Question about 2005 Dodge Caravan

6 Answers

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?


Dennis Lackey

Posted by Dennis L on

  • 4 more comments 
  • 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.



  • 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.



6 Answers


  • Level 1:

    An expert who has achieved level 1.


    An expert that has over 10 points.


    An expert whose answer got voted for 2 times.

  • Contributor
  • 1 Answer

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

  • Anonymous Sep 26, 2008

    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.




  • Level 1:

    An expert who has achieved level 1.


    An expert whose answer got voted for 2 times.

  • Contributor
  • 1 Answer

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



  • Level 1:

    An expert who has achieved level 1.

    New Friend:

    An expert that has 1 follower.


    An expert whose answer got voted for 2 times.

  • Contributor
  • 1 Answer

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


  • Level 3:

    An expert who has achieved level 3 by getting 1000 points


    An expert that got 10 achievements.


    An expert that got 5 achievements.

    Vice President:

    An expert whose answer got voted for 100 times.

  • Master
  • 375 Answers

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

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. [email protected]

Posted on Jul 02, 2008


The Xzz should be in your VIN #

Posted on Jun 17, 2008

Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:

1 Answer

Misfire on #5 cyl

2005 Dodge Grand Caravan 3.8L engine misfire on cylinder 5. > Edmunds Answers
Aug 14, 2012 - MIL on; cylinder 5 misfire; most noticeable at idle in gear ... This could be caused by an EGR valve that is sticking partly open and not closing ...

OBD-II Trouble Code: P0305 Cylinder 5 Five Misfire Detected
A P0305 code means that the the car's computer has detected that one of the engine'scylinders is not firing properly. In this case it's cylinder #5.

ODB Code P0305- Misfire in #5 Cylinder - 2008 Dodge ... > ... > Grand Caravan > 2008 Dodge Grand Caravan
Feb 22, 2011 - ... do something with a misfire in the #5 cylinder of my V6 4.0L engine. ... ODB Code P0305- Misfire in #5 Cylinder on 2008 Dodge Grand Caravan .... My2005 dodge grand caravan jerks when it shifts into gear what could it be.

My Dodge Grand Caravan has a Cylinder 5 Misfire,? ' Yahoo An

Dec 05, 2015 | 2005 Dodge Grand Caravan

1 Answer

Can a check engine light with and error code of EGR cause black soot in the tailpipe of a 2005 dodge grand caravan???

Hi. The black soot is that your engine is running too rich. I would have checked out the O2 sensor. The O2 sensor tells the computer how much gas is needed to run your car. If the sensor is malfunctioning or dead the computer will make the engine run with more gas (rich) Go to your mechanic and have him run the code scanner. I would also clean out the EGR valve which you can do yourself. Good luck

Feb 27, 2015 | 2005 Dodge Caravan

1 Answer

Where on the vehicle do i find the engine option code to determine the correct egr valve for a 2005 3.8L grand caravan

The eighth digit in the VIN number is the engine code. On the outside of the vehicle look threw the windshield on the drivers side down by the bottom of the glass. You will see the VIN number 17 digits

Sep 16, 2011 | 2005 Dodge Caravan

1 Answer

The check engine light for my 2005 Dodge Grand Caravan is on. The engine is a 3.8 V6 engine. The error code that it is displaying is P0406 or EGR issue. It is my understanding when you have an issue with...

I would clear the code and see if it returns. If the EGR valve is stuck open, it would make it buck or shutter. If the EGR valve is not functioning right, or clogged up, it will effect proformance. I would replace the EGR valve. I read that it's a common problem.

May 15, 2010 | 2005 Dodge Caravan

3 Answers

Code p0406 dodge grand caravan 3.8 engine. Is it the EGR valve or the O2 sensor?

P406 is a EGR code, EGR will also cause a knocking/ pinging sound when there bad. Very common problem. The position sensor inside the valve goes bad. Your going to have to replace the whole EGR valve and it can put out variety of codes from P0401 to P0406. The new valve will solve the problem and easy to replace, you can pick one up at Auto Zone and they can give you the step by step instructions to replacing the EGR with common tools. Good luck and hope this helps.

Jul 06, 2009 | 2005 Dodge Caravan

1 Answer

2005 dodge grand caravan getting code p0406

3.3 engines has the egr valve with have to replace the whole unit. code p0406 what its trying to tell you your egr valve circuit is short to has failed .

Jul 04, 2009 | 2005 Dodge Grand Caravan

1 Answer

2005 grand caravan-erg valve needs to be replace

had same problem 2005 Grand Caravan clean electrical connection to egr valve before replacing valve corrosion causes a low voltage to valve shows OBDII code P0404

Jan 13, 2009 | 2005 Dodge Caravan

1 Answer

2005 jeep grand 5.7 hemi p0406 code

egr valve located on front of motor on passenger side mounted to cylinder head below valve cover

Jan 04, 2009 | 2001 Dodge Grand Caravan

2 Answers

2006 Dodge Grand Caravan - EGR code

I replaced the EGR Valve ($80 after tax), problem solved, vanruns great now. Now my problem is that I can't get the light to turn off.

Jul 14, 2008 | 2006 Dodge Grand Caravan

Not finding what you are looking for?
2005 Dodge Caravan Logo

19,252 people viewed this question

Ask a Question

Usually answered in minutes!

Top Dodge Experts


Level 3 Expert

85239 Answers

Colin Stickland
Colin Stickland

Level 3 Expert

22485 Answers

Jeffrey Turcotte
Jeffrey Turcotte

Level 3 Expert

8984 Answers

Are you a Dodge Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides