For 1990-2009 cars
Engine Controls Components
EVAP and EGR Controls
OBD II Symbol Description Notice
Powertrain Control Module Connector End Views
Handling ESD Sensitive Parts Notice

### Circuit Description

An Exhaust Gas Recirculation (EGR) system lowers the Oxides of Nitrogen (NOx) emission levels that are caused by high combustion temperatures. This is accomplished by feeding small amounts of exhaust gases back into the combustion chamber. When the air/fuel mixture is diluted with the exhaust gases, the combustion temperatures are reduced.

A linear EGR valve is used on this system. The linear EGR valve is designed to accurately supply exhaust gases to the engine without the use of the intake manifold vacuum. The valve controls the exhaust flow going into the intake manifold from the exhaust manifold through an orifice with a PCM controlled pintle. The PCM controls the pintle position by using inputs from the Throttle Position (TP) sensor and the Manifold Absolute Pressure (MAP) sensor. The PCM then commands the EGR valve to operate when necessary by controlling an ignition signal through the PCM. This can be monitored on a scan tool as the Desired EGR Position.

The PCM monitors the results of the command through a feedback signal. By sending a 5 volt reference and a ground to the EGR valve, a voltage signal representing the EGR valve pintle position travels to the PCM. This feedback signal can also be monitored on a scan tool and is the actual position of the EGR pintle. The Actual EGR Position should always be near the commanded or the Desired EGR Position.

### Conditions for Setting the DTC

• | DTCs P0106, P0107, P0108, P0112, P0113, P0117, P0118, P0121, P0122, P0123, P0200, P0300-P0304, P0335, P0502, P0506, P0507, and P1441 not set.

• | The ignition voltage is greater than 11.7 V.

• | The PCM sees less than 0.11 voltage from the EGR valve sensor.

• | A malfunction is present for 25 seconds.

### Action Taken When the DTC Sets

• | The Malfunction Indicator Lamp (MIL) will illuminate after two consecutive ignition cycles in which the diagnostic runs with the fault active.

• | The PCM will record the operating conditions at the time during which the diagnostic fails. This information will store in the Freeze Frame and Failure Records buffers.

• | A history DTC stores.

• | The coolant fan turns ON.

• | The EGR disables.

### Conditions for Clearing the MIL/DTC

• | The MIL will turn OFF after three consecutive ignition cycles in which the diagnostic runs without a fault.

• | A history DTC will clear after 40 consecutive warm-up cycles without a fault.

• | The MIL/DTCs can be cleared by using the scan tool.

### Diagnostic Aids

Due to the moisture that is associated with exhaust systems, the EGR valve may freeze and stick in colder weather at times. After the vehicle is brought into a warm shop for repairs, the valve warms and the problem disappears. By watching the Actual EGR and the Desired EGR Positions on a cold vehicle with a scan tool, you can easily verify the malfunction. Check the freeze frame data in order to determine if the DTC set when the vehicle was cold by viewing the Engine Coolant Temperature (ECT).

If a condition occurs where the EGR valve signal is pulled low (but not to zero), the PCM will learn the new lower value as zero. When the EGR valve signal returns to normal the PCM interprets this as a value indicating that the EGR valve did not close and may set this DTC.

### Test Description

The numbers below refer to the step numbers on the Diagnostic Table.

1. The Powertrain OBD System Check prompts you to complete some of the basic checks and to store the freeze frame and failure records data on the scan tool if applicable. This creates an electronic copy of the data captured when the malfunction occurred. The scan tool stores this data for later reference.

2. Commanding the EGR valve open determines whether the EGR system can control the EGR valve accurately and if the malfunction is present.

3. If the EGR valve 5 volt reference is shorted to ground, the DMM will read no voltage and an additional DTC will set and the engine performance will be poor. When this circuit is open, only a DTC P0405 will set.

4. Jumping the 5 volt reference circuit to the signal circuit checks the signal circuit and PCM.

   The scan tool should display the Actual EGR Position as 100 percent if the signal circuit and the PCM are OK.

5. Although the PCM and the circuitry acted correctly in the previous step, a problem may still lie within the terminals which would not show up in any probe type testing. Check for the following conditions:

• | Terminals for being backed out

• | Improperly formed or damaged

• | Poor tension

6. All circuits to the EGR valve are OK at this point. The malfunction lies internally in the EGR valve and therefore must be replaced. Be sure to remove all of the gasket material from the EGR mounting surface. Even a small amount of material may cause a DTC P0401 to set. Refer to Exhaust Gas Recirculation Valve Replacement for On Vehicle Service of the EGR valve.

