DTC P0401:00 [PCM (SKYACTIV-D 2.2)]

id0102j5704200

Engine Type

Item	Reference
Fuel injector (6 pin type), Without SCR System	(See Fuel injector (6 pin type), Without SCR System.)
Fuel injector (6 pin type), With SCR System	(See Fuel injector (6 pin type), With SCR System.)

Note

•  To determine the malfunctioning part, proceed with the diagnostics from “Function Inspection Using M-MDS”.

Fuel injector (6 pin type), Without SCR System

Details On DTCs

DESCRIPTION	EGR flow insufficient detected
DETECTION CONDITION	Determination conditions	•  The EGR volume is lower than the specification for the target value for a continuous specified time.
	Preconditions	•  During EGR control •  Engine speed: 1,300—2,500 rpm •  Fuel injection amount:15—50 mm3/stoke •  Engine torque: 80—240 N·m {8.2—24 kgf·m, 60—177 ft·lbf}
	Drive cycle	•  2
	Self test type	•  CMDTC self test
	Sensor used	•  EGR valve •  Intake shutter valve •  MAF sensor •  MAP sensor No.2 •  Boost air temperature sensor •  Exhaust gas pressure sensor No.1 •  Exhaust gas temperature sensor No.1
FAIL-SAFE FUNCTION	•  Inhibits engine-stop by operating the i-stop function.
VEHICLE STATUS WHEN DTCs ARE OUTPUT	•  Check engine light is illuminated
POSSIBLE CAUSE	•  Erratic signal to PCM ―  MAF sensor signal malfunction ―  MAP sensor No.2 signal malfunction ―  Boost air temperature sensor signal malfunction ―  Exhaust gas pressure sensor No.1 signal malfunction ―  Exhaust gas temperature sensor No.1 signal malfunction ―  Input signal part connector or terminals malfunction ―  Input signal part related circuit malfunction •  Intake shutter valve malfunction •  EGR valve malfunction (stuck close) •  Air suction in intake air system between turbocharger and intake manifold •  EGR system passage malfunction (restriction) •  PCM malfunction

System Wiring Diagram

•  Not applicable

Function Explanation (DTC Detection Outline)

•  The PCM performs diagnosis of the EGR system by comparing the target EGR volume with the actual.

•  The PCM monitors the flow volume during EGR implementation.

•  The PCM calculates the difference between the target EGR flow volume and the actual EGR flow volume during EGR implementation. If the monitored, actual flow volume is lower than the specification for the target flow volume, the PCM determines that there is inadequate flow volume.

•  The PCM performs diagnosis when each of the preconditions during drive cycle is met. If a malfunction is detected, the malfunction detection counter begins counting up. The value of the malfunction detection counter is maintained while the preconditions are not being met. If the cumulative value of the malfunction detection counter exceeds the threshold during the first drive cycle, a malfunction is determined and a pending code is stored.

•  If the PCM determines that the malfunction recurs from the next drive cycle and thereafter, it stores a DTC and turns on the check engine light.

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Repeatability Verification Procedure

Caution

•  When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.

•  While performing this step, always operate the vehicle in a safe and lawful manner.

1.  Clear the DTC from the PCM memory using the M-MDS. (See CLEARING DTC [PCM (SKYACTIV-D 2.2)].)

2.  Start the engine and warm it up completely.

3.  Drive the vehicle for 1 min at a speed of 100 km/h {62.1 mph} or more.

4.  Repeat Step 3 operation above 2 times.

PID Item/Simulation Item Used In Diagnosis

Item	Definition	Unit	Condition/Specification
EXHPRES1	Exhaust gas pressure (No.1)	KPa {MPa}, mBar {Bar}, psi, in H20	•  Idle (after warm up): Approx. 100 kPa {1 bar, 14.5 psi} •  Racing (engine speed above 2,000 rpm): Approx. 125 kPa {1.27 kgf/cm2, 18.1 psi} •  Racing (engine speed above 4,000 rpm): Approx. 245 kPa {2.50 kgf/cm2, 35.5 psi}
EXHTEMP1	Exhaust gas temperature (No.1)	°C, °F	Displays the exhaust gas temperature
CACT12	Boost air temperature	°C, °F	Displays the boost air temperature
MAF	Mass air flow	g/sec	•  Switch ignition ON (engine off): Approx. 0.4 g/sec {0.13 Ib/min} •  Idle (after warm up): Approx. 3.2 g/sec {0.42 Ib/min} •  Racing (engine speed above 2,000 rpm): Approx. 9.2 g/sec {1.12 Ib/min} •  Racing (engine speed above 4,000 rpm): Approx. 70 g/sec {9.3 Ib/min}
MAP	Manifold absolute pressure	KPa {MPa}, mBar {Bar}, psi, in H20	•  Switch ignition ON (engine off): Approx. 100 kPa {1 bar, 14.5 psi} •  Idle: Approx. 80 kPa {0.8 bar, 12 psi}

