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P0406






P0406-EGR POSITION SENSOR CIRCUIT HIGH





For a complete wiring diagram Refer to the Wiring Information

- When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.

- Set Condition:
The PCM detects that the EGR Valve Assembly input voltage is above the maximum acceptable value.





Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.Pre-Diagnostic Troubleshooting Procedure

1. DTC IS ACTIVE
1. Start the engine and allow it to reach normal operating temperature.

WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in personal injury or death.

NOTE: Diagnose and repair any system voltage or sensor supply voltage DTCs before continuing with this test.

2. With the scan tool, select View DTCs.

Is the status Active for this DTC?

Yes

- Go to 2

No

- Refer to the *CHECKING FOR AN INTERMITTENT DTC Diagnostic Procedure.Checking for an Intermittent DTC

2. (K856) 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE




1. Turn the ignition off.
2. Disconnect the EGR Valve Assembly connector.
3. Disconnect the Powertrain Control Module (PCM) connector.
4. Turn the ignition on.
5. Measure the voltage of the (K856) 5 Volt Supply circuit in the EGR Valve Assembly harness connector.

Is there any voltage present?

Yes

- Repair the (K856) 5 Volt Supply circuit for a short to voltage.
- Perform the PCM Verification Test.PCM Verification Test

No

- Go to 3

3. (K34) EGR SIGNAL CIRCUIT SHORTED TO VOLTAGE




1. Measure the voltage of the (K34) EGR Signal circuit in the EGR Valve Assembly harness connector.

Is there any voltage present?

Yes

- Repair the (K34) EGR Signal circuit for a short to voltage.
- Perform the PCM Verification Test.PCM Verification Test

No

- Go to 4

4. (K34) EGR SIGNAL CIRCUIT SHORTED TO THE (K856) 5 VOLT SUPPLY CIRCUIT




1. Measure the resistance between the (K34) EGR Signal circuit and the (K856) 5 Volt Supply in the EGR Valve Assembly harness connector.

Is the resistance below 100 ohms?

Yes

- Repair the (K34) EGR Signal circuit for a short to the (K856) 5 Volt Supply circuit.
- Perform the PCM Verification Test.PCM Verification Test

No

- Go to 5

5. (K34) EGR SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE




1. Turn the ignition off.

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.

2. Measure the resistance of the (K34) EGR Signal between the EGR Valve Assembly harness connector and the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?

Yes

- Go to 6

No

- Repair the (K34) EGR Signal for an open circuit or high resistance.
- Perform the PCM Verification Test.PCM Verification Test

6. (K900) SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE





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.

1. Measure the resistance of the (K900) Sensor Ground circuit between the EGR Valve Assembly harness connector and the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?

Yes

- Go to 7

No

- Repair the (K900) Sensor Ground circuit for an open circuit or high resistance.
- Perform the PCM Verification Test.PCM Verification Test

7. EGR VALVE ASSEMBLY




1. Turn the ignition off.
2. Connect the Powertrain Control Module (PCM) connector.
3. Connect a jumper wire between the (K900) Sensor Ground circuit and the (K34) EGR Signal circuit in the EGR Valve Assembly harness connector.
4. Turn the ignition on.
5. With the scan tool, read the EGR Valve Assembly signal voltage.

NOTE: The sensor voltage should be approximately 0.0 volts (plus or minus.1 volt) with the jumper wire in place.

Does the scan tool display the voltage as described above?

Yes

- Replace the EGR Valve Assembly.
- Perform the PCM Verification Test.PCM Verification Test

No

- Go to 8

8. POWERTRAIN CONTROL MODULE (PCM)
1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the EGR Valve Assembly and the Powertrain Control Module (PCM).
2. Look for any chafed, pierced, pinched, or partially broken wires.
3. Look for broken, bent, pushed out or corroded terminals.
4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
5. Look for the data to change or for the DTC to reset during the wiggle test.
6. Search for any Technical Service Bulletins that may apply.

Were any problems found?

Yes

- Repair as necessary.
- Perform the PCM Verification Test.PCM Verification Test

No

- Replace and program the Powertrain Control Module (PCM).
- Perform the PCM Verification Test.PCM Verification Test

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