P0401 EGR Code Dodge Caravan, Plymouth Voyager, Town and Country?

  • Fix code P0401 EGR Code on Dodge Caravan, Plymouth Voyager, Town and Country 3.3L and 3.8L Shops are reporting consistent P0401 EGR Codes on 1996-2001 Chrysler minivans. These EGR valves are vacuum operated and the valve operation is measured by a pressure transducer. To check the EGR, start the engine and apply vacuum to the EGR valve.

Where is the EGR valve located on a 3.3 Dodge Caravan?

Find the EGR valve, which is located on the engine intake manifold.

Where is the EGR valve on a Town & Country?

Open the hood and locate the EGR valve on the upper area of the engine, next to the valve cover. The valve resembles a thick mushroom with a round, metal hat. It mounts to the engine and connects to the exhaust system through a large metal pipe.

What are the symptoms of a bad EGR valve?

EGR valve symptoms can vary, however, the most common symptoms of a faulty EGR valve are explored below:

  • Your engine has a rough idle.
  • Your car has poor performance.
  • You have increased fuel consumption.
  • Your car frequently stalls when idling.
  • You can smell fuel.
  • Your engine management light stays on.

What does the code P0404 mean?

When P0404 is triggered, it means that the PCM has been told that the valve is performing in a way that is outside of its specified parameters. More specifically, the PCM has been told that the valve is closed when it should be open, or vice-versa.

Where is the EGR valve on a 2003 Chrysler Town and Country?

There’s a cover plate at the end of the cylinder head and another on top of the intake. That’s where the EGR valve and tube go.

What does an EGR valve do?

It connects the exhaust manifold to the intake manifold and is controlled by either a vacuum or a built-in electric step motor. The function of the EGR valve is to control the flow of exhaust gas being recirculated depending on the engine load.

Which way does metal EGR gasket go?

When installing Fel-Pro exhaust manifold gaskets, if there is a smooth, metallic side and a composite side, the metallic side should be installed facing out, meaning toward the exhaust manifold.

How do you clean the EGR valve on a Dodge Ram 1500?

Spray the EGR cleaner into the unit, holding the can about six inches away while spraying. Make sure you get the spray inside the valve (where the piston is) by spraying through the breath holes in the brass “flying saucer” top. This will loosen the carbon deposits inside and free up the plunger.

Dodge Caravan P0401: EGR – Insufficient Flow Diagnosis

P0401is a typical OBDII fault code that will appear in theDodge Caravan when the vehicle is started. It has anything to do with the emissions system and is abbreviated as: The EGR system on a vehicle is in charge of recirculating exhaust gases in order to reduce the vehicle’s emissions production and reduce pollution. The EGR system of the Caravan is composed of three major components. The EGR Valve, the Differential Pressure Sensor, and the Actuator Solenoid are the components in question. P0401is a generic code, which means that it will have the same meaning regardless of the year (1996 or later) or the model, and it will have the same meaning regardless of which manufacturer constructed the vehicle (Dodge Caravan or not).

Dodge Caravan P0401 Symptoms

The majority of the time, when P0401 is triggered, there will be no symptoms other than the service engine light turning on quickly. If the situation is acute, you may hear a faint pinging or knocking sound.

  • The service engine soon light will be on when the code P0401 is entered. There may be a distinct knocking sound that emanates from the car under certain circumstances. It’ll sound nearly like a piston smack when it happens.

