2007 Dodge Grand Caravan 3.3 - P0404 (EGR valve)

[Number_35]

The "money light" (CEL) came on while my wife was driving a couple of days ago. No driveability issues at all, just the CEL.

P0404 is typically a bad EGR valve (or a bad signal to it).

I will do some troubleshooting, but if the EGR valve itself turns out to be bad, I will have to replace it. (That is, unless I can clean it - I have successfully cleaned a couple of carboned-up Mazda EGR valves in the past. I don't know whether that's possible with the Dodge part, or even if that's the issue. Both Mazdas ran terribly with a dirty EGR valve.)

I was a bit shocked by the price of the genuine Mopar part.

Are any of the aftermarket parts worth using?

 

[CharBaby]

Well, IDK about MOPAR OE parts however, I'd still stick with OE emission parts over anything aftermarket.

This might help although it's a 2005 w/3.8L

 

[Number_35]

Well, IDK about MOPAR OE parts however, I'd still stick with OE emission parts over anything aftermarket.

This might help although it's a 2005 w/3.8L

Thanks, I watched that one last night. Eric O's troubleshooting is a pleasure to watch.

I figured after he brought it halfway back to life by tapping it with a hammer he had a diagnosis, but he went through checking the inputs anyway.

 

[Number_35]

I removed the EGR valve and sprayed a bunch of brake cleaner and penetrating oil into the two ports, both very sooty.

Would have liked to let it sit overnight, but we need to use the van tomorrow morning, so I put it back together. The CEL is out for now, but that's due to me disconnecting the battery, so time will tell.

Removing the EGR valve was not as straightforward for me as it was for the YouTube wizards.

The alternator was blocking the lower bolt, so I had to move it. To remove the alternator I had to remove the serpentine belt, which meant pulling the RF wheel and a splash shield.

With just a wee bit extra clearance, I could have left the alternator in place - thanks, Dodge!

 

[Number_35]

The CEL stayed off for about 20 km, but is back with the same P0404 code.

I can replace the EGR valve with an expensive genuine part, replace it with a used part, replace it with an aftermarket unit, or just live with it.

 

[t1snwrbrdr12]

I removed the EGR valve and sprayed a bunch of brake cleaner and penetrating oil into the two ports, both very sooty.

Would have liked to let it sit overnight, but we need to use the van tomorrow morning, so I put it back together. The CEL is out for now, but that's due to me disconnecting the battery, so time will tell.

Removing the EGR valve was not as straightforward for me as it was for the YouTube wizards.

The alternator was blocking the lower bolt, so I had to move it. To remove the alternator I had to remove the serpentine belt, which meant pulling the RF wheel and a splash shield.

With just a wee bit extra clearance, I could have left the alternator in place - thanks, Dodge!

You can get it with a good 1/4” drive swivel socket. I think I used to crack them loose with the perfect depth straight socket and ratchet, then used a swivel to back it out as much as possible, then fingers. It sucks but it’s better than loosening the alternator to get to it. Have had to loosen the alternator after someone buggered up the egr bolt, but if you’ve already loosened it once you should be able to sneak it out now.

 

[Number_35]

You can get it with a good 1/4” drive swivel socket. I think I used to crack them loose with the perfect depth straight socket and ratchet, then used a swivel to back it out as much as possible, then fingers. It sucks but it’s better than loosening the alternator to get to it. Have had to loosen the alternator after someone buggered up the egr bolt, but if you’ve already loosened it once you should be able to sneak it out now.

Have you had success with any of the aftermarket units? The > $C400 for a genuine Mopar one is more than I'd care to pay.

 

[BrianF]

I did the valve on my parents old 2005 GC. Was a PIA for what it really was. I tried cleaning it to no avail. A new one fixed it for good. That was in about 2009/10.

 

[Number_35]

I did the valve on my parents old 2005 GC. Was a PIA for what it really was. I tried cleaning it to no avail. A new one fixed it for good. That was in about 2009/10.

Did you use a genuine Mopar part?

 

[BrianF]

That's a great question that I cannot answer. Likely something from Napa as my folks live in a tiny town, far away from the dealer. Mind you, the van now sits in my driveway but I'm 800km away and cannot check.

 

[t1snwrbrdr12]

Have you had success with any of the aftermarket units? The > $C400 for a genuine Mopar one is more than I'd care to pay.

I worked at a dealer so we only used mopar. Idk the quality of aftermarket, sorry.

 

[Number_35]

I bought a new EGR valve locally. Made in Mexico. Looks to be of decent quality, and came with new bolts and gaskets.

I was able to remove the EGR mounting bolts with the alternator in place, but was leery about getting the bottom one in straight.

Figured out a quick and effective shortcut - removed the top alternator-mounting bolt, left the bottom one alone, and loosed the lower side-mounted one at the back. Was then able to pivot the top of the alternator away from the EGR valve, and then had a straight shot into the bottom EGR valve mounting hole.

No wheel/splash shield/serpentine belt removal required.