MIL ILLUMINATION DIAGNOSTIC TROUBLE CODES P0401, P0403, P0404, P0405, P0406
TECHNICAL SERVICE BULLETIN
Reference Number(s): 18-021-04, Date of Issue: May 4, 2004
ARTICLE BEGINNING
SUBJECT
MIL Illumination Diagnostic Trouble Codes P0401, P0403, P0404, P0405, P0406
OVERVIEW
This bulletin involves replacing the EGR valve.
MODELS
2004 (DR) Ram Truck
SYMPTOM/CONDITION
The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was
caused by one or more of the following DTC's:
P0401-EGR SYSTEM PERFORMANCE
P0403-EGR CONTROL CIRCUIT
P0404-EGR POSITION SENSOR PERFORMANCE
P0405-EGR POSITION SENSOR LOW
P0406-EGR POSITION SENSOR HIGH
DIAGNOSIS
Using a Scan Tool (DRBIII(R) or StarSCAN(tm)) with TechCONNECT or the appropriate Diagnostic
Procedures Manual, verify all engine systems are functioning as designed. If DTC's are present, other than
those listed, record them on the repair order and repair as necessary before proceeding further with this
bulletin.
If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair
Procedure.
PARTS REQUIRED
PARTS REQUIRED
GROUP:Vehicle Performance
NOTE: This bulletin applies to vehicles equipped with a 5.7L engine (sales code
EZA) built on or before March 12, 2004 (MDH 0312XX).
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REPAIR PROCEDURE
1. Open the hood.
2. Disconnect the battery.
3. The electronic EGR valve and solenoid assembly is attached to the front of the right cylinder head. An
exhaust gas routing tube connects the EGR valve to the intake manifold.
4. Disconnect the electrical connector from the EGR solenoid (Fig. 1 ).
Qty. Part No. Description
1 53032209AE Valve, EGR
1 05277928 Gasket, EGR Tube Flange
1 53032212AA Gasket, EGR Valve
NOTE: Service Bulletin 18-010-04 must be performed in conjunction with this repair.
CAUTION: Do not start the engine between installing the EGR Valve and
performing SB 18-010-04 (PCM Flash Reprogramming). Both repairs
must be performed before the engine is started.
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Fig. 1: EGR Tube Bolts
5. Remove the two bolts connecting the EGR tube to the EGR valve assembly (Fig. 1 ).
6. Remove the gasket located between the EGR tube flange and the EGR valve assembly.
7. Remove two EGR valve to cylinder head mounting bolts (Fig. 2 ).
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Fig. 2: EGR Valve Location
8. Separate the EGR valve assembly from the cylinder head.
9. Remove and discard the metal gasket located between the cylinder head and the EGR valve assembly.
10. Clean both gasket surfaces on the EGR tube and the cylinder head.
11. Position a new metal gasket (p/n 53032212AA) between the cylinder head and the new EGR valve
assembly (p/n 53032209AE).
12. Install the two EGR valve to cylinder head mounting bolts and tighten to 29.9 Nm (265 in. lbs.).
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13. Position a new gasket, p/n 05277928, between the EGR tube flange and the EGR valve assembly.
14. Install the two bolts connecting the EGR tube to the EGR valve assembly (Fig. 1 ). Tighten the bolts
to 11.8 Nm (105 in. lbs.).
15. Connect the electrical connector to the EGR solenoid.
16. Connect the battery negative cable.
17. Perform Service Bulletin 18-010-04 in conjunction with this repair.
POLICY
Reimbursable within the provisions of the warranty.