Question about 2005 Dodge Caravan

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EGR Valve - Engine Option Code

I have a 2005 Dodge Grand Caravan, 3.3L engine, and have been getting a warning light. OBD test says it's the EGR valve. I have done a little tapping with a plastic hammer, which seems to help, but the light returns. I've tried to buy a new one, but I'm told by the parts stores that I have to have the 'Engine Option Code (Xzz)'. One suggested that it might be on the valve itself, but I can't tell unless I take it off.

Can you please tell me how I can find the Engine Option Code?

Thanks,

Dennis Lackey

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  • Dennis L Jun 12, 2008

    Thanks for responding, but you missed the point of the post. I know the costs. It runs from about $92.00 to $118.00 US in my area. But there are two listed for parts, depending on whether there is an 'Engine Option Code' or not. It's on the front of the engine, with only a couple of bolts to the manifold. Should be easy to change myself. But my problem is knowing the 'Engine Option Code' so I can order the right one.



    Thanis,



    Dennis

  • Dennis L Sep 25, 2008

    Thanks av8r4christ,



    I ended up getting one from a Dodge dealer for $75.00, which was a little cheaper than from local distributors. Local dealers here in Chicago suburbs are very expensive, so I was in Galena, IL, a small town in NW Illinois and got it from a dealer there. Next day service.



    You're right about wrench sizes and most details, but on my 3.3L engine, the valve sits on the front of the exhaust manifold to the right of the alternator.



    Thanks for the reply. Very insightful.



  • Anonymous Jan 03, 2009

    I have an 05 caravan check engine light is on trouble code is P0406 It says EGR Flow sensor A circuit high input any idea if this means I have to replace the whole EGR valve or not

  • Anonymous Jan 03, 2009

    I have an 2005 dodge caravan check engine is on trouble code says P0406 EGR Floe Sensor A Circiut High Input. Does this mean I have to replace the EGR Valve or is there another sensor I should be looking at???

  • Anonymous Mar 04, 2009

    Same here,  VIN does not show XZZ but the local dodge dealer printed out a built list for me which shows that I do have the XZZ "Mid-year introduction tracking".


    They sold me a EGR valve which has a slightly different part number as the one originally on my car.  The original one is 4861662-AB.  They sold me 4861662-AE.  Installation went fine but the gas mileage is only about 19mpg.  I suspect this is the wrong EGR.

  • Anonymous May 22, 2009

    I have the same problem. 2005 TC. The XZZ option is a different part number as mentioned previously. The two numbers are the one with the XZZ option (4861662AB) and the other without that option (4861635AF). The XZZ option EGR is backordered to the manufacturer so it looks like I'm going with the dealer part also - if available.

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Hi, this is my first post. I had the same problem with my 2005 Grand Caravan. Great van, but all of the sudden, the check engine light came on, and then it started driving "jerky." I found this post, along with others on the web, and diagnosed it myself. Let me outline how I did that, since this will accumulate info from several different sites:

1. I turned the ignition key from the "on" to the "run" position about 5 times, and a code showed up in the mileage slot. My code was P 0404, which read more like "tripP 0404".
2. I looked up that code on google, and also asked the guy at Autozone. Both said it was a bad EGR valve.

**Side note: there is a little thing here in the 2005 Grand Caravan called a "XZZ Option Code" in relation to the EGR valve. As in, when you go to get a new EGR valve, they are going to ask you if you need the "XZZ Option" or the "XZZ Exception." When you ask the guy at Autozone what the difference is, he doesn't know. So, after a little research, the difference is this: if your VIN has the letters "XZZ" in it, then you need the "XZZ Option." If your VIN doesn't have "XZZ" then you don't need that option. (Thanks a lot, Dodge, for that bit of stupidity.)***

3. Autozone didn't have the EGR in stock, but Federated Auto Parts (aka KOI, in our area--Cincinnati) had five in stock, so I got one--it cost me about $85.00
4. After getting home, I changed it out, in the following steps.
a. I disconnected the battery.
b. I disconnected the electrical line coming to the EGR (by the way, the EGR sits just above the alternator...and if you don't know what the alternator is, take the parts to your local mechanic and ask him to change it out for you...)
c. I disconnected the vacuum line that comes into the top of the EGR, as well as disconnecting the other end of that line, just to get it out of the way. That took 4 bolts, and they were 8 mm.
d. I removed the two bolts (10mm) holding the EGR in place, and they were a bit tight to get to. I would suggest a 1/4" drive U-joint to get to the bottom one, but a two inch extension held just right will get the job done--I didn't have the u-joint for my socket so it can be done without it...not much fun though.)
e. I replaced the metal gasket (it came in the box with the new EGR), and reversed the steps to put everything back together.

After restarting and test driving the minivan, I have no check engine light, and the "shuttering" is gone. I'm about to drive to Texas next week...we'll see if it solved the problem. More news later.

I love the internet. Ride free, citizen!
"Some people have money. Some people have knowledge. Unfortunately, the people with knowledge usually end up with the other people's money."

Posted on Sep 25, 2008

  • av8r4christ Sep 26, 2008

    Dennis,
    It seems your 2005 Grand Caravan must have the letters "XZZ" in the VIN. (That would be the reason for needing the "Engine Option Code.") If that is the case, you need the EGR valve that is made for that type of minivan. The guy at the parts store will be able to supply you the proper EGR based on which one you need--tell him you have:
    1. 2005 Grand Caravan
    2. 3.3L engine
    3. VIN includes "XZZ," thus you need the EGR that is made for the XZZ. (He will see it on his computer--his computer will ask him this exact question...AutoZone asked me...I didn't know what the XZZ option was, so I did some research.)

    Don't be fooled by the wording. "XZZ Option Code" merely means that it is a different design in the 2005 Grand Caravans. You don't have to have any special code to order the new part.

    Hope it helps.


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I had to call my Dodge dealer to find out if my 2005 Caravan SXT had the XZZ option and it does. I had to give him my vin #, but IT DOES NOT say in the vin XZZ

Posted on Jan 27, 2009

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XZZ is not in the VIN, I repeat NOT IN THE VIN! you need to call the dealer, give them the vin and he'll tell you if you have the "XZZ" option or not.

Posted on Dec 15, 2009

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EGR valves are only around £80-90 new, would be surprised if it cost £200 to replace it...even with labour! (Unless its through Vauxhall)

More info here
http://groups.google.co.uk/groups?q=...roups&ct=title

Posted on Jun 12, 2008

Email me with you vin # and I will tel you your enigine option code. Or you could just email me and I will give you the dealer here's number or email and you can give them the vin and they will give you the code directly. MrRodneyLong@Gmail.com

Posted on Jul 02, 2008

The Xzz should be in your VIN #

Posted on Jun 17, 2008

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