Question about 2004 Dodge Ram 1500
The EGR valve is located in the front right of the motor, slightly below the alternator. It is about the size of a large bottle of pills with an attachment on it.
First, unlock the air filter cover and remove the air filter. Place a screwdriver in the ring sticking out above the air filter box below the windshield trim piece to hold up the air filter cover up and out of the way. The air filter box sits on three holders with rubber ends. Grasp the air filter box with both hands and lift straight up off the holders and out of the engine compartment. This will give you a clear view of the EGR valve and room to work as well. Next, remove the wiring harness by sliding the red tab on the connector out of it's centered, locked position. Then remove the connector by pulling it away from the EGR valve. The EGR valve has 4 bolts. 2 are 8mm and the other 2 are 10mm. Remove all 4 bolts, being careful not to drop or lose thegaskets on either end of the EGR valve. Removing these bolts is best done with a 1/4" ratchet with deep-well sockets or regular sockets and a small extension. Remove the EGR valve and either replace with a new one or spray inside thoroughly with carbeurator cleaner to free up the plunger action inside. This will break up the carbon on the inside, allowing the plunger that is in the valve to move freely, which is the likely cause if the problem. After soaking, it may be necessary to use a screwdriver to break free and exercise the plunger. Place the tip of screw driver inside the opening in center of the EGR valve on move the plunger in and out. This may be difficult, so use spray liberally. Wipe carbon deposits off any area the will touch the gaskets and clean off excess spray. Re-install EGR valve the same way it came off, making sure to reattach wiring and secure. Note: If a check-engine light is on prior to replacing the EGR valve, disconnect the positive terminal on the battery and wait 30 seconds for the computer to reset itself. Reconnect the positive terminal and start engine. If problem persists, consult the dealer. hope this helps friend.
All most forgot, if you do disconnect the battery, make sure your radio is turned off. If you leave your radio on when you disconnect the battery, your going to be prompted to enter the radio code to have it active again. Sorry my bad. keep me posted.
Posted on Jun 20, 2009
Base on the year 2004,you probably has 65,000+ miles on the motor.
It will take about 2 hours of cleaning time on the EGR valve and the EGR passage.
I recommend,it the metal parts soak over-night and use a Shop Vac to pull out the carbon.
vacuum leaks on intake manifold,
the air tube between the air filter.
intake manifold vacuum hose.
clean throttle plate with Berryman carburator cleaner
SEE sample picture HERE
Also remove carbon built up behind the EGR valve and the EGR passage tube.
Vacuum leak WILL offset the intended 14.7 to 1 air fuel ratio.
More un-metered air (leaks) will lean out the fuel mixture.
Use small amount of Berryman carb clearer at potential air leak area will help you identify trouble spot.
At idle,just spray and listen for the RPM surge.
The in-rush of carb clearer will increase the RPM on the motor.
Record the problem spot(s) and address it later.
EGR carbon built up require 2+ hours to clean from start to finish.
You will need a new EGR base gasket before your start.
Locate and remove the EGR valve after the vehicle is cool down.
Carefully record the connector and vacuum line (for older vehicle) location by drawing an easily to follow diagram.
Remove the EGR valve.
Inspect the location of the carbon built-up inside the valve and the EGR passage tube.
SOAK these areas with WD-40 spary.
You will need a small screwdriver,cloth hanger and lot of newspaper and time to get this cleaning done right.
RE-SOAK the carbon and let it sit for over-night will also help.
One the last round,pass a shop vacuum of the EGR valve and the passage pipe.
Install the new EGR gasket and connectors.
Allow the vehicle to warm up outdoor to burn up any remaining WD-40.
Take it for a test drive.
Please rate my answer if it's useful to you.
Posted on Dec 19, 2009
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Posted on Jan 02, 2017
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