P0403-EGR SOLENOID CIRCUIT

For a complete wiring diagram Refer to Section 8W.

When Monitored:
Engine running. Battery voltage greater than 10 volts.
Set Condition:
The EGR solenoid control circuit is not in the expected state when requested to operate by the PCM. One Trip Fault.

Possible Causes

(Z42) EGR SOLENOID GROUND CIRCUIT OPEN

(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE

(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND

(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND CIRCUIT

(K35) EGR SOLENOID CONTROL CIRCUIT OPEN

EGR SOLENOID ASSEMBLY

PCM

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

Diagnostic Test

1.ACTIVE DTC

Is the DTC Active at this time?

Yes

Go To 2

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

2.EGR SOLENOID ASSEMBLY

NOTE: Make sure the test light is probing the circuits before actuating the EGR Solenoid or a DTC may set and not allow the actuation.

Does the 12-volt test light flash on and off during the actuation?

Yes

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

Go To 3

3.(Z42) EGR SOLENOID GROUND CIRCUIT OPEN

Does the test light illuminate brightly?

Yes

Go To 4

Repair the open in the (Z42) EGR Solenoid ground circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

4.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE

Is the voltage above 1.0 volt?

Yes

Repair the short to battery voltage in the (K35) EGR Solenoid Control circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 5

5.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND

Is the resistance below 100 ohms?

Yes

Repair the short to ground in the (K35) EGR Solenoid Control circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 6

6.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND CIRCUIT

Is the resistance below 5.0 ohms?

Yes

Repair the short between the (K900) Sensor ground circuit and the (K35) EGR Solenoid Control circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

Go To 7

7.(K35) EGR SOLENOID CONTROL 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 (K35) EGR Solenoid Control 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)