DTC Troubleshooting

DTC P0404: EGR Valve Circuit Range/Performance Problem

NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting information.

1. Turn the ignition switch ON (II).
2. Clear the DTC with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm without load (in Park or neutral) until the radiator fan comes on, then let it idle.
4. Do the EGR TEST in the INSPECTION MENU with the HDS.

Is the result OK?

YES - Intermittent failure, the system is OK at this time. Clean any carbon build-up on the EGR valve with throttle plate and induction cleaner.

NO - Go to step 5.

5. Turn the ignition switch OFF.
6. Disconnect the EGR valve 6P connector.




7. At the sensor side, measure resistance between EGR valve 6P connector terminals No. 1 and No. 2.

Is there 100 k ohm or more?

YES - Go to step 26.

NO - Go to step 8.




8. Measure resistance between EGR valve 6P connector terminals No. 1 and No. 3.

Is there 100 k ohm or more?

YES - Go to step 26.

NO - Go to step 9.




9. Check for continuity between EGR valve 6P connector terminal No. 6 and body ground.

Is there continuity?

YES - Go to step 10.

NO - Repair open in the wire between the EGR valve and G101, then go to step 27.

10. Jump the SCS line with the HDS.
11. Disconnect ECM/PCM connector B (24P).




12. Check for continuity between ECM/PCM connector terminal B5 and body ground.

Is there continuity?

YES - Repair short in the wire between the ECM/PCM (B5) and the EGR valve, then go to step 27.

NO - Go to step 13.




13. Connect EGR valve 6P connector terminal No. 4 to body ground with a jumper wire.




14. Check for continuity between ECM/PCM connector terminal B5 and body ground.

Is there continuity?

YES - Go to step 15.

NO - Repair open in the wire between the ECM/PCM (B5) and the EGR valve, then go to step 27.

15. Remove the EGR valve.
16. Clean the intake manifold EGR port and the passage inside the EGR valve with throttle plate and induction cleaner.
17. Install the EGR valve.
18. Reconnect the EGR valve 6P connector.
19. Reconnect ECM/PCM connector B (24P).
20. Turn the ignition switch ON (II).
21. Reset the ECM/PCM with the HDS.
22. Do the ECM/PCM idle learn procedure.
23. Start the engine. Hold the engine speed at 3,000 rpm without load (in Park or neutral) until the radiator fan comes on, then let it idle.
24. Do the EGR TEST in the INSPECTION MENU with the HDS.

Is the result OK?

YES - Go to step 33.

NO - Go to step 25.

25. Turn the ignition switch OFF.
26. Replace the EGR valve.
27. Reconnect all connectors.
28. Turn the ignition switch ON (II).
29. Reset the ECM/PCM with the HDS.
30. Do the ECM/PCM idle learn procedure.
31. Start the engine. Hold the engine speed at 3,000 rpm without load (in Park or neutral) until the radiator fan comes on, then let it idle.
32. Do the EGR TEST in the INSPECTION MENU with the HDS.
33. Check for Temporary DTCs or DTCs with the HDS.

Is DTC P0404 indicated?

YES - Check for poor connections or loose terminals at the EGR valve and the ECM/PCM. If the connections and terminals are OK, go to step 35.

NO - Go to step 34.

34. Monitor the OBD STATUS for DTC P0404 in the DTCs MENU with the HDS.

Does the screen indicate PASSED?

YES - Troubleshooting is complete. If any other Temporary DTCs or DTCs were indicated in step 33, go to the indicated DTCs troubleshooting.

NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the ECM/PCM, then go to step 1 and recheck. If the screen indicates EXECUTING, keep driving until a result comes on. If the screen indicates OUT OF CONDITION, go to step 32.

35. Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM.
36. Do the EGR TEST in the INSPECTION MENU with the HDS.
37. Check for Temporary DTCs or DTCs with the HDS.

Is DTC P0404 indicated?

YES - Check for poor connections or loose terminals at the EGR valve and the ECM/PCM. If the ECM/PCM was updated, substitute a known-good ECM/PCM, then go to step 36. If the ECM/PCM was substituted, go to step 1.

NO - Go to step 38.

38. Monitor the OBD STATUS for DTC P0404 in the DTCs MENU with the HDS.

Does the screen indicate PASSED?

YES - If the ECM/PCM was updated, troubleshooting is complete. If the ECM/PCM was substituted, replace the original ECM/PCM. If any other Temporary DTCs or DTCs were indicated in step 37, go to the indicated DTCs troubleshooting.

NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the ECM/PCM. If the ECM/PCM was updated, substitute a known-good ECM/PCM, then go to step 36. If the ECM/PCM was substituted, go to step 1. If the screen indicates EXECUTING, keep driving until a result comes on. If the screen indicates OUT OF CONDITION, go to step 36.