EGR System Malfunction - 3.0L
NOTE:
The following test procedures are for DTCs P0400, P0401, P0404 and P0408.
EGR CONNECTOR INSPECTION/ACTION CHART
| STEP | INSPECTION | ACTION | |
|---|---|---|---|
| 1 |
|
Yes | If Continuous Memory DTC P1406 appears, see DIFFERENTIAL PRESSURE FEEDBACK (DPFEGR) SENSOR MALFUNCTION . If KOER DTC P1408 appears with P0401, go to next step. Otherwise, go to step 12. |
| No | Perform PCM Quick Test. See PCM QUICK TEST . | ||
| 2 | RUN KOER SELF-TEST WHILE MONITORING EGR VACUUM
|
Yes | The vacuum indicated is sufficient to open the EGR valve. Fault is unlikely to be in EGR vacuum control system. Go to next step. |
| No | The vacuum indicated is insufficient to open EGR valve. Go to step 6. |
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| 3 | INSPECT DPFEGR SENSOR PRESSURE HOSES
|
Yes | Repair pressure hoses as necessary. Go to step 17. |
| No | Go to next step. | ||
| 4 | CHECK DPFEGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Replace DPFEGR sensor. See DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SYSTEM - SENSOR . Go to next step. |
| No | Reconnect pressure hoses. Go to step 6. |
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| 5 | CHECK EGR VALVE FUNCTION BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Restore vehicle. Go to step 11. |
| No | Remove and inspect the EGR valve for signs of contamination, unusual wear, carbon deposits, binding, leaking diaphragm and other damage. If EGR valve is OK, look for an obstructed EGR port in intake manifold or plugged orifice tube assembly. Repair as necessary. Go to step 17. |
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| 6 | CHECK VACUUM SOURCE AND VACUUM HOSES TO AND FROM EGR VACUUM REGULATOR (EGRVR) SOLENOID
|
Yes | Restore vehicle. Go to next step. |
| No | Isolate fault and repair as necessary. Go to step 17. |
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| 7 | CHECK VPWR TO EGR VACUUM REGULATOR (EGRVR) SOLENOID
|
Yes | Key OFF. Go to next step. |
| No | Repair open in EGRVR solenoid VPWR circuit. Go to step 17. |
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| 8 | MEASURE RESISTANCE ACROSS EGR VACUUM REGULATOR (EGRVR) SOLENOID
|
Yes | Go to next step. |
| No | Replace EGRVR solenoid. See EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR VALVE - 3.0L (4V) . Go to step 17. |
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| 9 | CHECK EGR VACUUM REGULATOR (EGRVR) CIRCUIT FOR SHORT TO PWR
|
Yes | Repair EGRVR circuit for short to PWR. Go to step 17. |
| No | Go to next step. | ||
| 10 | CHECK EGR VACUUM REGULATOR (EGRVR) CIRCUIT FOR OPEN IN HARNESS
|
Yes | Go to next step. |
| No | Repair open in EGRVR circuit. Go to step 17. |
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| 11 | CHECK EGR VACUUM REGULATOR (EGRVR) SOLENOID VACUUM OUTPUT CAPACITY BY GROUNDING EGRVR CIRCUIT
|
Yes | Replace PCM. See POWERTRAIN CONTROL MODULE (PCM) . Go to step 17. |
| No | Replace EGRVR solenoid. See EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR VALVE - 3.0L (4V) . Go to step 17. |
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| 12 | INSPECT EGR SYSTEM FOR AN INTERMITTENT FAILURE
|
Yes | Repair fault as necessary. Go to step 17. |
| No | Go to next step. | ||
| 13 | INSPECT DPFEGR SENSOR PRESSURE HOSES
|
Yes | Repair pressure hoses as necessary. Go to step 17. |
| No | Go to next step. | ||
| 14 | CHECK DPFEGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Replace DPFE sensor. See DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SYSTEM - SENSOR . Go to step 17. |
| No | Go to next step. | ||
| 15 | CHECK EGR VALVE FUNCTION BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Go to next step. |
| No | Remove and inspect the EGR valve for signs of contamination, unusual wear, carbon deposits, binding, leaking diaphragm and other damage. If EGR valve is OK, look for an obstructed EGR port in intake manifold. Repair as necessary. Go to step 17. |
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| 16 | INSPECT EGR VACUUM SIGNAL SUPPLY FOR INTERMITTENT FAILURE
|
Yes | Isolate fault and repair as necessary. Go to next step. |
| No | Unable to duplicate or identify fault at this time. (In cold climates, the EGR valve may temporarily freeze shut and thaw when the engine warms up causing the intermittent DTC). See TEST 3: INTERMITTENT . |
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| 17 | VERIFY TROUBLESHOOTING OF DTCs COMPLETED
|
Yes | Replace PCM. See POWERTRAIN CONTROL MODULE (PCM) . Repeat PCM Quick Test. See PCM QUICK TEST . |
| No | If any other DTC is present, go to applicable DTC inspection. If no DTC is present, troubleshooting complete. |
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NOTE:
The following test procedures are for DTCs P0402.
