P0401 now, after fixing P0406 with a new EGV valve/solenoid

[khnitz]

I'm working on this 2009 SXT 3.5L 62TE, trying to get some last issues resolves before it goes to its next owner (I'm selling it to a friend of my sister).

 

I had a P0406 code (P0406-EGR POSITION SENSOR CIRCUIT HIGH) and replaced the EGR Valve.  That code has not reappeared.   Old vs. New EGR solenoid/valve shown below:

 

After about a day of driving which allowed the learn/test cycle to complete, a different DTC appeared - P0401 (P0401-EGR SYSTEM PERFORMANCE).  I haven't been able to find a clear path to resolving this one in the searching I've done - any suggestions?

 

The new valve came with new gaskets, which were installed.  I did remove and reattach the connection at the intake manifold that goes to the EGR valve - it may not be exactly centered in that opening/rubber gasket at the intake manifold, though - this is about the only thing I did/changed that I could think might be having an effect.

 

Any advice here is appreciated!  Oh, and is the correct term for this the EGR valve, or EGR solenoid?  Or is it a combination Valve+Solenoid?  Curious minds want to know...

[John/Horace]

If you have bi directional scanner that can access it, hold solenoid and cycle it, should feel it click pretty hard. Wire harness could be ratty. Gasket looks well made with centering cut outs for studs.

 

Sometimes mopar cars fussy for oem stuff.  Mopar on line sites offering decent discounts lately.

 

 

[Dean H]

A EGR system leak will set this code.

 

Go through your work and get it sealed.

 

 

[khnitz]

45 minutes ago, Dean H said:

A EGR system leak will set this code.

 

Go through your work and get it sealed.

 

 

Yeah, that's what I'm thinking, too.  I don't like the way that EGR tube-to-intake manifold junction was aligned.  I'm going to buy a new EGR tube gasket/seal (the Fel-Pro 72928 is readily available) and then re-align it all and see if that does the trick.

[5rebel9]

Make sure to check the tube for good flow and not carboned up,and if possible the intake manifold it goes into. 

A cracked tube will give an odd exhaust engine sound when at a point of EGR opening. But for the age of the car, I'm betting on blocked flow between the valve and intake manifold(or inside the manifold).

LAST resort could be a defective EGR valve.

[khnitz]

I tested the EGR tube and it is flowing and does not have cracks/leaks.

 

But I do have a question on the gasket for the EGR inlet on the intake manifold.  When I searched, the Fel-Pro 72928 (blue in the picture below) came up as the applicable gasket.  BUT, it appears to be too small.  It does fit over the end of the tube, but then it's O.D. fits inside the OE gasket (tan in the picture below) with clearance - so it's not really doing anything.  So, I don't think this 72928 gasket is the right one, or, it is meant for a different location on the vehicle.

 

Here is the EGR inlet on the intake manifold with the gasket that was already there installed - is that all that is supposed to be there?

 

Here is the inlet without the gasket.

 

My OE gasket has a nick on the I.D. surface (red circle), but the sealing surface looks to be the ridge (green arrow).

 

Looks like this OE seal is PN 04667931.

 

Thanks for any advice/help!

Edited December 4, 2025 by khnitz

[khnitz]

It's too late to edit the above post - drat!  The correct OE PN for that EGR gasket is 04667431.

[khnitz]

Since removing the EGR tube, wiping the seal clean, and then re-installing the EGR tube, and clearing all code - I've driven a couple hundred miles and the EGGR P0401 code has not returned!  I read the DTCs at some point on Friday and it showed that the P0401 code was still pending (because the ODB EGR cycle hadn't completed yet - not enough miles had been driven), but later on Sunday after more driving over the weekend, it showed no DTCs!  So, it's good to have this one resolved.

[khnitz]

Man, my early morning typing is atrocious.  I meant to type "OBD EGR"...