P0401 Causes: Dodge Caravan

Finding the source of the P0401 error code in a Caravan is usually not too difficult to figure out. The following are the most often seen reasons:

  • Blocked EGR Tube — Over time, the tube that transports exhaust gases back to the engine may get clogged with debris. It can also get twisted or kinked as a result of this. Particularly relevant if you are encountering P0401 shortly after doing engine maintenance. Examine the tube to see if it is fractured, blocked, or otherwise damaged
  • And In most cases, the EGR valve itself will not be the first location to look for issues with a vehicle’s performance. However, they are undoubtedly the root cause of P0401 on a regular basis. Engine Vacuum Issues – The EGR valve is dependent on engine vacuum to function properly. In other words, if you are seeing P0401 and other codes, it is possible that the P0401 is an indication of broader issues. As an example, if the motor is not operating properly in order to provide adequate vacuum to activate the EGR valve, the code P0401 will frequently be generated. Sensor Failure — The Differential Pressure Feedback-EGR sensor might become defective, causing the EGR valve to become inoperable and the code to be generated.
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Caravan P0401 Fix

The good thing about P0401 is that it almost never costs a lot of money to correct, and it is typically rather simple to identify the problem because it is located directly on top of the engine. The majority of people read P0401 Insufficient EGR flow and immediately search up the pricing of an EGR valve to see how inexpensive it is and simply replace it. This may be a costly error. This is due to the fact that the EGR valve is not usually the source of the problem. Here are some of the most often seen solutions for resolving the P0401 error:

  • Examine the EGR Tube- It’s a good idea to check the tube leading to the EGR because it’s commonly the source of the P0401 error code. It’s also simple and quick to check, and replacing it is not difficult. Unless it’s cracked, you’ll have to get a replacement. If it’s clogged, you can get away with cleaning it and replacing it
  • Otherwise, you’ll have to replace it. Check the DPFE Sensor Voltage- If you are comfortable working with a voltage meter, go ahead and test it yourself. Here’s a nice post on how to do it from It Still Runs that can help you out: How to Perform a DPFE Sensor Test
  • Test the EGR Valve- A vacuum gauge can assist you in determining whether or not the EGR valve itself has failed. It can be tested using an avacuum gauge, according to this article from Autozone.


It is quite simple to do an EGR system test on your vehicle. The DPFE sensor proves to be the most difficult to work with. If you’re not certain in your ability to handle that, you can always try everything else first. It is possible to be reasonably certain that the DPFE is at fault based on the process of elimination. If you have anything to say about P0401 that you would want to share, please do so in the comments section below. Wishing you the best of luck!

1996 Dodge Grand Caravan LE EGR, Solenoid and Transducer Problems 101

The most recent update was made on March 20, 2006. (See the Document Revision History for further information.) Introduction. Although these procedures were originally written for the 1996 Dodge Grand Caravan LE, they are applicable to all 1996, 1997, and 1998 Dodge Caravan, Plymouth Voyager, and Chrysler TownCountry Mini-vans equipped with the 3.8L engine, as well as all 1997 and 1998 Dodge Caravan, Plymouth Voyager, and Chrysler TownCountry Mini-vans equipped with the 3.8L engine. These processes may also be applicable to other calendar years.

  1. Before you begin, you should run your vehicle identification number via Dodge’s Recall Check Procedure.
  2. Obtain the last 8 characters of your vehicle’s VIN and enter them here to see if your vehicle is currently subject to any uncompleted or incomplete recalls or customer satisfaction notifications.
  3. If you follow these instructions, your task will be significantly easier.
  4. The Document Revision History section is included at the conclusion of this document.
  5. .
  6. A single EGR assembly consisting of the valve, solenoid, and backpressure transducer.
  7. The EGR Valve Assembly, two new nuts, and a new gasket are all included in this package.

When used together with the Power Control Module (PCM) located under the hood, the EGR Valve Assembly captures and re-circulates exhaust gases from the exhaust manifold (which is located in back of engine compartment, near the firewall) in order to reduce various Nitrous (NxO) emissions into the atmosphere.

