Question about 2006 Chrysler Town & Country

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Bolt is stripped, very tight and can't remove from egr valve

"how do you remove egr valve with stripped bolts 10mm to engine block"

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  • mike loshbough
    mike loshbough May 11, 2010

    its the bottom one isn't ?

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  • Master
  • 410 Answers

The only thing that I can think to help you out is to either drill a small hole in the center of the bolt and then try to get a flat head screw driver in to unscrew it.  Or the other option would be to get those special socket sets that are designed to take out stripped bolts.  The set I have is from Sears and I have used it many times so I know they work but I'm sure you can save some money if you go to Home Depot or Lowes.  Good luck!

Posted on May 24, 2009

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The engine malfunction light turn on and brought it to the dealer. said P0406 and needs egr replacement. but the light turns off again and after a week it turns on again for 1 day. now the light is gone....


Sounds like you have a carbon buildup in the valve. The EGR should be located near the altenator on the right side of the engine, depending on what engine you have. 4 bolts, 2 8mm and 2 10mm.. take it off and careful not to lose the metal gaskets.. spray the valve down with carb cleaner and wipe it out.. pump the valve to make sure it plunges ok and replace. should fix your problem. Or you can replace the valve yourself new for about $80.
Here is the procedure if you care to do it yourself.

Tools: 8 mm socket, 10 mm socketEquipment: Replacement EGR Valve, Replacement EGR Gasket (metallic)1. Disconnect the electrical fitting attached to the EGR valve. You will need to unlock it (red tab) and then depress the latch near the rear of the fitting before sliding it off.2. Disconnect the vacuum tube connected to the top of the EGR valve using an 8 mm socket. It may be easier to remove the entire vacuum tube by diconnected it at the top of the engine as well (also 8 mm).3. Using a universal socket joint (I found using a 1/4" drive was necessary to get the clearances around the alternator), remove the 2 bolts holding the EGR valves to the exhaust manifold of the engine using a 10 mm socket. The bottom bolt is a very tight clearance.4. Remove the valve and gasket.5. To install, reverse the steps using the new EGR Valve and EGR Gasket.6. The 10 mm bolts should be torqued to 225 in-lbs7. The 8 mm bolts that fasten the vacuum tube to the EGR valve should be torqued to 100 in-lbs.
Tip: I have found that if you loosen the alternator mounting bolts, you can get just a little more wiggle room to get a socket on the bottom bolt.

Good luck, i hope this helps, please rate me a fixya.

Jun 28, 2011 | 2005 Dodge Caravan

Tip

How to replace your egr valve and how to tell the difference


Here is an easier way to replace your exhaust gas recirculation valve on a non flex fuel 2005 3.3L. First off, the egr valve is located right above your alternator, it has 4 bolts in it, a pipe which goes from the top of the egr to the intake, and a plug in style wiring terminal. You'll need a 3/8 drive ratchet with a 9mm and 10mm socket, a 3/8 to 1/4 adapter, a 2 1/2 inch and 12 inch 3/8 drive socket extension, a small hammer, and a small 10mm open ended wrench to perform this repair. Also be sure you have the correct egr, there are 2 call the dealer with the last 9 digits of your vin to verify the one you need, I opted for the mopar replacement (100 after tax) parts store's have slightly cheaper aftermarket replacements. First, disconnect your wiring to the transducer, there is a plastic retainer (which locks the plug in place) you'll need to push it in to unlock it then press the back of the plug down and pull it out . Next remove the two 5/16 or 9mm bolts from the flange at the top of the egr where the recircirculation line goes back to the intake/throttle body. There are two 10mm bolts which hold the egr to the motor, the first is easy to remove, the second is blocked by the alternator. here is where some people have problems trying to figure out how to get to it. Don't remove the alternator, your serpentine belt, or anything else. I used a 12 inch 3/8 socket extension and a small hammer to tap the top flange (of the first two bolts you should have removed) towards the firewall as far back as you can get it. Now that you have a little bit of room to work with you can use a small 10mm wrench to remove the bolt. It is still a tight squeeze but you can do it. Once the old egr has been removed inspect the mating surface on the block where you will install the new one and make sure you have a clean surface for the new gasket. You'll need to obviously install the last bolt you removed first in the reinstallation process, then install the other bolts. You can also reuse the gasket from the recirc pipe if it is not damaged. Plug the wire in and lock it back with the retainer clip. Make sure all your tools have been picked up from the engine compartment and start your vehicle. Your engine light should go out now provided that was the only fault that triggered it. Good luck

on Feb 25, 2011 | Dodge Caravan Cars & Trucks

1 Answer

Where would the screw or nut be on the oil pan of a 1995 crown vic be to drain the old oil