7. Reprogram the replacement PCM and perform the crankshaft position system variation learn procedure. Refer to the latest Techline procedures for PCM reprogramming and Crankshaft Position System Variation Learn for the crankshaft position system variation learn procedure.

8. Check for the following conditions:

• | Terminals for being backed out

• | Improperly formed or damaged

• | Poor tension

9. It is very important to clear the DTCs for this diagnostic. The clearing function allows the EGR valve to relearn a new pintle position as the old position was inaccurate due to the malfunction that caused the DTC. Clear the DTC with the ignition switch turned ON, with the engine OFF, or when the engine is idling. If the PCM sees an EGR command, the new pintle position will not be learned.

10. If no malfunctions are present at this point and no additional DTCs were set, refer to Diagnostic Aids for additional checks and information.

#### DTC P0405 - Exhaust Gas Recirculation (EGR) Valve Sensor Signal Low

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Did you perform the Powertrain On-Board Diagnostic (OBD) System Check? | -- | Go to Step 2 | Go to Powertrain On Board Diagnostic (OBD) System Check
2 |

1. Turn ON the ignition switch leaving the engine OFF.
2. Install a scan tool.
3. Command the EGR valve to the specified values.

Does the Actual EGR Position follow the Desired EGR Position?

0%, 20%, 50%, 70%, 100%

Go to Step 15

Go to Step 3

3 |

1. Turn OFF the ignition switch.
2. Disconnect the EGR valve electrical connector.
3. Turn ON the ignition switch leaving the engine OFF.
4. Connect a DMM to ground.
5. Probe the 5.0 V reference circuit to the EGR valve.

Does the DMM read near the specified value?

5.0 V

Go to Step 4

Go to Step 5

4 | Connect a jumper wire between the following circuits:

• | EGR valve 5.0 volt reference circuit

• | EGR valve signal circuit

Does the Actual EGR Position display the specified value?

100%

Go to Step 6

Go to Step 7

5 |

1. Connect the test light to B+.
2. Probe the 5.0 V reference circuit to the EGR valve.

Does the test light illuminate?

--

Go to Step 8

Go to Step 9

6 |

1. Turn OFF the ignition switch.
2. Check for the following conditions in the EGR valve 5.0 V reference and EGR valve signal circuits:

• | Open circuit

• | Poor electrical terminal connections

3. Repair the circuits as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 10

7 |

1. Connect the test light to B+.
2. Probe the signal circuit to the EGR valve.

Does the test light illuminate?

--

Go to Step 11

Go to Step 12

8 |

1. Turn OFF the ignition switch.

Important: The Powertrain Control Module (PCM) uses a single internal 5.0 volt power supply power to all the engine control components. If one component shorts its 5.0 volt reference circuit to ground or battery voltage, the other 5.0 volt reference circuits will also have a low or high voltage.

2. Check for a short to ground in the EGR valve 5.0 V reference circuit.
3. Repair the circuit as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 13

9 |

1. Turn OFF the ignition switch.
2. Check for an open in the EGR valve 5.0 V reference circuit.
3. Repair the circuit as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 14

10 | Replace the EGR valve. Refer to the Exhaust Gas Recirculation Valve Replacement . Is the action complete? | -- | Go to Step 15 | --
11 |

1. Turn OFF the ignition switch.
2. Check for a short to ground in the EGR valve signal circuit.
3. Repair the circuit as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 13

12 |

1. Turn OFF the ignition switch.
2. Check for an open in the EGR valve signal circuit.
3. Repair the circuit as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 14

13 | Replace the PCM. Refer to the Powertrain Control Module Replacement/Programming . Is the action complete? | -- | Go to Step 15 | --
14 |

1. Check for the following conditions in the affected circuits at the PCM:

• | Open circuit

• | Poor electrical terminal connection

2. Repair the circuit as necessary. Refer to Wiring Repairs in Wiring Systems.

Was a repair necessary?

--

Go to Step 15

Go to Step 13

15 |

1. Using the scan tool, clear the DTCs.
2. Start the engine.
3. Idle the engine at the normal operating temperature.
4. Operate the vehicle within the conditions for setting this DTC as specified in the supporting text.

Does the scan tool indicate that this diagnostic ran and passed?

--

Go to Step 16

Go to Step 2

16 | Check to see if any additional DTCs are set. Does the scan tool display any DTCs that you have not diagnosed? | -- | Go to the applicable DTC table | System OK