  1. Over time, this valve may get blocked with carbon deposits, and/or the diaphragm may harden as a result of the heat, and the valve may cease to respond to vacuum in order to open and shut.
  2. This is what your old EGR Valve Assembly will look like after removed (notice the carbon deposits in the inlet and outlet ports).
  3. Over time, you may notice a decrease in the efficiency of your gas mileage.
  4. It is just more expensive to do so.
  5. Searching for Diagnostic Trouble Codes (DTCs) and Scan Tool “P” Codes is important.
  6. Generally speaking, it is a good idea to obtain BOTH of these codes because different combinations of DTC and “P” codes might signal a variety of different problems in different vehicles.
  7. In this particular instance, however, replacing the EGR Valve Assembly “can” resolve both combinations of DTC and “P” codes at the time of replacement.

I say “can” because If this tube has been blocked with carbon deposits over time, it is probable that it may require replacement (although in my case, replacement was not necessary).

Despite the fact that my Haynes handbook recommended that I replace this tube, I did not do so.

I went this way since removing the EGR Tube is a major pain in the neck.

When I change the plugs or have another cause to remove the windshield wiper cowling, I’ll take care of the EGR Tube problem then and there.

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Be cautious not to start your vehicle; merely turning the ignition on and off will be sufficient to ignite the dashboard idiot lights.

When this occurs, the DTC32 will flash three times, stop, and then flash twice (DTC32) to display the exact EGR problem code for “Insufficient flow.” Finally, the Check Engine light will blink five times, stop, and then flash five times again (DTC55) to signal the conclusion of the DTC codes.

In the event that you bring your car to Auto Zone or Advance Auto and ask them to check your OBD II codes (which they will do for free), they will almost certainly supply you with one or more “P” error codes.

It is possible that you will receive a P0403.

Take out your checkbook and head to your nearest dealer (or somewhere else), confident in the knowledge that you are about to beat this bad boy, save yourself a hundred dollars or so in mechanic labor charges, and take your significant other out to dinner tonight where you can discuss (among other things) your supreme automotive prowess:naughty.

citizen or permanent resident.

In order to qualify for this offer, you must be a U.S.

DATA ON COST COMPARISONS: Work is completed by my dealer; work is completed by me According to my dealer, the following parts cost $58CT: EGR Valve (Assembly) State Sales Tax on Parts – $3.48Labor (1.25 hours At $85/hour) – $106.25Total Dealer Price – $167.73State Sales Tax on Parts – $3.48Total Dealer Price – $167.73 My Actual Expenses Valve (Assembly) for the EGR – $58CT State Sales Tax on Parts – $3.48Labor (1.25 hours @ $0/hour) – $0State Sales Tax on Labor – $3.48 My TOTAL ACTUAL COST was $61.48 and my TOTAL SAVINGS were $106.25.

  1. I was able to lower my repair expense by more than 63 percent.
  2. Should this not be done, you run the danger of shorting out a number of components that are EXTREMELY EXPENSIVE to repair.
  3. This also clears all fault codes stored in your vehicle’s computer memory and prepares your vehicle’s Power Control Module (PCM) to accept a newly fitted, electronically controlled EGR Valve Assembly that has been recently installed.
  4. Once again, the designers at Chrysler chose a difficult-to-see location for the bolts—though in this case, they were fortunately not impossible to reach.
  5. 3.) Clear the area around the EGR Valve Assembly with wiring and vacuum lines in order to obtain access to the bolts that hold the old EGR Valve Assembly to the Throttle Body.
  6. Apart from the EGR Valve Assembly, there was nothing else that needed to be unbolted.
  7. Move them out of harm’s way securely after removing the vacuum line and disconnecting the PCM connector from the old EGR Solenoid, as shown in Figure 4.

5.) Obtain a 10mm long socket and a 1/4″ or 3/8″ ratchet to complete the task.

By reaching below the Throttle Body snorkel with your left hand, you may locate both bolt heads and then insert the socket onto the bolt heads with your right hand.

6.) Take your time.

After that, carefully remove the old EGR Valve Assembly from the vehicle.

Fortunately, the gasket should be able to be removed fully without breaking.

Check to see that the bolts on the new EGR Valve Assembly are in the correct holes and have passed through the gasket completely.

