P0404

Circuit Description
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 Control Module (PCM/VCM) 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 will set a DTC P0404 if it detects a large enough difference between desired EGR position and actual EGR pintle position.

Conditions for Running the DTC
The ignition voltage is more than 5 volts

Conditions for Setting the DTC
The difference between the actual EGR position and the desired EGR position is more than 10 percent for more than 10 seconds.

Action Taken When the DTC Sets
^ The Control Module illuminates the Malfunction Indicator Lamp (MIL) if a failure is detected during 2 consecutive key cycles.
^ The Control Module will set the DTC and records the operating conditions at the time the diagnostic fails. The Control Module stores the failure information in the scan tools Freeze Frame and/or the Failure Records.

Conditions for Clearing the MIL/DTC
^ The Control Module turns OFF the MIL after 3 consecutive drive trips when the test has Run and Passed.
^ A history DTC will clear if no fault conditions have been detected for 40 warm-up cycles (coolant temperature has risen 22°C (40°F) from the start-up coolant temperature and the Engine Coolant Temperature is more than 70°C (158°F) during the same ignition cycle).
^ Use the scan tool Clear Information function.

Diagnostic Aids
Excessive carbon deposits may cause a restriction of movement in the EGR pintle. This problem may be compounded in cold weather with moisture freezing in the valve. Check for full range operation in the EGR system with the scan tool.

Check for excessive exhaust back pressure. Refer to Restricted Exhaust System Check.

An intermittent may be caused by any of the following conditions:
^ A poor connection
^ Rubbed through wire insulation
^ A broken wire inside the insulation

Thoroughly check any circuitry that is suspected of causing the intermittent complaint. Refer to Intermittents and Poor Connections Diagnosis.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step will determine if the VCM can control the EGR valve.
3. Commanding the EGR valve to the specified values determines whether the VCM can control the EGR accurately. Production variations may not allow the EGR valve to be commanded to 100 percent.
12. There are certain circuits in the VCM C4 connector that could cause a short to voltage to the EGR valve control circuit that may disappear when the C4 connector is disconnected. Checking each individual circuit for a short to the EGR valve control circuit with a DMM will confirm if such a condition exists.
13. If the EGR valve 5 volt reference is shorted to voltage, the DMM will read battery voltage and additional DTCs may be set.
21. A problem may exist within the terminals which would not show up in probe type testing. Be sure to check the terminals for being backed out, improperly formed or damaged.
23. A problem may exist within the terminals which would not show up in probe type testing. Be sure to check the terminals for being backed out, improperly formed, or damaged.