P0401-EGR SYSTEM PERFORMANCE





For a complete wiring diagram Refer to Section 8W.

Theory of Operation


Exhaust gas recirculation is a method of reducing emissions of oxides of nitrogen. As the inert exhaust gas is recirculated, the mixture absorbs heat in the combustion chamber without interacting with the fuel/air mixture and reduces the formation of NOx emissions. After the EGR monitor conditions are met, the EGR valve is turned on and off momentarily. The EGR monitor calculated the difference in engine roughness from the EGR off condition to the EGR condition. This engine combustion stability difference as measured by engine roughness is the measure of a functional EGR system.


Possible Causes
(Z906) EGR SOLENOID GROUND CIRCUIT OPEN
(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K35) EGR SOLENOID CONTROL CIRCUIT OPEN
EGR SOLENOID ASSEMBLY
PCM


Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).



Diagnostic Test

1. ACTIVE DTC

Start the engine.
Allow the engine to reach normal operating temperature.
With a scan tool, select View DTCs.

NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data.



Is the DTC Active or Pending at this time?

Yes


No

2. EGR OPERATION

NOTE: If the vehicle is running rough at idle (scan tool not actuating) follow the yes path to continue.


Turn all accessories off.
Start the engine.
Allow the engine to reach normal operating temperature.
With the scan tool, enter Engine System Test, then EGR System Test.
Actuate the FLOW function in the EGR System Test.

Did the engine run rough or stall?

Yes


No

3. EGR VALVE OPEN AT IDLE

Turn the ignition off.
Disconnect the EGR Solenoid Assembly harness connector.
Start engine. Attempt to allow the engine to idle.

Does the engine run rough or stall?

Yes


No

4. EGR VALVE ASSEMBLY INSPECTION

Inspect the EGR Assembly for the following.
Gasket(s) for leaking
Damage and/or holes in the EGR tube(s)
Carbon build up on or near the EGR pintle and passage ways.
Obstruction in the EGR tubes.

Were any problem found?

Yes


No

5. (K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE



Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Ignition on, engine not running.
Measure the voltage on the (K35) EGR Solenoid Control circuit in the EGR Solenoid connector.

Is the voltage above 1.0 volt?

Yes


No

6. EGR SOLENOID ASSEMBLY



Disconnect the EGR Solenoid harness connector.
Using a 12-volt test light, jump across the (K35) EGR Solenoid Control terminal and the (Z906) Ground terminal in the EGR Solenoid harness connector.
With the scan tool, actuate the EGR solenoid.

Does the 12-volt test light flash on and off?

Yes


No

7. (Z906) EGR SOLENOID GROUND CIRCUIT OPEN



Turn the ignition off.
Using a 12-volt test light connected to battery voltage, probe the (Z906) EGR Solenoid ground circuit in the EGR Solenoid harness connector.

Does the 12-volt test light illuminate brightly?

Yes


No

8. (K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND



Disconnect the C2 PCM harness connector.
Measure the resistance between ground and the (K35) EGR Solenoid Control circuit in the EGR Solenoid harness connector.

Is the resistance below 100 ohms?

Yes


No

9. (K35) EGR SOLENOID CONTROL CIRCUIT OPEN


CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install Miller Special Tool #8815 to perform diagnosis.


Measure the resistance of the (K35) EGR Solenoid Control circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?

Yes


No

10. PCM

NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.


Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.

Were there any problems found?

Yes


No