In order to get the threads started, I simply placed the 10mm socket over the new bolt heads and turned the bolt heads by hand to get the threads started.

This ensures that the replacement EGR Valve Assembly is installed uniformly throughout the vehicle.

of torque each (equal to 180in.lbs.).

These are the ones you may have detached in order to obtain access to the old EGR Valve Assembly bolts, as well as the ones you may have disconnected from the old EGR Valve Assembly prior to removing it from the vehicle.

You will notice with great delight that your Check Engine light has been turned off.

NOTE: If your Check Engine light does illuminate and your DTC and “P” codes are the same as they were previously, take your car to Advance Auto or Auto Zone and have them clear all codes for you before continuing (although they should have been cleared when you removed the negative cable from the battery).

Cross your fingers that you will not be required to do so. It’s a major pain in the neck. HISTORY OF DOCUMENT REVISIONS Published on the 16th of March, 2006. Pictures were added on March 20, 2006, and minor editing edits were made on April 1, 2006.

Town & Country/Grand Caravan Problem Codes

Thank you so much for taking the time to comment. I’d want to add that the majority of the miles was accumulated on highway drives. My current problem is that the dealer has no idea what is wrong with my vehicle. According to what I was told, the dealer mechanics have communicated with the Dodge corporation on a number of occasions. To my mind, they’re all simply making educated guesses. A computer (or perhaps just a module?) and two exhaust-related sensors have been changed by this team. Yesterday, I spoke with the dealer once again, and they informed me that they would need to speak with a Dodge engineer again.

  • He said he’d phone me and that he’d meet me at the testing station later in the afternoon.
  • I was wondering whether you had any experience with testing stations whose software was not compatible with all makes and models of automobiles.
  • He found nothing wrong.
  • In less than two months, I’ve made more than a dozen visits between the testing facility and the dealer.
  • Once again, thank you.
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Dodge Caravan Questions – Help me please

Kimberly posed the question. @ 8:26 p.m. on May 31, 2015 information on the 2001 Dodge Caravan Sport FWD MaintenanceRepair is the sort of question. I’m in need of assistance with my 2001 Dodge Grand Caravan. It is emitting a lot of black smoke from its exhaust and spitting really loudly. It has the ability to drive, but it does it in a terrible manner and barely travels 20 mph. Please assist me. This is the only road forward for me. I had my egrvalve changed, a new fuel filter installed, and my cadilaic converter removed.

It took 45 minutes to drive it.

6 Answers

On the way home yesterday night, I stopped by a parts store and the only code that showed up was p0401, which was egr, according to the staff, and has been changed. Check for a faulty fuel pressure regulator or extremely high fuel pressures, as well as a faulty temperature sensor. This was beneficial to 1 person. It is also possible that a fuel injector is jammed open; thus, a not running fuelpressure leak down test should be done on the vehicle.1 people found this article helpful No, we haven’t done an ecm reset yet, but we did a code test at home using the keys on and off, and the codes p1684, p0508, p0403, and p 0135 came up.

Thanks for all of our responses; he’s going to try all of the things you’ve advised. This was reported to be helpful by 2 people. One person found this article to be helpful. I have a 2002 carvan that will not start. We have changed the starter plugs and nothing has worked.

Related Questions

I’m in need of assistance with my 2001 Dodge Grand Caravan. It is emitting a lot of black smoke from its exhaust and spitting really loudly. It has the ability to drive, but it does it in a terrible manner and barely travels 20 mph. Please assist me. This is the case. Performing routine maintenance and repairs on a 2001 Dodge Caravan Sport FWD

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I’m having trouble with my 2001 Dodge Grand Caravan and need some assistance. This vehicle is spewing black smoke from its exhaust and spitting quite loudly at the present time. This vehicle will drive, but it will drive horribly and will only travel 20 miles per hour on average. Thank you so much for your assistance! As an example, consider the following: The maintenance and repair of a 2001 Dodge Caravan Sport FWD

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