P0405

P0405-EGR POSITION SENSOR CIRCUIT LOW

For a complete wiring diagram Consult Diagrams/Electrical

- When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.

- Set Condition:
The PCM detects that the EGR Valve Assembly input voltage is below the minimum acceptable value.

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.Initial Inspection and Diagnostic Overview

Diagnostic Test

1. DTC IS ACTIVE
Start the engine and allow it to reach normal operating temperature.

WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in personal injury or death.

NOTE: Diagnose and repair any system voltage or sensor supply voltage DTCs before continuing with this test.

With the scan tool, select View DTCs.
Is the DTC Active at this time?

Yes

- Go to 2

No

- Refer to the *CHECKING FOR AN INTERMITTENT DTC Diagnostic Procedure. Checking For An Intermittent DTC

2. (F856) 5 VOLT SUPPLY CIRCUIT VOLTAGE

Turn the ignition off.
Disconnect the EGR Valve Assembly connector.
Turn the ignition on.
Measure the voltage of the (F856) 5 Volt Supply circuit in the EGR Valve Assembly harness connector.
Is the voltage above 4.5 volts?

Yes

- Go to 6

No

- Go to 3

3. (F856) 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Turn the ignition on.
Disconnect the C1 and C2 Powertrain Control Module (PCM) connectors.
Measure the resistance between ground and the (F856) 5 Volt Supply circuit in the EGR Valve Assembly harness connector.
Is the resistance above 100 ohms?

Yes

- Go to 4

No

- Repair the short to ground in the (F856) 5 Volt Supply circuit.
- Perform the PCM Verification Test. Powertrain Verification Test

4. (F856) 5 VOLT SUPPLY CIRCUIT SHORTED TO (K900) SENSOR GROUND CIRCUIT

Measure the resistance between the (F856) 5 Volt Supply circuit and the (K900) Sensor Ground circuit in the EGR Valve Assembly harness connector.
Is the resistance above 100 ohms?

Yes

- Go to 5

No

- Repair the short between the (F856) 5 Volt Supply circuit and the (K900) Sensor Ground circuit.
- Perform the PCM Verification Test. Powertrain Verification Test

5. (F856) 5 VOLT SUPPLY CIRCUIT OPEN OR HIGH RESISTANCE

Turn the ignition off.
Disconnect the C2 Powertrain Control Module (PCM) connector.
Measure the resistance between ground and the (K34) EGR Signal circuit in the EGR Valve Assembly harness connector.
Is the resistance above 100 ohms?

Yes

- Go to 7

No

- Repair the short to ground in the (K34) EGR Signal circuit.
- Perform the PCM Verification Test. Powertrain Verification Test

7. (K34) EGR SIGNAL CIRCUIT SHORTED TO (K900) SENSOR GROUND CIRCUIT

Measure the resistance between the (K34) EGR Signal circuit and the (K900) Sensor Ground circuit in the EGR Valve Assembly harness connector.
Is the resistance above 100 ohms?

Yes

- Go to 8

No

- Repair the short between the (K34) EGR Signal circuit and the (K900) Sensor Ground circuit.
- Perform the PCM Verification Test. Powertrain Verification Test

8. EXCESSIVE RESISTANCE IN THE (K34) EGR SIGNAL CIRCUIT

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 (K34) EGR Signal circuit between the EGR Valve Assembly harness connector and the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?

Yes

- Go to 9

No

- Repair the excessive resistance in the (K34) EGR Signal circuit.
- Perform the PCM Verification Test. Powertrain Verification Test

9. EGR VALVE ASSEMBLY
Turn the ignition off.
Connect the C2 Powertrain Control Module (PCM) connector.
Turn the ignition on.
With the scan tool, read the EGR Valve Assembly signal voltage.

NOTE: The sensor voltage should be approximately 5.0 volts (plus or minus.1 volt) with the connector disconnected.

Does the scan tool display the voltage as described above?

Yes

- Verify that there is good pin to terminal contact in the Solenoid and the Powertrain Control Module connectors. If OK, replace the EGR Valve Assembly.
- Perform the PCM Verification Test. Powertrain Verification Test

No

- Go to 10

10. POWERTRAIN CONTROL MODULE (PCM)
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the EGR Valve Assembly and the Powertrain Control Module (PCM).
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out or corroded terminals.
Verify that there is good pin to terminal contact in the Solenoid and the Powertrain Control Module connectors.
Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
Look for the data to change or for the DTC to reset during the wiggle test.
Search for any Technical Service Bulletins that may apply.
Were any problems found?

Yes

- Repair as necessary.
- Perform the PCM Verification Test.Powertrain Verification Test

No

- Replace and program the Powertrain Control Module (PCM).
- Perform the PCM Verification Test.Powertrain Verification Test