Diagnostic Instructions

DTC Descriptors

DTC P0403: Exhaust Gas Recirculation (EGR) Solenoid Control Circuit

DTC P0404: Exhaust Gas Recirculation (EGR) Open Position Performance

DTC P0405: Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage

DTC P0406: Exhaust Gas Recirculation (EGR) Position Sensor Circuit High Voltage

Diagnostic Fault Information

Circuit	Short to Ground	Open/High Resistance	Short to Voltage	Signal Performance
Ignition 1 Voltage	P0342, P0562	--	--	P0400, P0402, P1402
Solenoid Control	P0403	--	P0403, P0563	P0400, P0402, P1402
5-Volt Reference	P0107, P0404, P0405	P0404, P0405	--	P0400, P0402, P1402
EGR Position Sensor Signal	P0403, P0405	P0404, P0406	P0404, P0406	P0400, P0402, P1402
Low Reference	--	P0404, P0406	--	P0400, P0402, P1402

Typical Scan Tool Data

EGR Position Sensor

Circuit	Short to Ground	Open	Short to Voltage
Operating Conditions: Engine operating in Closed Loop. Parameter Normal Range: 0.60-0.80 Volts
Ignition 1 Voltage	0.71 Volts	--	--
5-Volt Reference	0.71 Volts	0.01 Volts	1.56 Volts
EGR Position Sensor Signal	0.01 Volts	5.00 Volts	5.00 Volts
EGR Solenoid Control	3.78 Volts	--	--
Low Reference	--	5.00 Volts	--

Circuit Description

Voltage is provided to the exhaust gas recirculation (EGR) valve by the ignition 1 voltage circuit through a fuse. Ground is provided to the EGR valve on the control circuit by a low side driver within the engine control module (ECM). The ECM monitors the voltage on the control circuit of the EGR valve to determine if a failure is present.

The ECM monitors the position of the EGR valve through the EGR valve position sensor. The EGR valve position sensor sends a feedback voltage on the signal circuit to the ECM. The EGR position sensor voltage varies depending on the position of the EGR valve.

Conditions for Running the DTC

P0403, P0405, and P0406

P0404

Conditions for Setting the DTC

P0403

The ECM detects an open, short to ground or voltage on the control circuit of the EGR valve.

P0404

The ECM detects the learned position of the EGR pintle position is out of range.

P0405

The ECM detects the EGR position sensor is less than 0.16 volt.

P0406

The ECM detects the EGR position sensor is greater than 4.90 volts.

Action Taken When the DTC Sets

Conditions for Clearing the MIL/DTC

Reference Information

Schematic Reference

Engine Controls Schematics

Connector End View Reference

Description and Operation

Exhaust Gas Recirculation (EGR) System Description

Electrical Information Reference

Scan Tool Reference

Circuit/System Verification

1. Ignition ON, observe the EGR position sensor voltage parameter. The reading should be between the range of 0.60-0.80 volt.
2. With a scan tool, command the EGR valve ON. The EGR position sensor voltage should fluctuate between 0.60-4.00 volts for 3-5 seconds.
3. If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data List.

Circuit/System Testing

1. Ignition OFF, disconnect the harness connector at the EGR valve.
2. Ignition ON, verify that a test lamp illuminates between the ignition 1 voltage circuit and battery ground.

⇒	If the test lamp does not illuminate, test the ignition 1 voltage circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition 1 voltage circuit fuse is open, test all components connected to the ignition 1 voltage circuit and replace as necessary.

3. Connect a test lamp between the control circuit and the ignition 1 voltage circuit.
4. Command the EGR solenoid ON with a scan tool. The test lamp should turn ON and OFF for 3-5 seconds.

⇒	If the test lamp is always ON, test the control circuit for a short to ground. If circuit/connections test normal, replace the ECM.

⇒	If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If circuit/connections test normal, replace the ECM.

5. Ignition OFF, test for less than 1 ohm of resistance between the low reference circuit and ground.

⇒	If greater than 1 ohm, test the low reference circuit for an open/high resistance. If the circuit/connections test normal, replace the ECM.

Important: The 5-volt reference circuits are internally and externally connected at the ECM. Other component DTCs may be set. If other DTCs are set, review the electrical schematic and diagnose the applicable circuits and components.

6. Ignition ON, test for 4.8-5.2 volts between the 5-volt reference circuit and ground.

⇒	If less than 4.8 volts, test the 5-volt reference circuit for a short to ground or open/high resistance. If the circuit/connections test normal, replace the ECM.

⇒	If greater than 5.2 volts, test the 5-volt reference circuit for a short to voltage. If the circuit/connections test normal, replace the ECM.

7. Verify that the EGR position sensor parameter is greater than 4.90 volts.

⇒	If less than 4.90 volts, test the signal circuit for a short to ground. If the circuit/connections test normal, replace the ECM.

8. Ignition ON, install a 3-amp fused jumper wire between the signal circuit and the low reference circuit. Verify the scan tool EGR position sensor parameter is less than 0.2 volt.

⇒	If greater than 0.2 volt, test the signal circuit for a short to voltage or an open/high resistance. If the circuit/connections test normal, replace the ECM.

9. If all circuits/connections test normal, test or replace the EGR valve.

Component Testing

1. Ignition OFF, disconnect the harness connector of the EGR valve.

Important: The EGR must be near 20°C (68°F) in order for an accurate measurement.

2. Measure for 7.8-8.6 ohms of resistance between the ignition 1 voltage and control circuit terminal of the EGR valve.

⇒	If the resistance is out of the specified range, replace the EGR valve.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.