P0404-EGR POSITION SENSOR RATIONALITY OPEN





For a complete wiring diagram Refer to Section 8W.

Theory of Operation


The EGR valve has a position sensor and the EGR position rationality is designed to make sure that the valve moves freely within its operating range. Closed valve position reference check verifies that the valve is within its allowable upper and lower limits. The EGR position rationality test looks for a sustained error relative to commanded valve position.


Possible Causes
(K34) EGR SENSOR SIGNAL CIRCUIT OPEN
(K34) EGR SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE
(K900) SENSOR GROUND 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 SOLENOID ASSEMBLY

Ignition on, engine not running.
With the scan tool, actuate the EGR Solenoid.
Allow the EGR Solenoid to actuate for at least 15 seconds.
Feel the EGR Solenoid for operation.
Stop actuation.

Does EGR Solenoid operate while actuating and then turn off when actuation test is stopped?

Yes


No

3. (K34) EGR SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE



Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the C2 PCM harness connector.
Ignition on, engine not running.
Measure the voltage of the (K34) EGR Sensor Signal circuit in the EGR Solenoid harness connector.

Is the voltage above 1.0 volt?

Yes


No

4. (K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE



Measure the voltage on the (K35) EGR Solenoid Control circuit at the EGR Solenoid harness connector.

Is the voltage above 1.0 volt?

Yes


No

5. (K900) SENSOR GROUND CIRCUIT OPEN



Turn the ignition off.

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 (K900) Sensor ground circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?

Yes


No

6. (K34) EGR SENSOR SIGNAL CIRCUIT OPEN



Measure the resistance of the (K34) EGR Sensor Signal circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?

Yes


No

7. 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