Service Engine Soon (SES) Light Illuminated, Multiple Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) P1404 and/or P0404 (Install EGR Valve Kit and Reprogram PCM)

This bulletin is being revised to update the information in the first Important statement in the Correction section. Please discard Corporate Bulletin Number 06-06-04-002A (Section 6 - Engine).

Some customers may comment on a Service Engine Soon (SES) light illuminated on the instrument cluster. Some vehicles may have previously been serviced for this same condition. Technicians may also find a DTC P1404 and/or DTC P0404 which may have led to previous EGR valve and PCM replacements.

Important: The EGR valve kit, P/N 89018175, has the following parts required to perform an EGR System changeover for the vehicles listed in this bulletin only. Please be advised that some early produced kits may contain an instruction sheet that has an error in the wiring portion of the procedure. Therefore, it is advised that the instructions included in the kit be discarded and that only the instructions contained in the bulletin be used.

Important: This EGR valve kit is used to convert a Delphi EGR valve equipped LX9 engine used in the Chevrolet Malibu and Pontiac G6 to a Siemens valve. This kit contains all necessary parts for conversion. The powertrain control module (PCM) calibration must be updated for the Siemens EGR valve to work correctly. Failure to install an updated calibration when using this conversion kit may cause PCM diagnostic codes to set, resulting in a "Service Engine Soon" indicator lamp to illuminate.

EGR Valve Identification

Refer to the illustrations below. Siemens EGR valves have a horizontal electrical connector. Delphi EGR valves have a vertical electrical connector. If a Siemens valve is already installed, it is not necessary to install this kit. Individual components are serviced.

Install the parts listed in this bulletin using the following procedure:

1. Disconnect the negative battery cable at the battery.



2. Remove the exhaust gas recirculation (EGR) valve pipe bolt .
3. Remove the EGR pipe assembly bolts from the exhaust manifold.
4. Remove the EGR pipe.



5. Disconnect the exhaust gas recirculation (EGR) valve harness electrical connector.
6. Remove the EGR valve bolts.
7. Remove the EGR valve.
8. Remove the EGR valve gasket.

Important: Remove all old gasket material from intake manifold with a gasket scraper.

9. Clean and inspect the EGR valve gasket mating surfaces.
10. Install a new EGR valve gasket, P/N 12593632.
11. Install the new EGR valve, P/N 12581876.



12. Install the original EGR valve bolts.

Tighten:
EGR valve bolts to 25 N·m(18 lb ft).

13. Install the new EGR valve pipe assembly, P/N 12586606, to the EGR valve and to the exhaust manifold.



14. Install the new EGR pipe bolts to the exhaust manifold.

Tighten:
EGR pipe bolts to the exhaust manifold to 25 N·m(18 lb ft).

15. Install the original EGR pipe bolt to the EGR valve.

Tighten:
EGR pipe bolt to the EGR valve to 30 N·m(22 lb ft).

Important: In the following steps, care must be taken to prevent cross-wiring of the two gray colored EGR wire leads (located at pin A and pin D). Cross-wiring will result in an MIL to be set. Before cutting the wiring harness leads, mark the gray leads using tape so the location will be remembered on assembly.

16. Take the disconnected exhaust gas recirculation (EGR) valve harness electrical connector and cut the wires directly at the base of the connector. Open the EGR electrical conduit to expose the wire leads.
17. Strip approximately 6 mm (1/4 in) of insulation from all five EGR circuit harness connector wires

Important: Refer to this bulletin for the Exhaust Gas Recirculation (EGR) Valve Wiring Harness Connector End View schematic for the installation of the new EGR Valve Wiring Harness Connector, P/N 15306175.

Important: Use splice seal connectors supplied in the wiring harness kit (P/N 15306175) when replacing the EGR Valve Wiring Harness Connector.

18. Install the new EGR valve wiring harness connector, P/N 15306175 (includes splice connectors, terminals and wire leads), to the existing engine wiring harness.
19. Use a heat gun to shrink the tubing and set the glue in the connectors.
20. Wrap the new EGR valve wiring harness leads with electrical tape and secure them into the EGR valve electrical harness conduit.
21. Connect the EGR valve electrical connector.
22. Reprogram the PCM with the latest calibrations for the EGR system changeover. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate SI procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 1.0, which was broadcast to dealers on 1/8/06. For dealerships that use CDs, they will be mailed on 1/15/06. As always, make sure your Tech®2 is updated with the latest software version.

For vehicles repaired under warranty, use: