Diagnostic Aids
- Due to moisture associated with exhaust systems, the EGR valve may freeze and stick in cold weather at times. After the vehicle is brought into a warm shop for repairs, the valve warms and the condition disappears. By watching the actual EGR and desired EGR positions on a cold vehicle with a scan tool, the fault can be easily verified. Check the Freeze Frame data to determine if the DTC set when the vehicle was cold by viewing the engine coolant temperature (ECT).
- For an intermittent condition, refer to Intermittent Conditions .
| Step | Action | Values | Yes | No |
|---|---|---|---|---|
| Schematic Reference: Engine Controls Schematics (European Emissions)
or Engine Controls Schematics (Non European Emissions) Connector End View Reference: Engine Controls Connector End Views |
||||
| 1 | Did you perform the Diagnostic System Check - Engine Controls? | - | Go to Step 2 | Go to Diagnostic System Check - Engine Controls |
| 2 | Is DTC P0405 or P0406 also set? | - | Go to Diagnostic Trouble Code (DTC) List | Go to Step 3 |
| 3 |
|
15% | Go to Step 4 | Go to Step 5 |
| 4 |
|
- | Go to Step 5 | Go to Diagnostic Aids |
| 5 |
|
1% | Go to Step 6 | Go to Step 13 |
| 6 |
IMPORTANT:
Use the J 35616-200
Test Lamp Kit for this test. If the J 35616-200
is not available, use a test lamp that measures between 25-30 ohms. Connect a test lamp between the 5-volt reference circuit and the low reference circuit of the EGR valve position sensor.Does the test lamp illuminate? |
- | Go to Step 8 | Go to Step 7 |
| 7 | Connect a test lamp between the 5-volt reference circuit of the EGR valve position sensor and a good ground. Does the test lamp illuminate? |
- | Go to Step 15 | Go to Step 14 |
| 8 |
|
99% | Go to Step 9 | Go to Step 16 |
| 9 | Connect a test lamp between the ignition 1 voltage circuit of the EGR valve and a good ground. Does the test lamp illuminate? |
- | Go to Step 10 | Go to Step 20 |
| 10 |
|
- | Go to Step 11 | Go to Step 17 |
| 11 |
|
3 Ω | Go to Step 12 | Go to Step 20 |
| 12 |
|
0.5 V | Go to Step 18 | Go to Step 17 |
| 13 | Test the signal circuit of the EGR valve position sensor for a short to voltage. Refer to Circuit Testing
and Wiring Repairs
in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 19 |
| 14 | Test the 5-volt reference circuit of the EGR valve position sensor for an open or high resistance. Refer to Circuit Testing
and Wiring Repairs
in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 19 |
| 15 | Test the low reference circuit of the EGR valve position sensor for an open or high resistance. Refer to Circuit Testing
and Wiring Repairs
in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 19 |
| 16 | Test the signal circuit of the EGR valve position sensor for the following conditions:
Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 19 |
| 17 | Test the control circuit of the EGR valve for an open or high resistance. Refer to Circuit Testing
and Wiring Repairs
in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 19 |
| 18 | Test the EGR valve for the following:
Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 21 |
| 19 | Test for an intermittent and for a poor connection at the engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections
and Repairing Connector Terminals
in Wiring Systems. Did you find and correct the condition? |
- | Go to Step 23 | Go to Step 22 |
| 20 | Repair the ignition 1 voltage circuit of the EGR valve for one of the following conditions:
Refer to Wiring Repairs in Wiring Systems. Did you complete the repair? |
- | Go to Step 23 | - |
| 21 | Replace the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement (Non European Emissions)
or Exhaust Gas Recirculation Valve Replacement (European and North American Emissions)
. Did you complete the replacement? |
- | Go to Step 23 | - |
| 22 | Replace the ECM. Refer to Engine Control Module Replacement
. Did you complete the replacement? |
- | Go to Step 23 | - |
| 23 |
|
- | Go to Step 2 | Go to Step 24 |
| 24 | Observe the Capture Info with a scan tool. Are there any DTCs that have not been diagnosed? |
- | Go to Diagnostic Trouble Code (DTC) List | System OK |