Oil Pan - REMOVAL & INSTALLATION

4.6L Engine
If your vehicle is equipped with air conditioning, refer to General Informatcion and Maintenance for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.
  1. Have the A/C system recovered by a MVAC-trained, EPA-certified, automotive technician.
  2. Disconnect the battery cables, negative cable first, and remove the air inlet tube.
  3. Relieve the fuel system pressure and disconnect the fuel lines; Drain the cooling system and remove the cooling fan and shroud.
CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
  1. Remove the upper radiator hose. Remove the wiper module and support bracket.
  2. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
  3. Remove the engine harness connector from the retaining bracket on the brake vacuum booster and detach the connector and transmission harness connector.
  4. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
  5. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
  6. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
  7. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
  8. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
  9. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
  10. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
  11. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1 / 2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
  12. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.
It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.
  1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.
See Figures 1, 2 and 3


zjlimited_583.jpg

Fig. 1: Position of wood blocks under the engine mounts-4.6L engine

zjlimited_584.jpg

Fig. 2: Oil pump pickup tube-4.6L engine

zjlimited_585.jpg

Fig. 3: Oil pan bolt torque sequence-4.6L engine



To install:

  1. Clean the oil pan and inspect for damage. Clean the sealing surfaces of the front cover and engine block. Clean and inspect the oil pickup tube and replace the O-ring.
  2. If removed, position the oil pickup tube on the oil pump and hand start the 2 bolts. Install the bolt retaining the pickup tube to the main bearing stud spacer hand tight.
  3. Tighten the pickup tube-to-oil pump bolts to 6-9 ft. lbs. (8-12 Nm), then tighten the pickup tube-to-main bearing stud spacer bolt to 15-22 ft. lbs. (20-30 Nm).
  4. Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and rear seal retainer meets the cylinder block. Position the oil pan on the engine and install the bolts. Tighten the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
  5. Position the jack and wood block under the oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack.
  6. Install the engine mount through bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
  7. Position the EGR valve and tube assembly in the vehicle and connect to the exhaust manifold. Tighten the line nut to 26-33 ft. lbs. (35-45 Nm).
Loosen the line nut at the EGR valve prior to installing the assembly into the vehicle. This will allow enough movement to align the EGR valve retaining bolts.
  1. Cut the wire and position the exhaust system to the manifolds. Install the 4 nuts and tighten to 20-30 ft. lbs. (27-41 Nm). Make sure the exhaust system clears the crossmember. Adjust as necessary.
  2. Install a new oil filter and lower the vehicle.
  3. Install the bolt retaining the right engine mount to the lower engine bracket. Tighten to 15-22 ft. lbs. (20-30 Nm).
  4. Install a new gasket on the EGR valve and position on the intake manifold. Install the 2 bolts retaining the EGR valve to the intake manifold and tighten to 15-22 ft. lbs. (20-30 Nm). Tighten the EGR tube line nut at the EGR valve to 26-33 ft. lbs. (35-45 Nm). Connect the vacuum hoses to the EGR valve and tube.
  5. Install the blower motor resistor. Position the heater outlet hose, install the upper stud and tighten the upper and lower bolts to 15-22 ft. lbs. (20-30 Nm). Install the ground ******** the stud and tighten to 15-22 ft. lbs. (20-30 Nm).
  6. Connect the heater outlet hose and the throttle valve cable. If necessary, adjust the throttle valve cable.
  7. Attach the engine connector and transmission harness connector. Install the harness connector on the brake vacuum booster.
  8. Connect the air conditioning compressor outlet hose to the compressor and install the bolt retaining the hose to the right coil bracket.
  9. Install the upper radiator hose and connect the fuel lines. Install the wiper module and retaining bracket.
  10. Install the cooling fan and shroud and fill the cooling system. Fill the crankcase with the proper type and quantity of engine oil.
  11. Connect the negative battery cable and install the air inlet tube. Start the engine and check for leaks.
  12. Have a MVAC-trained, EPA-certified, automotive technician evacuate and recharge the air conditioning system.

Hope this helps (remember to rate this helps).

