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DTC P0401: EGR System Failure: Testing

  1. Turn ignition on. Using scan tool, read DTCs. If Good Trip counter is displayed for DTC P0401 and displayed count is "0", go to next step. If Good Trip counter is not displayed for DTC P0401 or displayed count is not "0", go to step  12.
  2. Start engine. Allow engine to reach normal operating temperature. If engine runs rough or stalls, turn ignition off and go to next step. If engine does not run rough or stall, go to step  6.
  3. Disconnect vacuum hose from EGR valve. Start engine. If engine does not run rough or stall, go to next step. If engine runs rough or stalls, remove EGR valve. Check for an obstruction that would keep EGR valve open. Repair as necessary and retest. If no obstruction is found, replace EGR valve.
  4. Turn ignition off. Disconnect EGR solenoid connector. Disconnect PCM connectors. PCM is located on left side of instrument panel, near front of battery. Measure resistance between ground and Dark Blue/Violet wire at EGR solenoid harness connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Dark Blue/Violet wire.
  5. Ensure ignition is off. Reconnect PCM connectors. Using a test light connected to positive battery voltage, probe Dark Blue/Violet wire at EGR solenoid wiring harness. Using scan tool, actuate EGR solenoid and observe test light. If test light flashes on and off, replace EGR solenoid. If test light does not flash on and off, replace PCM. Program the new PCM. See PROGRAMMING .
  6. Turn ignition off. Disconnect vacuum supply hose from EGR solenoid. Start engine and allow it to idle. Using vacuum gauge, check vacuum on vacuum supply hose for EGR solenoid. If vacuum is more than 10 in. Hg, go to next step. If vacuum is 10 in. Hg or less, repair vacuum supply to EGR solenoid.
  7. Reinstall vacuum supply hose on EGR solenoid. Ensure engine is still idling. Disconnect vacuum hose from top of EGR valve. Connect a vacuum pump to EGR valve and apply vacuum. If engine runs rough or stalls, reconnect vacuum hose on EGR valve and go to next step. If engine does not run rough or stall, remove EGR valve. Check for an obstruction that would keep EGR valve from opening. Repair as necessary and retest. If no obstruction is found, replace EGR valve.
  8. Turn ignition off. Disconnect EGR solenoid connector. Turn ignition on. Using a test light connected to ground, probe Pink/Gray wire at EGR solenoid harness connector. If test light illuminates, go to next step. If test light does not illuminate, repair open in power circuit to EGR solenoid. See WIRING DIAGRAMS article.
  9. Measure voltage between ground and Dark Blue/Violet wire at EGR solenoid harness connector. If voltage is less than one volt, go to next step. If voltage is one volt or more, repair short to voltage in Dark Blue/Violet wire.
  10. Turn ignition off. Disconnect PCM connectors. PCM is located on left side of engine compartment, near front of battery. Measure resistance of Dark Blue/Violet wire between EGR solenoid harness connector and terminal No. 40 at PCM C1 harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue/Violet wire.
  11. Ensure ignition is off. Reconnect PCM connectors. Using a test light connected to positive battery voltage, probe Dark Blue/Violet wire at EGR solenoid wiring harness. Using scan tool, actuate EGR solenoid and observe test light. If test light flashes on and off, inspect EGR solenoid backpressure hose and tube for obstructions and damage. Repair or replace backpressure hose and tube as necessary. If backpressure hose and tube are okay, replace EGR solenoid.
  12. Check exhaust system for leaks. Repair exhaust as necessary and retest. If no exhaust leaks are found, conditions for DTC to set do not exist or fault is an intermittent problem. Start engine and allow it to idle. Ensure engine is at normal operating temperature. Using scan tool, monitor parameters related to DTC while wiggling connectors and wiring harness. If value changes while wiggling connectors and wiring harness, repair connectors and wiring harness where wiggling caused value to change. If value does not change, review Freeze Frame data using scan tool. Attempt to duplicate condition that caused DTC to set. Check for any related technical service bulletins that may apply. Visually inspect related connectors and wiring harness. Repair connectors and wiring harness as necessary. See WIRING DIAGRAMS article. If no problems are indicated, test is complete.
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