Workshop Manual

6E–305
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DTC P0404 – EGR Open Stuck
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
— Go to Step 2
Go to OBD
System
Check
2 1. Ignition “ON”, engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor “DTC” info for DTC P0404
until the DTC P0404 test runs. Note the result.
Does the Tech 2 indicates DTC P0404 failed this
ignition?
— Go to Step 3
Refer to
Diagnostic
Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals?
— Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
— Verify repair
Is the action
complete?
5 1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
Was excessive carbon deposit on EGR valve shaft?
— Go to Step 6 Go to Step 7
6 1. Clean up EGR valve shaft and inside of EGR valve.
2. Visually inspect damage of pintle and seat if is bent,
leakage may occur.
Was there any severe damage which affects function?
— Go to Step 8
Verify repair
Go to
Step 7
7 1. Reconnect.
2. Ignition “OFF”.
3. Install the Tech 2.
4. Run the engine at idle.
5. On the Tech 2, select EGR Control Test.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly?
— — Go to Step 8
8 Replace the EGR valve.
Does DTC P0404 still fail “DTC” test on the Tech 2?
— Go to Step 9 Verify repair
9 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to
On-Vehicle Service in
Powertrain Control Module and Sensors for
procedures.
And also refer to latest Service Bulletin.
Check to see if the Latest software is released or not.
And then Down Load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
Is the action complete?
— Verify repair —