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DTC P0404: EGR Position Sensor Performance: Testing

  1. Turn ignition on, engine not running. With the DRBIII®, read DTCs and record the related Freeze Frame data. Is the Good Trip counter displayed and equal to zero? If yes, go to next step. If no, go to step  11.
    2. NOTE: Diagnose all other EGR DTC(s) first before continuing.
  2. Start the engine. With the DRBIII®, read the EGR Position Sensor voltage. If voltage is below 3.5 volts, go to next step. If voltage is between 3.5 volts and 4.3 volts, go to step  5. If voltage is above 4.3 volts, go to step  6.
    3. 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. Use Miller Special Tool (8815) when performing diagnosis at PCM harness connectors.
  3. Turn the ignition off. Disconnect the EGR Solenoid harness connector. Disconnect the PCM harness connectors. Measure the resistance of the 5-Volt Supply circuit from the EGR Solenoid harness connector to the appropriate terminal at Miller Special Tool. Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair the open/high resistance in the 5-Volt Supply circuit.
  4. Measure the resistance between ground and the EGR Sensor Signal circuit at the EGR Solenoid harness connector. Is the resistance below 5.0 ohms? If yes, repair the short to ground in the EGR Sensor Signal circuit. If no, replace EGR Solenoid assembly.
  5. Ensure the ignition is off. Reconnect the EGR Solenoid harness connector and the PCM harness connectors. Turn ignition on, engine not running. With the DRBIII®, actuate the EGR Solenoid. Allow the EGR Solenoid to actuate for at least 15 seconds. Feel the EGR Solenoid for operation. Stop actuation. Does the EGR Solenoid operate during actuation test and then turn off when actuation test was stopped? If yes, go to step  11. If no, go to DTC P0403: EGR CONTROL CIRCUIT .
  6. Turn the ignition off. Disconnect the EGR Solenoid harness connector. Turn ignition on, engine not running. Measure the voltage of the EGR Sensor Signal circuit at the EGR Solenoid harness connector. Is the voltage above 4.3 volts? If yes, go to next step. If no, go to step  8.
    7. 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. Use Miller Special Tool (8815) when performing diagnosis at PCM harness connectors.
  7. Turn the ignition off. Ensure the EGR Solenoid is disconnected. Disconnect the PCM harness connectors. Measure the resistance of the Sensor Ground circuit from the EGR Solenoid harness connector to the appropriate terminal at Miller Special Tool. Is the resistance below 5.0 ohms? If yes, replace the EGR Solenoid assembly. If no, repair the open in the Sensor Ground circuit.
  8. Measure the resistance of the EGR Sensor Signal circuit from the EGR Solenoid harness connector to the appropriate terminal at Miller Special Tool. Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair the open in the EGR Sensor Signal circuit.
  9. Measure the resistance between the EGR Solenoid Control circuit and the Sensor Ground circuit at the EGR Solenoid harness connector. Is the resistance below 5.0 ohms? If yes, repair the short to Sensor Ground circuit in the EGR Solenoid Control circuit. If no, go to next step.
  10. Measure the resistance between ground and the EGR Sensor Signal circuit at the EGR Solenoid harness connector. Is the resistance below 100 ohms? If yes, repair the short to ground in the EGR Sensor Signal circuit. If no, go to next step.
    11. NOTE: Before continuing, check the PCM harness connectors for corrosion, damage or terminal push out. Repair as necessary.
  11. There are no possible causes remaining, replace PCM. Program the new PCM. See PROGRAMMING .
    12. WARNING: When the engine is operating, do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing.
  12. The conditions that set the DTC are not present at this time. The following may help in identifying the intermittent condition. With the engine running at normal operating temperature, monitor the DRBIII® parameters related to the DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review the DRBIII® Freeze Frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. Were any of the above conditions present? If yes, repair as necessary. If no, test is complete.
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