For 1990-2009 cars

### Circuit Description

The powertrain control module (PCM) monitors the exhaust gas recirculation (EGR) valve pintle position input to ensure that the valve responds properly to commands from the PCM. The PCM compares the EGR position sensor with desired EGR position when the valve is commanded open. If the difference between the EGR position sensor and Desired EGR position is more than 15 percent, this diagnostic trouble code (DTC) will set.

### Conditions for Running the DTC

• | The ignition voltage is greater than 11 volts.

• | The EGR valve is commanded to open.

### Conditions for Setting the DTC

• | The difference between the EGR position sensor and the desired EGR position is more than 15 percent.

• | The condition is present for more than 20 seconds.

### Action Taken When the DTC Sets

• | The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails.

• | The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.

### Conditions for Clearing the MIL/DTC

• | The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail.

• | A current DTC, Last Test Failed, clears when the diagnostic runs and passes.

• | A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic.

• | Clear the MIL and the DTC with a scan tool.

### Diagnostic Aids

Inspect for the following conditions:

Excessive deposits on the EGR pintle or seat--Remove the EGR valve and inspect for deposits that may interfere with the EGR valve pintle extending completely or cause the pintle to stick.

If the condition is intermittent, refer to Intermittent Conditions .

### Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. This step verifies that the malfunction is present.

2. If DTC P0404 will only set under certain conditions, the malfunction may be intermittent. Refer to Diagnostic Aids. If an intermittent wiring condition is not present, test for a faulty connection at the PCM or the EGR valve. If the connections are OK and DTC P0404 continues to set, replace the EGR valve.

Step | Action | Values | Yes | No
--- | --- | --- | --- | ---
Schematic Reference: Engine Controls Schematics
1 | Did you perform the Diagnostic System Check-Engine Controls? | -- | Go to Step 2 | Go to Diagnostic System Check - Engine Controls
2 | Important: If any of the following DTCs are set, diagnose the other DTC first.

• | Refer to DTC P0403

• | Refer to DTC P0405

1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. With a scan tool, command the EGR valve from 0 percent to 100 percent.

Does the EGR position sensor remain within 15 percent of the Desired EGR position at all commanded positions?

--

Go to Step 3

Go to Step 4

3 |

1. Observe the Freeze Frame/Failure Records data for this DTC.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text or as close to the Freeze Frame/Failure Records data that you observed.

Does the DTC fail this ignition?

--

Go to Step 4

Go to Diagnostic Aids

4 |

1. Turn OFF the ignition.
2. Disconnect the EGR valve connector.
3. Turn ON the ignition, with the engine OFF.
4. With a scan tool, observe the EGR position sensor parameter.

Does the scan tool indicate that the EGR position sensor is at the specified value?

0%

Go to Step 5

Go to Step 8

5 | Measure the voltage from the 5-volt reference circuit of the EGR position sensor to the low reference circuit of the EGR position sensor. Does the DMM display voltage near the specified value? | 5 V | Go to Step 6 | Go to Step 7
6 | Important: : If the fuse opens, locate and repair a short to ground in the signal circuit. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Connect a fused jumper between the 5-volt reference circuit of the EGR position sensor and the EGR valve position signal circuit of the EGR position sensor.

Does the scan tool indicate that the EGR position sensor is near the specified value?

100%

Go to Step 12

Go to Step 10

7 | Measure the voltage from the 5-volt reference circuit of the EGR position sensor to a good ground. Does the DMM display voltage near the specified value? | 5 V | Go to Step 9 | Go to Step 11
8 | Test the EGR valve position signal circuit 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 16 | Go to Step 13
9 | Test the low reference circuit 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 16 | Go to Step 13
10 | Test the EGR valve position signal circuit for high resistance or a high resistance short to ground. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 13
11 |

1. Test the 5-volt reference circuit of the EGR position sensor for an open, a short to ground, or a short to voltage.
2. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 16

Go to Step 13

12 | Inspect for poor connections at the harness connector of the EGR valve. 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 16 | Go to Step 14
13 | Inspect for poor connections at the harness connector of the PCM. 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 16 | Go to Step 15
14 | Replace the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement . Did you complete the replacement? | -- | Go to Step 16 | --
15 | Replace the PCM. Refer to Powertrain Control Module Replacement . Did you complete the replacement? | -- | Go to Step 16 | --
16 |

1. Use the scan tool in order to clear the DTCs.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text.

Does the DTC run and pass?

--

Go to Step 17

Go to Step 2

17 | With a scan tool, observe the stored information, Capture Info. Does the scan tool display any DTCs that you have not diagnosed? | -- | Go to Diagnostic Trouble Code (DTC) List | System OK