An Exhaust Gas Recirculation (EGR) system is used to lower Oxides of Nitrogen (NOx) emission levels caused by high combustion temperatures. It accomplishes this by feeding small amounts of exhaust gases back into the combustion chamber. When the air/fuel mixture is diluted with the exhaust gases, 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 intake manifold vacuum. The valve controls 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 using inputs from the Throttle Position (TP) and Manifold Absolute Pressure (MAP) sensors. 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 its 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 is sent 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 Desired EGR Position . The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor circuit is closed. If the PCM detects an closed pintle this DTC will set.

Due to the moisture 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 desired EGR positions on a cold vehicle with a scan tool, the fault can be verified easily. Check the freeze frame data to determine if the DTC set when the vehicle was cold by viewing the Engine Coolant Temperature (ECT).

Number(s) below refer to the step number(s) on the Diagnostic Table.

1. The Powertrain OBD System Check prompts the technician to complete some basic checks and store the freeze frame and failure records data on the scan tool if applicable. This creates an electronic copy of the data taken when the malfunction occurred. The information is then stored on the scan tool 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. When the EGR valve electrical connector is disconnected, the scan tool should display the Actual EGR Position as 0%. If it does not, the malfunction lies either in the EGR signal circuit or the PCM.

5. If the EGR valve 5.0 volt reference is shorted to voltage, the DMM will read battery voltage and additional DTCs may be set and engine performance will be poor.

6. The replacement PCM must be reprogrammed and the crankshaft position system variation procedure must be performed. Refer to the latest Techline procedures for PCM reprogramming and the Powertrain Control Module Description portion of the service manual for the Crankshaft Position System Variation Procedure .

11. A poor electrical connection may have caused this DTC to set. The test light will still illuminate if the circuit is OK but the terminal connection was poor. Be sure to check the terminals for being backed out, improperly formed or damaged, and for poor tension.

13. 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 all gasket material is removed from the EGR mounting surface. Even a small amount of material may cause a DTC P0404 to set. Refer to the Exhaust Gas Recirculation Valve Replacement for theOn Vehicle Service of the EGR valve.

14. Check the terminals for being backed out, improperly formed or damaged, and for poor tension.

15. Clearing the DTCs is a very important step 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. The DTC must be cleared with the ignition switch ON, with the engine OFF or when the engine is idling. If the PCM sees a EGR command, the new pintle position will not be learned.

16. If no malfunctions have been found at this point and no additional DTCs were set, refer to the Diagnostic Aids for additional checks and information.