Jan 30, 2011 | 1995 Ford Crown Victoria

1 Answer

Need to do oil change. can not find oil pan. where is it located



1. Remove the upper radiator hose. Remove the wiper module and support bracket.

  1. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
  2. Remove the engine harness connector from the retaining bracket on the brake vacuum booster and detach the connector and transmission harness connector.
  3. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
  4. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
  5. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
  6. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
  7. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
  8. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
  9. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
  10. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1 / 2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
  11. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.

It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.
  1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.



20871a3.jpg

Fig. 3: Oil pan bolt torque sequence-4.6L engine (click over pic fo zoom).


Hpe helps (remember to rate this).

Oct 05, 2010 | 1994 Mercury Grand Marquis

1 Answer

Main bolt for alternator has been removed.


a 1/4"10 mm swivel will break it loose then it sould only be finger tight i have never crossed one any tighter keep the top on tight until the bottom comes loose

Sep 04, 2009 | 2006 Dodge Grand Caravan

1 Answer

06 doge caravan DTC P0406


the egr valve is located on front cylinder head,just above the alternator..there is a plug and a metal tube coming from it..remove tube on both ends..unplug connector..2 bolts that hold on are fairly tight and lower bolt is a tight fit at alternator..1/4"drive 10mm socket ground down works well..make sure you disconnect battery while you are changing valve..sometimes code will reset even after you replace egr valve..valve available at dodge dealer..get a new tube gasket as well

Apr 08, 2009 | 2006 Dodge Caravan

1 Answer

Location of EGR Valve


Found the info!!

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. Please don't forget to rate!!!!

Mar 14, 2009 | 2005 Dodge Dakota

1 Answer

I need to replace the EGR valve.


No need to remove or move the alternator. You can get on the 10mm bolt with a short 1/4" socket and ratchet. Take the EGR tube off first, be careful not to lose the tube to EGR valve gasket. I usually use anti-seize when I put the EGR valve back on. That would be the mount bolts for the valve and the tube.

Mar 07, 2009 | 2005 Dodge Grand Caravan

2 Answers

2005 Dodge 1500 code p0404 EGR valve.


The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head ,

  1. Remove electrical connector (5) at top of EGR valve solenoid.
  2. Remove tube mounting bolt (1) at intake manifold.
  1. Remove two bolts (4) connecting EGR tube (1) to valve assembly.
  2. Remove gasket located between EGR tube flange and EGR valve assembly.
  3. Remove two EGR valve mounting bolts (5).
  4. Separate valve assembly (3) from engine.
  5. Remove and discard metal gasket located between cylinder head and valve assembly.
INSTALLATION
  1. Clean area at rear of left cylinder head where it joins base of EGR valve.
  2. Clean EGR tube where it joins EGR valve.
  3. Position new gasket between EGR valve and cylinder head.
  4. Position EGR valve to cylinder head. Install and tighten two bolts (5). Refer to Torque Specifications.
  5. Position new gasket between EGR tube flange and EGR valve assembly.
  6. Position EGR tube (1) to side of EGR valve and into intake manifold.
    1. Install EGR tube flange bolt (1) at intake manifold. Tighten bolt. Refer to Torque Specifications.
    2. Connect electrical connector (5) to top of EGR valve solenoid (2).Do a final tightening of two EGR tube bolts (4). Refer to Torque Specifications

Feb 05, 2009 | 2005 Dodge Ram 1500

4 Answers

How to replace egr valve on the 3.5 v-6 in the 05 300 touring


Its on the passenger side on top behind the motor. its easier to take the black cover off the top of the motor. its a iron pipe running from the egr valve to the cover on top of the motor. disconnect it from the cover. its two bolts holding the egr valve on. unplug the plug thats holding it on and take those two bolts out and bring it out on the passenger side. take the iron pipe off the old egr valve and put it on the new one. no silicone needed. place it back in and bolt it down. its gone be a lil tricky gettin it back in but itll go. after its tighten down put the cover back on the engine. plug all of the sensors back up and make sure all hoses are hooked back in place. make sure u connect the iron pipe back to the cover and be careful with the seal inside the cover cause if u break it it will leak air like the problem i had its not bad as it sounds just take your time. if u see EP BAS when u get thru u probably left a sensor unplugged or an air leak. if that happens hit me back and ill tell u how to fix it

Jul 30, 2008 | 2005 Chrysler 300

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