Exhaust Gas Recirculation (EGR) System Diagnosis. Chevrolet Chevy G Van 1996

For 1990-2009 cars only

Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy G Van 🢒 Engine 🢒 Engine Controls - 5.0L, 5.7L, and 7.4L 🢒 Exhaust Gas Recirculation (EGR) System Diagnosis

Exhaust Gas Recirculation (EGR) System Diagnosis Table with Linear EGR Valve

Circuit Description

In order to control the Exhaust Gas Recirculation (EGR), the control module operates the linear EGR valve. The linear EGR valve is a small motor with a pintle that is normally closed. By providing a ground path, the control module will open the pintle and allow the exhaust gasses to pass through the valve. The control module of the EGR is based on the following inputs:

•	The engine coolant temperature - above 25°C.

•	The TP OFF idle

•

MAP

•

BARO

•	Park/Neutral position

•	The pintle position sensor.

If DTC P0401 or P1406 is stored, refer to the applicable DTC table. This chart is used for a malfunctioning valve, plugged EGR passages, or improper wiring connections.

Test Description

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

At idle, the EGR valve should not be open greater than 3%. A faulty park/neutral position Trans Range (TR) position pressure switch or the EGR valve stuck open will allow exhaust gasses to enter the combustion chamber and create a rough idle condition.

This step checks the ability of the pintle to be manually commanded to the desired positions.

This step checks the electrical circuit of the EGR valve and connecting components.

This step checks for plugged EGR passages or a faulty EGR valve.

EGR System Check With Linear EGR Valve

Step	Action	Value(s)	Yes	No
1	Was the Powertrain On-Board Diagnostic (OBD) System Check performed?	--	Go to Step 2	Go to Powertrain On Board Diagnostic (OBD) System Check
2	Set the parking brake and block the drive wheels. Install a scan tool. Check the Transmission Range (TR) switch position. Have the engine idling at the normal operating temperature. With a scan tool command the EGR pintle position to the specified value. Increase the RPM to specified value. Is the actual EGR pintle position greater than the specified value?	0% 2000 RPM 3%	Go to Step 15	Go to Step 3
3	With a scan tool command a 25% position step increase (0% To 25%, 25% To 50%, 50% To 75%, 75% To 100%). 2. Observe the MAP and actual EGR pintle position for the specified value. The EGR should increase by about 25% of position, and the MAP should also increase. Is the actual EGR pintle position stable, and within 10% of position of desired EGR pintle position command after the specified value?	3 sec 2 sec	Go to Step 4	Go to Step 6
4	Set the EGR pintle position to the specified value. Did the MAP increase when the actual pintle responded?	25%	Go to Step 5	Go to Step 13
5	Set desired EGR pintle position to specified value. Is the desired EGR pintle position at the specified value?	100%	--	Go to Step 14
6	Check the fuse. Replace the fuse if necessary. Is the action complete?	--	Go to Step 16	Go to Step 7
7	Check for any open circuits in wiring to EGR valve coil. Repair if necessary. Refer to Wiring Repairs in Engine Electrical. Is the action complete?	--	Go to Step 16	Go to Step 8
8	Check for any faulty connections to the EGR valve coil. Repair if necessary. Refer to Wiring Repairs in Engine Electrical. Is the action complete?	--	Go to Step 16	Go to Step 9
9	Connect the J 39200 DVM. Check for reference the voltage at EGR valve. Is the voltage at the specified value?	5 V	Go to Step 10	Go to Step 11
10	Turn ON the ignition leaving the engine off. Remove the EGR valve, leaving the connector on. Push in the pintle of EGR valve. Hold in the pintle of EGR valve. Check for voltage at position sensor signal from valve. Is any voltage present?	--	Go to Step 11	Go to Step 14
11	Check for an open in circuit from control module to EGR valve in the pintle position circuit. Repair if necessary. Refer to Refer to Wiring Repairs in Engine Electrical. Is the action complete?	--	Go to Step 16	Go to Step 12
12	Replace the control module. Refer to VCM Replacement/Programming (With KS Calibration PROM) . Is the action complete?	--	Go to Step 16	--
13	Check the EGR valve passages for blockages. Repair if necessary. Is the action complete?	--	Go to Step 16	--
14	Replace the EGR valve. Refer to EGR Valve Replacement for the 4.3L, 5.0L, 5.7L. Refer to Exhaust Gas Recirculation Valve Replacement for the 7.4L. Is the action complete?	--	Go to Step 16	--
15	EGR valve is stuck open. Replace the EGR valve. Refer to EGR Valve Replacement for the 4.3L, 5.0L, 5.7L. Refer to Exhaust Gas Recirculation Valve Replacement for the 7.4L. Is the action complete?	--	Go to Step 16	--
16	Turn ON the ignition leaving the engine off. Using a scan tool, command the component ON and off. Does the component operate properly?	--	System OK	Go to Step 1

Exhaust Gas Recirculation (EGR) System Diagnosis EGR Valve Overview

Results Of Incorrect Operation

With too much EGR flow at idle, cruise, or cold operation, any of the following conditions may occur:

•	The engine stops after a cold start.

•	The engine stops at idle after deceleration.

•	The vehicle surges during cruise.

•	The vehicle idles roughly..

If the EGR valve stays open all of the time, the engine may not idle. A DTC P0401 may set. Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient for the 4.3L engine. Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient for V8 applications.

Too little or no EGR flow allows the combustion temperatures to get too high during acceleration and load conditions. This could cause the following conditions:

•	Spark knock (detonation)

•	Engine overheating

•

DTC P0401

System Check

The Linear EGR System Check table covers the diagnosis of the EGR system. Refer to EGR System Diagnosis (System Check) for V6. Refer to EGR System Diagnosis (System Check) for V8.