I have 2007 wrangler-X, bare bones, 6-spd with 130k miles. In november I got a few PO404 errors that I cleared and never came up again. Last month I got that dreaded intake/coolant leak on the drivers side. I replaced the manifold gasket and got that all squared away. Since I was there and it gave me troubles earlier this winter, I replaced the EGR valve. It's been great for a month and I started getting the error again. It is always at the same time. After about 45-50mins driving, around 40-50 mph, wet snowy weather 40 Deg F and EGR commanded to be 100%. Any help would be great....Thanks, Z

Just for the sake of saying it, I was surprised to see so much blow-by in the intake manifold for the care that I have given this rig. Always clean oil etc. It did not look to be exhaust but blacked oil in intake manifold area. I run no muffler just the CAT and the rig has used 1quart of oil between changes since the 60K mile mark. I do not want to throw another EGR at it. I have the "freeze Frame" data to share if anyone is techy.....

 

I have cleaned the grounds and reset error a few times. No cure yet. Freeze frame data reports valve commanded to be 100% with 25-35% error. According to the formula for the percent error [(Actual EGR Position – Commanded EGR) ÷ Commanded EGR] = EGR Error. My EGR is +25-35% apparently more open than it is supposed to be. I have a rather "dumb" scan tool so I cannot command it open and closed at will or capture any data until a recognized error occurs. I am temped to put the old EGR back in and see what happens. I think I read in the Haynes manual that sometimes the dealer will need to reset parameters after an EGR is replaced? I have found no other reference to this...... Still looking for ideas..... Thanks

 

I have an 08 and I have been through 4 or 5 egr valves. Last one went in under 6 months. Had it replaced with an OEM one. Hopefully it will last a couple of years.

 

Since the last post I've reset the error maybe 15 times. I finally got fed up with it cleaned the OEM EGR and put it back in. It lasted a week and coded out again. This time the error was around -100%. The "new" valve was giving me errors of around -36% (I think?). Im reluctant to try another new valve, I do not want to visit the dealer, I have checked quite a few things that lead up to it being the valve itself. Anyone have good information on this valve for testing purposes? Thanks.......Z

 

I don't have any good information just wanted to say I finally got the 404 code after 147K miles. Stayed on for ~200 miles and went off. Dealer replaced it under warranty and have not had an issue since. That was two weeks ago.

 

I did finally breakdown and replaced the EGR again. I got about 3-4 months of no code. Now Wham! Its a daily event. Considering buying factory EGR from dealer but just hate to spend the money. I have checked all grounds and wires etc. At this point, I just want to bypass the system. Does anyone know a good way to go about that? I think the newbies call that an EGR Delete? Its the same kind of error P0404. Basically stating the EGR is not in the position it is commanded to be in. I have not had the current one out to bench test. When I bench test the others, they open when energized and the feedback (reference circuit) seems to act like the potentiometer that it is. Thanks, Z