6.7L Cummins Forum

Yesterday the Malfunction Indicator Light illuminated. Today using the Edge Insight the error code was: P040; unknown. I used the Insight to clear the code and started the engine. The MIL was no longer illuminated. Does anyone know anything about this error code? Should I be worried? The truck has 33K miles and this is the first error code.

P0404-egr Position Sensor Performance Diesel
In the 6.7 Cummins Turbo Diesel Forum Squid has posted a list of all fault codes. It has helped me out several times. As far as what does that mean I don't know someone will be along to help out.
Cummins 6.7L Turbo Diesel -
Heres an attempt at a link to it.

Patrick

The EGR on non C&C version trucks consists of three parts:

1. EGR bypass (seen on the passenger side on the exhaust manifold attached to the EGR cooler)
2. EGR valve (located on top of the intake horn)
3. EGR airflow throttle valve (unit attached to the intake side of the intake horn)

Most likely, the EGR valve on the intake horn could be sticking (its plunger based with return spring). The unit, EGR bypass, is pulley based and very hard to make stick. Cleaning the EGR is simple, but make sure you purchase a replacement gasket first. All that has to be removed and cleaned is the actuator (dark grey unit with the connector on it). Soot could be getting into the plunger area making it stick possibly.

If memory serves correct, these codes relate to the EGR valve:

P0404-egr Position Sensor Performance Diesel
P0405-egr Position Sensor Circuit Low

and these codes relates to the EGR bypass:

P0400-egr System Flow Malfunction
P0401-egr System Performance
P0402-egr Flow Excessive Detected
P0403-egr Control Circuit/open

and these relates to the EGR airflow valve:

P0487-egr Airflow Throttle Control Circuit A Open
P0488-egr Airflow Throttle Control Circuit Performance

Hope that helps. Nothing to be overly concerned about, easy to clean or can skip till the 2nd time the same code comes up.

Cheers.

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Here ya go. I know it says to replace the Valve but I'd first clear the code and see if it comes back. If so, I'd next clean the system before replacing anything.

Theory of Operation


The EGR valve contains three hall effect sensors to detect position. The three position sensors correspond to 6 valid sectors that the valve can be in. If the valve position skips a sector(s), a fault counter is incriminated, else decremented. Once the counter equals a calibrated threshold, the rationality fault becomes active. The position sensors are integral to the valve assembly and are not serviced separately. The ECM will light the MIL lamp once the diagnostic runs and fails in two consecutive drive cycles. The ECM will turn off the MIL lamp once the diagnostic runs and passes in 4 consecutive drive cycles.

• When Monitored: Key on, engine off & while running.
• Set Condition: EGR solenoid internal position reading does not follow expected values.

Possible Causes
EGR SOLENOID POSITION SENSOR



Diagnostic Test

1. OTHER DTC'S

Ignition on engine off.
With a scan tool, read DTCs.

Do you have any additional EGR related DTC's?

Yes

• Repair all other DTC's first

No

• Replace EGR valve.

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2007.5 Dodge Ram 3500 HD,QC, 6.7L Cummins, 6speed Auto, 4X4, Bighorn Edition.
Click for installs: Carr Steps PML Diff Cover Edge Juice with Attitude Volant Intake Hankook ATM RF10

Hey Squid that's cheating using the manuals. I am glad to see that we hit the same point. I am too lazy to get the cd's out .....

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Thank you for the responses, they are much appreciated. I cleared the code on Sunday and the MIL light went out and has not returned - so far. I suspect it will return soon. When it comes on, I will most likely take it to a stealership since it is still under warranty.

On Monday we towed the fiver from northern LA to Moreno Vally, a three hour drive though some steep hills. We have driven a couple hundred miles since Monday and no MIL light.

I'll let you know when the light comes back on. Cheers, Dixiedawg
P.S. I'll update my avatar in the next week or two.

It may not come back. I have had Phantom codes show up and after being cleared never come back. I've even had a couple of codes that aren't even applicable to a 6 cylinder diesel engine................. guess she want's to be a Hemi in her next life, LOL. NOT!

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2007.5 Dodge Ram 3500 HD,QC, 6.7L Cummins, 6speed Auto, 4X4, Bighorn Edition.
Click for installs: Carr Steps PML Diff Cover Edge Juice with Attitude Volant Intake Hankook ATM RF10