EGR SYSTEM INSPECTION/ACTION CHART
| STEP | INSPECTION | ACTION | |
|---|---|---|---|
| 1 |
|
Yes | Go to next step. |
| No | Perform PCM Quick Test. See PCM QUICK TEST . | ||
| 2 | CHECK FOR EGR FLOW AT IDLE WITH EGR VACUUM HOSE DISCONNECTED
NOTE:
|
Yes | Key OFF. There is possible EGR flow at idle. Inspect pressure hoses first for pinching and icing. If OK, remove and inspect the EGR valve and EGR tube for signs of contamination, unusual wear, carbon deposits, binding or other damage. Repair as necessary. Use EGR valve cleaner if needed. Go to step 15. |
| No | Reconnect vacuum hose to EGR valve. Go to next step. |
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| 3 | CHECK FOR EGR FLOW AT IDLE WITH EGR VACUUM HOSE CONNECTED
|
Yes | There is possible EGR flow at idle. Go to next step. |
| No | The fault is intermittent. Inspect pressure hoses for pinching or icing. Repair as necessary. If OK, Go to step 11. |
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| 4 | CHECK EGR SYSTEM VACUUM HOSES FOR INTEGRITY AND CONNECTION
NOTE:
|
Yes | Go to next step. |
| No | Repair vacuum hoses as necessary. Go to step 14. |
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| 5 | CHECK DPFEGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Replace DPFE sensor. See DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SYSTEM - SENSOR . Go to step 15. |
| No | Reconnect DPFEGR sensor. Go to next step. |
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| 6 | CHECK FOR EGR FLOW AT IDLE WITH DIFFERENTIAL PRESSURE EGR VACUUM REGULATOR CONNECTOR OFF
|
Yes | This indicates a fault in the differential pressure EGR vacuum regulator. Go to next step. |
| No | Go to step 8. | ||
| 7 | INSPECT EGR VACUUM REGULATOR SOLENOID VENT FOR PLUGGING
NOTE:
|
Yes | Repair differential pressure EGR vacuum regulator as necessary. If unable to repair, replace the solenoid. See EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR VALVE - 3.0L (4V) . Go to step 15. |
| No | Replace EGR vacuum regulator solenoid. See EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR VALVE - 3.0L (4V) . Go to step 15. |
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| 8 | MEASURE RESISTANCE ACROSS DIFFERENTIAL PRESSURE EGR VACUUM REGULATOR
|
Yes | Go to next step. |
| No | Replace differential pressure EGR vacuum regulator. See EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR VALVE - 3.0L (4V) . Go to step 15. |
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| 9 | CHECK DIFFERENTIAL PRESSURE EGR VACUUM REGULATOR CIRCUIT (BR/P) FOR SHORT TO GROUND IN HARNESS
|
Yes | Go to next step. |
| No | Repair short circuit. Go to step 15. |
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| 10 | CHECK DIFFERENTIAL PRESSURE EGR VACUUM REGULATOR CIRCUIT (BR/P) FOR SHORT TO VREF
|
Yes | Replace PCM. See POWERTRAIN CONTROL MODULE (PCM) . Go to step 15. |
| No | Repair short circuit. Go to step 15. |
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| 11 | CHECK DPFEGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP
|
Yes | Replace DPFEGR sensor. See DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SYSTEM - SENSOR . Go to step 15. |
| No | Reconnect DPFEGR sensor. Go to next step. |
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| 12 | CHECK DPFEGR SENSOR VOLTAGE WHILE EXERCISING EGR VALVE
|
Yes | Inspect EGR valve for signs of contamination, unusual wear, carbon deposit, binding and other damage. Repair or replace as necessary. Go to step 15. |
| No | Go to next step. | ||
| 13 | MONITOR EGR VALVE VACUUM WHILE WIGGLING (BR/P) CIRCUIT
NOTE:
|
Yes | Isolate fault and repair as necessary. Go to step 15. |
| No | Reconnect vacuum hose. Go to next step. |
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| 14 | INSPECT DIFFERENTIAL PRESSURE EGR VACUUM REGULATOR SOLENOID AND VACUUM HOSES FOR POTENTIAL PLUGGING
|
Yes | Repair EGR vacuum regulator solenoid or EGR vacuum hose as necessary. Go to next step. |
| No | Unable to duplicate or identify fault at this time. See TEST 3: INTERMITTENT with DPFEGR PID data and list of possible causes. |
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| 15 | VERIFY TROUBLESHOOTING OF DTCs COMPLETED
|
Yes | Replace PCM. See POWERTRAIN CONTROL MODULE (PCM) . Repeat PCM Quick Test. See PCM QUICK TEST . |
| No | If any other DTC is present, go to applicable DTC inspection. If no DTC is present, troubleshooting complete. |
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