P0405-EGR POSITION SENSOR CIRCUIT LOW

For a complete wiring diagram Refer to Section 8W.

When Monitored:
With the ignition on. Battery voltage above 10.0 volts.
Set Condition:
EGR Position Sensor Signal is less than 0.1 of a volt. One trip Fault.

Possible Causes

(F856) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

(F856) 5-VOLT SUPPLY CIRCUIT OPEN

(K834) EGR SIGNAL CIRCUIT SHORTED TO GROUND

(K834) EGR SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND CIRCUIT

EGR POSITION SENSOR

PCM

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

Diagnostic Test

1.EGR POSITION SENSOR BELOW 0.2 OF A VOLT

Is the voltage below 0.2 of a volt?

Yes

Go To 2

Go To 9

2.(F856) 5-VOLT SUPPLY CIRCUIT

Is the voltage between 4.5 to 5.2 volts?

Yes

Go To 3

Go To 6

3.EGR POSITION

Is the voltage above 4.5 volts?

Yes

Replace the EGR Solenoid Assembly.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 4

4.(K834) EGR SIGNAL CIRCUIT SHORTED TO GROUND

Is the resistance below 100 ohms?

Yes

Repair the short to ground circuit in the (K834) EGR Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 5

5.(K834) EGR SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND CIRCUIT

Is the resistance below 100 ohms?

Yes

Repair the short between the (K900) Sensor ground and the (K834) EGR Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 8

6.(F856) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Is the resistance below 100 ohms?

Yes

Repair the short to ground in the (F856) 5-volt Supply circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 7

7.(F856) 5-VOLT SUPPLY CIRCUIT OPEN

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.

Is the resistance below 5.0 ohms?

Yes

Go To 8

Repair the open in the (F856) 5-volt Supply circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

8.PCM

NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

Were there any problems found?

Yes

Repair as necessary.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Replace and program the Powertrain Control Module per Service Information.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

9.EGR POSITION SENSOR SWEEP

NOTE: The engine will run rough and possibly stall in the following test. Feather the accelerator pedal to keep the engine from stalling.

Is the voltage change smooth?

Yes

Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Replace the EGR Solenoid Assembly.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)