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TSB 18-021-04

MIL Illumination Diagnostic Trouble Codes P0401 P0403 P0404 P0405 P0406

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Date: May 4, 2004

Models: 2004 (DR) Ram Truck

NOTE: This bulletin applies to vehicles equipped with a 5.7L engine (sales code EZA) built on or before March 12, 2004 (MDH 0312XX).

Overview:
This bulletin involves replacing the EGR valve.

Symptom/Condition:
The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC’s:

P0401-EGR SYSTEM PERFORMANCE

P0403-EGR CONTROL CIRCUIT

P0404-EGR POSITION SENSOR PERFORMANCE

P0405-EGR POSITION SENSOR LOW

P0406-EGR POSITION SENSOR HIGH

Diagnosis:
Using a Scan Tool (DRBIII) with TechCONNECT or the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin.

If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure.

Parts Required:
Qty. Part No. Description
1 53032209AE Valve, EGR
1 05277928 Gasket, EGR Tube Flange
1 53032212AA Gasket, EGR Valve

Repair Procedure: 

NOTE: Service Bulletin 18-010-04 must be performed in conjunction with this repair.

CAUTION: Do not start the engine between installing the EGR Valve and performing TSB 18-010-04 (PCM Flash Reprogramming). Both repairs must be performed before the engine is started.
1.   Open the hood.
2. Disconnect the battery.
3. The electronic EGR valve and solenoid assembly is attached to the front of the right cylinder head. An exhaust gas routing tube connects the EGR valve to the intake manifold.
4. Disconnect the electrical connector from the EGR solenoid (Figure 1).
 
5. Remove the two bolts connecting the EGR tube to the EGR valve assembly (Figure 1).
6. Remove the gasket located between the EGR tube flange and the EGR valve assembly.
7. Remove two EGR valve to cylinder head mounting bolts (Figure 2).
8. Separate the EGR valve assembly from the cylinder head.
9. Remove and discard the metal gasket located between the cylinder head and the EGR valve assembly.
10. Clean both gasket surfaces on the EGR tube and the cylinder head.
11. Position a new metal gasket (p/n 53032212AA) between the cylinder head and the new EGR valve assembly (p/n 53032209AE).
12. Install the two EGR valve to cylinder head mounting bolts and tighten to 29.9 Nm (265 in. lbs.).
13. Position a new gasket, p/n 05277928, between the EGR tube flange and the EGR valve assembly.
14. Install the two bolts connecting the EGR tube to the EGR valve assembly (Figure 1). Tighten the bolts to 11.8 Nm (105 in. lbs.).
15. Connect the electrical connector to the EGR solenoid.
16. Connect the battery negative cable.
17. Perform Service Bulletin 18-010-04 in conjunction with this repair.
CAUTION: Do not start the engine between installing the EGR Valve and performing SB 18-010-04 (PCM Flash Reprogramming). Both repairs must be performed before the engine is started.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:   Description Amount
25-01-45-91 Replace EGR Valve 0.4Hrs.

Failure Code:

AM       Authorized Modification

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making DodgeRam.info possible.

 

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This page was edited on: May 3, 2004