GM Service Manual Online
For 1990-2009 cars only

Diagnostic Instructions

    • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
    • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
    •  Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0403:  Exhaust Gas Recirculation (EGR) Solenoid Control Circuit

DTC P046C:  Exhaust Gas Recirculation (EGR) Position Sensor Performance

Diagnostic Fault Information

Circuit

Short to Ground

High Resistance

Open

Short to Voltage

Signal Performance

EGR 5-Volt Reference Voltage

P0107, P0698, P2564

P0102, P0401, P046C

P0405

P0106, P0699, P2227, P2565

--

EGR Sensor Signal

P0405

P0101, P0405

P0405

P0406

--

EGR Low Reference

--

P0401, P046C

P0406

--

--

EGR MTR High Control

P0403

P0401, P046C

P0403

P046C

--

EGR MTR Low Control

P0403, P046C

P0401, P046C

P0403

P0403

--

Typical Scan Tool Data

EGR Position Sensor

Circuit

Short to Ground

Open

Short to Voltage

Operating Conditions: Engine running, ECT sensor is less than 60°C (140°F)

Parameter Normal Range: 0.98 Volts

EGR 5-Volt Reference Voltage

0 Volts

0 Volts

1.29 Volts

EGR Sensor Signal

0 Volts

0 Volts

4.98 Volts

EGR Low Reference

--

4.8 Volts

--

Circuit/System Description

The engine control module (ECM) uses the exhaust gas recirculation (EGR) position sensor to determine the position of the EGR valve. The ECM sends a reference voltage through the 5-volt reference circuit to the EGR position sensor. The ECM provides a voltage return path for the sensor through the low reference circuit. A variable voltage signal, based on the EGR valve position , is sent from the sensor to the ECM through the EGR position sensor signal circuit. The ECM compares the actual EGR position with the desired EGR position when the EGR valve is commanded open or closed.

The EGR valve is controlled by the ECM through the EGR motor high control and the EGR motor low control circuits. The ECM supplies voltage that is near ignition voltage to the high and low control circuits at all times. The ECM will pulse width modulation (PWM) the low control circuit to ground when EGR is desired. The lower the pulse width, the more the valve will open. The ECM will PWM the high control circuit to ground when the EGR valve is desired closed.

Conditions for Running the DTC

P0403

    • The engine is running for more than 0.5 second.
    • The EGR duty cycle is more than 10 percent.
    • DTC P0403 runs continuously when the above conditions are met.

P046C

    • DTCs P0401, P0402, P0403, P0642, or P0643 are not set.
    • The EGR valve is actively being controlled.
    • DTC P046C runs continuously when the above conditions have been met.

Conditions for Setting the DTC

P0403

    • The ECM detects an electrical malfunction on an EGR motor control circuit.
    • The above condition is present for more than 30 seconds.

P046C

    • The difference between the actual EGR position and the desired EGR position is more than 3 percent.
    • The above condition is present for more than 5 seconds.

Action Taken When the DTC Sets

    • DTCs P0403 and P046C are Type B DTCs.
    • Diesel particulate filter (DPF) regeneration is inhibited.

Conditions for Clearing the DTC

DTCs P0403 and P046C are Type B DTCs.

Reference Information

Schematic Reference

Engine Controls Schematics

Connector End View Reference

    •  Engine Control Module Connector End Views
    •  Engine Controls Connector End Views

Electrical Information Reference

    •  Circuit Testing
    •  Connector Repairs
    •  Testing for Intermittent Conditions and Poor Connections
    •  Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

    •  Scan Tool Data List
    •  Scan Tool Data Definitions
    •  Scan Tool Output Controls

Special Tools

EN-48565 EGR Test Harness

Circuit/System Verification

Important: If you cannot duplicate the condition, operate the vehicle within the conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records.

  1. Command the EGR valve to 30 percent with a scan tool. The commanded EGR position and the Actual EGR position should match.
  2. Engine running, observe the DTC information with a scan tool. DTCs P0403 or P046C should not set.
  3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame Records data.

Circuit/System Testing

Important: 

   • You must perform the Circuit/System Verification before proceeding with Circuit/System Testing.
   • Always replace the EGR valve gaskets when removal or replacement of the component is necessary.

  1. Turn OFF the ignition. Disconnect the EGR valve. Install the EN-48565 between the EGR valve and the harness connector.
  2. Turn ON the ignition. Command the EGR valve to 40 percent and back to 0 percent. The EGR test harness lamp should turn ON between 10 percent and 40 percent, and turn OFF at 0 percent.
  3. If the lamp does not turn ON and OFF, test both motor control circuits for an open/high resistance, short to voltage, or short to ground. If the circuits test normal, replace the control module.
    If the lamp turns ON and OFF, replace the EGR valve and EGR gaskets.

Repair Instructions

    •  Exhaust Gas Recirculation Valve Replacement
    •  Control Module References for ECM replacement, setup, and programming

Repair Verification

  1. Install any components or connectors that have been removed or replaced during diagnosis.
  2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced.
  3. Clear the DTCs.
  4. Turn OFF the ignition for 90 seconds.
  5. Duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate diagnostic procedure.
  6. Perform the Diesel Particulate Filter (DPF) Service Regeneration.