust me try it! It's easy

[Joefish44618]

I paid $80 for it...

Everything works awesome.. Reset the light by disconnecting the battery... Thanks for the Vid.... helped immensely!!!

[briansmobile1]

@Joefish44618 YESSSSSS!!!! Victory!!!!!!

[Joefish44618]

I replaced the EGR Valve and Sensor, but my check engine light is still on. Is there a way to reset the check engine light?

One more tip that I will add. I only had to replace the top part of my valve. My vehicle is a 3.8 6 cylinder all wheel drive 2002 limited chrysler.

By doing that I didnt have to mess around with the alternator bolt or take my wheel off... (: They part I use was a napa standard vavle and sensor.

[briansmobile1]

@Joefish44618 How much was the Napa part? A: to reset the light you can 1. disconnect the battery for 30 seconds 2. use a scan tool to clear the codes. 3. Pull the ECM fuse for 30 seconds.

[hardboot21]

i thought it helped with Nox, by keeping the engine from reaching over 500 deg c. and ya im from canada :)

btw thanks for the videos as brand new tech i enjoy watching your videos :)

[briansmobile1]

@hardboot21 You my friend are correct in that a failed EGR valve will cause excessive oxides of nitrogen, but it main function is to improve highway fuel economy by injecting inert exhaust back through the intake.