Diagnostic Instructions
| • | Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. |
| • | Review Strategy Based Diagnosis for an overview of the diagnostic approach. |
| • | Diagnostic Procedure Instructions provides an overview of each diagnostic category. |
DTC Descriptor
DTC P0401: Exhaust Gas Recirculation (EGR) Flow InsufficientCircuit Description
The control module tests the exhaust gas recirculation (EGR) system during deceleration. The control module does this by momentarily commanding the EGR valve to open while monitoring the signal circuit of the manifold absolute pressure (MAP) sensor. When the EGR valve is opened, the control module will expect to see a predetermined increase in MAP. If the expected increase in MAP is not detected, the control module records the amount of MAP difference that was detected and adjusts a calibrated fail counter towards a calibrated fail threshold level. The number of EGR flow test counts required to exceed the fail threshold may vary according to the amount of detected EGR flow error.
The EGR valve position sensor is monitored by the control module. The 5-volt reference circuit, the low reference circuit, and the EGR valve position signal circuit are used by the control module to determine the EGR valve position. The control module compares the EGR Position Sensor parameter with the desired EGR Position parameter when the valve is commanded open or closed.
The control module controls the EGR valve with a solid state device called a driver. The driver supplies the EGR solenoid with 12 volts that is pulse width modulated (PWM) through the EGR solenoid high control circuit. A ground path is provided by the control module through the EGR solenoid low control circuit. The driver has the ability to detect an electrical malfunction on the EGR solenoid control circuits.
When the ignition switch is turned ON, the control module records the EGR Learned Minimum Position. The control module compares the EGR Learned Minimum Position parameter to the EGR Position Sensor parameter.
The control module will only allow one EGR flow test during an ignition cycle. To aid in verifying a repair, the control module will allow between 9 and 16 EGR flow test counts during the first ignition cycle following a code clear event.
Conditions for Running the DTC
| • | DTCs P0016, P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0112, P0113, P0117, P0118, P0120, P0121, P0122, P0123, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0335, P0336, P0403, P0404, P0405, P042E, P0502, P0503, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2128, P2135, P2138 are not set. |
| • | The engine run time may need to be more than 3 minutes. |
| • | The Ignition 1 Signal parameter is between 11-18 volts. |
| • | The AC Relay Command parameter does not change. |
| • | The EGR position is less than 1 percent. |
| • | The transmission is in third or fourth gear. |
| • | The Current Gear parameter does not change. |
| • | The decel fuel cut-off (DFCO) mode is not active. |
| • | The Intake Air Temperature (IAT) sensor parameter is between 7-100°C (44.6-212°F). |
| • | The Engine Coolant Temperature (ECT) sensor parameter is between 75-150°C (167-302°F). |
| • | The Engine Speed parameter is between 1,000-1,500 RPM. |
| • | The Manifold Absolute Pressure (MAP) sensor parameter is between 17-43 kPa. |
| • | The Barometric Pressure (BARO) parameter is more than 74 kPa. |
| • | The Throttle Position (TP) sensor parameter is less than 1 percent. |
| • | The Vehicle Speed sensor parameter is between 45-113 km/h (28-70 mph) during deceleration. |
| • | The vehicle will need to be driven more than 80 km/h (50 mph), and then allowed to decelerate. When the vehicle is decelerating, while meeting all of the criteria listed above, the PCM will enable the EGR flow test to run. As the EGR flow test is running, you will see the desired EGR Position parameter and the EGR Position Sensor parameter on the scan tool momentarily change from 0 to a calibrated value above 0. Additionally, the EGR Flow Test Count parameter on the scan tool will increment when each EGR flow test is completed. |
Conditions for Setting the DTC
The MAP changes monitored by the PCM during the EGR flow tests indicate an insufficient amount of EGR flow.
Action Taken When the DTC Sets
DTC P0401 is a Type A DTC.
Conditions for Clearing the MIL/DTC
DTC P0401 is a Type A DTC.
Reference Information
Description and Operation
Exhaust Gas Recirculation (EGR) System Description
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Circuit/System Verification
- If DTCs P0107, P0108, P0403, P0404, P0405, or P0406 are also set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for further diagnosis.
- If the vehicle passes the Circuit/System Verification, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records data list.
Circuit/System Testing
- Verify the following conditions are not present:
- If all conditions test normal, replace the EGR valve.
| • | Incorrect EGR valve for engine application |
| • | A vacuum leak between the EGR valve and the intake manifold |
| • | Signs of external leakage usually indicated by carbon buildup around the mating surfaces of the components or an audible exhaust noise |
| • | Restrictions in the passages or EGR valve caused by carbon deposits or casting flash |
| • | MAP sensor for being shifted, stuck, skewed, and for correct vacuum supply--Refer to DTC P0106 . |
| Important: Restrictions can cause excessive back pressure and low engine vacuum . |
| • | Leaking, restricted, or modified exhaust system |
| • | Mechanical failure in the engine such as worn piston rings, camshaft, or incorrect timing components installation--Refer to Symptoms - Engine Mechanical . |
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
