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P0406 indicates high voltage on the EGR sensor circuit. this is recommended for every 30,000 miles be inspected. although EGR system do not requires periodic inspection. instead, check only if engine trouble's develop. most EGR's requires replacing EGR valve, cleaning passages and installing new vacuum hose. misrouted vacuum hose causes engine poor operation. so. not just to unplug it.
the egr valve can be changed from below but the left bolt must be done blindly by feel, (use a small mirror,) undue the 2 bolts and pull it out from the intake, careful to make sure the gasket on the end of the tube comes with it; the 2 bolts that hold the egr on also has a metal gasket; the hardest thing is to disconnect the electrical plug from below that connects the egr valve, - do not do this if you have no mech experience;
Check in the drivers side rear of engine take off the air housing and use 13mm. deep
socket w / 3inch ext. and air ratchet to remove 2 bolts, then take tire
off inner splash panel then 8mm wobble w / 24inch ext to take 1 tube bolts
loosen other one and pull out as ***. Reverse to install.
Hope this help to solve it (remember rated this post).
if this is a 4.7l engine, the valve is on the left rear of the intake. loosen the 8mm bolts that hold the egr intake tube to the egr valve, remove the egr bolts, disconnect wiring, remove valve and tube together, attach intake tube loosely to new valve, install new valve, tighten tube bolts to egr using a swivel socket, this is not a 5 minute job, so dont attempt unless you have some time and patience.
This Dodge EGR valve is a certain kind of device that is mounted right on your intake manifold which controls the amount of exhaust gasses back into your engine.
On a 2005 Dakota with 4.7 liter engine (non-HO), the EGR valve is located near the intake manifold on the driver's side right up against the firewall. It's hard to spot as it sits lower than the intake manifold.
To change it, remove the electrical connector. There's a red tab that needs to be pushed to one side and then you have to squeeze down on a tab to get it free. Using a 13 mm socket, remove the bolt that you can see. I had to use a 3 inch wobble extention and then a 8 inch extension with a deep well socket to reach it with my 3/8 inch ratchet.
There's a second bolt that you can't see between the EGR valve and the firewall. With a little trial and error and a lot more luck, you can reach the hidden bolt with the 3 inch wobble extension and a 13 mm deep well socket. Attach the ratchet after the socket is on and remove. This one isn't easy and if there's any Dodge engineers reading this one, a couple of extra inches of clearance between the valve and the firewall wouldn't have killed you no matter what the cost accountants said.
With both bolts removed, you should be able to pull out the metal pipe that connects the manifold to the EGR valve out of the manifold (Pull to the right) and then you can lift the valve out.
For assembly, the metal pipe connecting the intake manifold the EGR valve has to be removed and reinstalled on the new valve. It's held on with 2 5/16th" bolts. You should put the rear bolt on tight, but leave the front bold loose for the reinstall as some adjustment is necessary to get it put back together and the rear is a pain to tighten when installed.
Line up the bolts that attach the valve and get the rear 13 mm bolt (The one you couldn't see on disassembly) started. Do not start the other 13 mm bolt as you'll need to pivot the valve and pipe to the left in order to reinsert the pipe into the intake manifold. Once the pipe is in the intake manifold. Start the other 13 mm bolt and tighten both 13 mm bolts and then the 5/16" bolts holding the pipe onto the valve. Reinstall the electrical connection.
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