Yesterday the check engine light and battery light came light up on my 2001 Chrysler searing lxi with a 2.7liter. I first checked codes and p0403 is showing up and a blown fuse (02 ssr/alt/egr). I figured the blown fuse made sense with the 0403 code since both are related to the EGR. I figured I had a bad EGR. I replaced the EGR this morning and the fuse. I can start the car and it starts and runs just fine but instintantly blows the fuse. It will blow the fuse by just turning the key to on just before starting.
Any ideas?

 

Check here:

OBD-II Trouble Code: P0403 Exhaust Gas Recirculation Circuit Malfunction

There's probably a short in the wiring in that circuit. Look for a chafed or damaged wire.

 

I checked the connection and unwrapped the wires and retaped about the last 8 inches up tp the connection to the EGR.
Anything else?

 

Look carefully at the exhaust Manifolds where the O2 sensors bolt in...common for burnt and misrouted sensor harnesses......

Also, unplug the field connector from the alternator and re-check for the short.....

And last but not least, find a wiring diagram from IPM . Locate the splice and separate the wires one at a time until you find the shorted one......

 

any update?

 

I had to undo the whole wiring harness to locate a short in a wire that led to the 02 sensor.

 

Was it the rear bank downstream?