Chrysler Pacifica. Manual — part 357
Symptom:
P0404 - EGR POSITION SENSOR PERFORMANCE
When Monitored and Set Condition:
P0404 - EGR POSITION SENSOR PERFORMANCE
When Monitored:
Set Condition:
The EGR flow or valve movement is not what is expected.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
HIGH RESISTANCE IN 5 VOLT SUPPLY
EGR SENSOR SIGNAL CIRCUIT OPEN
EGR ASSEMBLY
EGR SOLENOID CONTROL CKT
INTERMITTENT CONDITION
EGR SENSOR SIGNAL CIRCUIT OPEN
EGR SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
SENSOR GROUND CIRCUIT OPEN
EGR ASSEMBLY (GROUND)
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIII
t, read DTCs and record the related Freeze Frame data.
Is the Good Trip displayed and equal to zero?
All
Yes
→ Go To 2
No
→ Refer to the INTERMITTENT CONDITION symptom in the
Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
NOTE: Diagnose all other EGR DTC(s) first before continuing.
Start the engine.
With the DRBIII
t, read the EGR Position Sensor voltage.
Choose a conclusion that best matches the EGR voltage reading.
All
Below 3.5 volts
Between 3.5 volts to 4.3 volts
Above 4.3 volts
149
DRIVEABILITY - NGC
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the 5 volt supply circuit from the EGR Solenoid harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 4
No
→ Repair the high resistance in the 5 Volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the EGR Sensor Signal circuit in the EGR Solenoid
harness connector to ground.
Is the resistance below 5.0 ohms?
All
Yes
→ Repair the short to ground in the EGR Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the EGR Assembly.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
Turn the ignition on.
With the DRBIII
t, actuate the EGR Solenoid.
Allow the EGR Solenoid to actuate for least 15 seconds.
Feel the EGR solenoid for operation.
Stop actuation.
Does EGR Solenoid operate during actuation test and then turn off when actuation
test was stopped?
All
Yes
→ Go To 6
No
→ Refer to the Driveability category and perform P0403 - EGR
Control Circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
150
DRIVEABILITY - NGC
P0404 - EGR POSITION SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
6
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
NOTE: Closely inspect the EGR tube(s) for obstructions, damage and holes.
Also, inspect the gasket(s) for leaks.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
With the engine running at normal operating temperature, monitor the DRBIII
t
parameters related to the DTC while wiggling the wire harness. Look for parameter
values to change and/or a DTC to set.
Review the DRBIII
t Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?
All
Yes
→ Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
7
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Turn the ignition on.
Measure the voltage of the EGR Sensor Signal circuit at the EGR Solenoid harness
connector.
Is the voltage above 4.30 volts?
All
Yes
→ Go To 8
No
→ Go To 9
8
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the Sensor Ground circuit from the EGR Solenoid harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
Yes
→ Replace the EGR Assembly.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Repair the open in the Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
151
DRIVEABILITY - NGC
P0404 - EGR POSITION SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
9
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the EGR Sensor Signal circuit from the EGR Solenoid
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 10
No
→ Repair the open in the EGR Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.
Disconnect the PCM harness connector.
Measure the resistance between ground and the EGR Sensor Signal circuit in the
EGR Solenoid harness connector.
Is the resistance below 100 ohms?
All
Yes
→ Repair the short to ground in the EGR Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To 11
11
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
152
DRIVEABILITY - NGC
P0404 - EGR POSITION SENSOR PERFORMANCE —
Continued
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