P0403-EGR SOLENOID CIRCUITFor 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(Z906) 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 OPENEGR SOLENOID ASSEMBLYPCM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).Diagnostic Test1.ACTIVE DTCIgnition on, engine not running.With a scan tool, select View DTCs.Is the DTC Active at this time?YesGo To 2NoRefer to the INTERMITTENT CONDITION Diagnostic Procedure.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)2.EGR SOLENOID ASSEMBLYTurn the ignition off.Disconnect the EGR Solenoid harness connector.Ignition on, engine not running.Turn off all accessories.Using a 12-volt test light connected to the (Z906) EGR Solenoid ground circuit, probe the (K35) EGR Solenoid Control circuit.With a scan tool, actuate the EGR solenoid.Does the 12-volt test light flash on and off?YesReplace the EGR Solenoid Assembly.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)NoGo To 33.(Z906) EGR SOLENOID GROUND CIRCUIT OPENTurn the ignition off.Using a 12-volt test light connected to the 12-volts, probe the (Z906) EGR Solenoid ground circuit in the EGR Solenoid harness connector.Does the test light illuminate brightly?YesGo To 4NoRepair the open in the (Z906) EGR Solenoid ground circuit.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)4.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGEIgnition on, engine not running.Disconnect the C2 PCM harness connector.Measure the voltage on the (K35) EGR Solenoid Control circuit in the EGR Solenoid connector.Is the voltage above 1.0 volt?YesRepair the short to battery voltage in the (K35) EGR Solenoid Control circuit.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)NoGo To 55.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUNDTurn the ignition off.Measure the resistance between ground and the (K35) EGR Solenoid Control circuit in the EGR Solenoid harness connector.Is the resistance below 100 ohms?YesRepair the short to ground in the (K35) EGR Solenoid Control circuit.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)NoGo To 66.(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND CIRCUITMeasure the resistance between the (K35) EGR Solenoid Control circuit and the (K900) Sensor ground circuit in the EGR Solenoid connector.Is the resistance below 5.0 ohms?YesRepair 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)NoGo To 77.(K35) EGR SOLENOID CONTROL CIRCUIT OPENDo 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.Measure the resistance of the (K35) EGR Solenoid Control circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.Is the resistance below 5.0 ohms?YesGo To 8NoRepair the open in the (K35) EGR Solenoid Control circuit.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)8.PCMBefore continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.Were there any problems found?YesRepair as necessary.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)NoReplace and program the Powertrain Control Module per Service Information.Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)