I have a 2007 Sebring Sedan w/ 2.7 litre E85 engine. It has 155,000 km (96,000 miles). For most of it's 7 years, the check engine light was on. Dealership claimed there was no fault code showing. It failed the 1st emission test with P0406 2 weeks ago. Chrysler dealership replaced the EGR, check engine light off. Drove 400 km, mostly highway. 2nd test failed with Cat, O2 and EGR "not ready". Planning on taking it back to dealership but any other suggestions to cure this would be much appreciated!
P0406 is normally caused by the EGR valve or the passage ways are clogged going to it. Since they replaced the valve suspect carbon build up behind it. I normally clean it out with a coat hanger then replace valve( some times I have to remove intake). I run SEAFOAM a to help clean it also. Now when a check engine light is cleared or battery is disconnected the READINESS MONITORS get reset and the vehicle needs to be driven to set them to READY. The monitors can be checked before failing again and should be checked. At my shop I always explain this and test them first for people, it's called customer service. When you fail an inspection there should be a free test within a specific time period (30 days here in RI). If they are charging you multiple times you should complain.
There are a lot of issues with this error. Some people are finding that the ecm (main computer) needs to be replaced from corrosion. Others are finding that the ECM can be flashed to another year to fix it. Some are finding corrosion on the connectios. There is a lot of info about it on this page: http://www.sebringclub.net/board/viewtopic.php?f=27&t=11337
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