An exhaust gas recirculation (EGR) system is used in order to lower oxides of nitrogen (NOx) emission levels caused by high combustion temperatures. The EGR 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 in order 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 control module controlled pintle valve. The control module commands the EGR by applying a 12 volt duty cycle to the EGR valve. This can be monitored on a scan tool as desired EGR position.

The control module can monitor the pintle position with the EGR pintle position signal. This sensor uses a variable resistor with a 5 volt reference, a signal circuit, and a ground. The signal circuit monitors changes in voltage on the variable resistor as the pintle moves.

The VCM tests the EGR system during deceleration by momentarily commanding the EGR valve open. The pressure in the intake manifold increases when the EGR valve is open. The VCM monitors the manifold absolute pressure (MAP) sensor signal during the EGR system diagnostic in order to determine the amount of EGR flow. The MAP sensor will detect an increase in manifold pressure as the EGR is cycled ON. If the amount of manifold pressure observed is less than expected by the VCM, DTC P0401 will be set.

The following conditions will set the DTC:

The change in MAP is less than a calibrated value for more than 2 seconds.

Notice: In order to prevent further damage if the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged converter) using the procedure found on the restricted exhaust system check. If the exhaust system is restricted, repair the cause; one of which might be an injector which is open due to one of the following reasons:

Intermittent test: If the connections and the harness appear OK, monitor a digital voltmeter connected between the EGR control circuit and ground while moving the related connectors and wiring harness. If the failure is induced, the voltage reading will change.

An intermittent may be caused by any of the following conditions:

Thoroughly inspect any circuitry that is suspected of causing the intermittent complaint. Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

If a repair is necessary, refer to Wiring Repairs or Connector Repairs in Wiring Systems.

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

2. Correct any MAP sensor DTCs first.

3. This test ensures that the EGR valve is allowing EGR flow and the VCM is capable of controlling the EGR valve.

7. Clearing the DTCs is a very important step in this diagnostic procedure. The clearing function allows the EGR valve to relearn a new minimum pintle position, as the old position was inaccurate due to the malfunction that caused this DTC.