Function Inspection Using M-MDS

STEP	INSPECTION		ACTION
1	PURPOSE: VERIFY RELATED SERVICE INFORMATION AVAILABILITY •  Verify related Service Information availability. •  Is any related Service Information available?	Yes	Perform repair or diagnosis according to the available Service Information. •  If the vehicle is not repaired, go to the next step.
		No	Go to the next step.
2	PURPOSE: IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA •  Is the DTC P0401:00 on FREEZE FRAME DATA?	Yes	Go to the next step.
		No	Go to the troubleshooting procedure for DTC on FREEZE FRAME DATA. (See DTC TABLE [PCM (SKYACTIV-D 2.2)].)
3	PURPOSE: RECORD VEHICLE STATUS AT TIME OF DTC DETECTION TO UTILIZE WITH REPEATABILITY VERIFICATION Note •  Recording can be facilitated using the screen capture function of the PC. •  Record the FREEZE FRAME DATA/snapshot data on the repair order.	—	Go to the next step.
4	PURPOSE: VERIFY IF DIAGNOSTIC RESULT IS AFFECTED BY OTHER RELATED DTCs OCCURRING •  Switch the ignition off, then ON (engine off). •  Perform the Pending Trouble Code Access Procedure and DTC Reading Procedure. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) •  Is the other PENDING CODE/DTC also present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D 2.2)].)
		No	Go to the next step.
5	PURPOSE: VERIFY IF THERE IS PID ITEM CAUSING DRASTIC CHANGES OF ACCELERATION FLUCTUATION BY INPUT SIGNAL TO PCM •  Access the following PIDs using the M-MDS: (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) ―  EXHPRES1 ―  EXHTEMP1 ―  CACT12 ―  MAF ―  MAP •  Is there any signal that is far out of specification?	Yes	Go to the next step.
		No	Go to the troubleshooting procedure to perform the procedure from Step 1.
6	PURPOSE: VERIFY CONNECTOR CONNECTIONS •  Access the following PIDs using the M-MDS: (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) ―  EXHPRES1 ―  EXHTEMP1 ―  CACT12 ―  MAF ―  MAP •  When the following parts are shaken, does the PID value include a PID item which has changed? ―  Exhaust gas pressure sensor No.1 ―  Exhaust gas temperature sensor No.1 ―  Boost air temperature sensor ―  MAF sensor ―  MAP sensor No.2 ―  PCM	Yes	Inspect the related wiring harness and connector. •  Repair or replace the malfunctioning part. Go to the troubleshooting procedure to perform the procedure from Step 5.
		No	Go to the troubleshooting procedure to perform the procedure from Step 1.

Troubleshooting Diagnostic Procedure

Intention of troubleshooting procedure

•  Step 1—2

―  Perform inspection of each separate part.

•  Step 3—4

―  Perform inspection of EGR valve passage

•  Step 5—6

―  Verify that the primary malfunction is resolved and there are no other malfunctions.

STEP	INSPECTION		ACTION
1	PURPOSE: INSPECT INTAKE SHUTTER VALVE CONTROL SYSTEM OPERATION •  Perform the Intake Shutter Valve Operation Inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [SKYACTIV-D 2.2].) •  Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
		No	Go to the next step.
2	PURPOSE: INSPECT EGR VALVE CONTROL SYSTEM OPERATION •  Perform the EGR Valve Operation Inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [SKYACTIV-D 2.2].) •  Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
		No	Go to the next step.
3	PURPOSE: INSPECT INTAKE AIR SYSTEM FOR AIR SUCTION •  Inspect for air leakage at the following: ―  Around connection of turbocharger and intake manifold Note •  Engine speed may change when rust penetrating agent is sprayed on the air suction area. •  Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
		No	Go to the next step.
4	PURPOSE: INSPECT FOR RESTRICTION OR CLOGGED IN EGR PASSAGE •  Switch the ignition off. •  Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) •  Visually inspect the EGR passage for clogging and the gasket correctly installed. •  Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to the next step. (If there is clogging caused by soot in the EGR valve, inspect around the EGR piping and clean or replace it.)
		No	Go to the next step.
5	PURPOSE: PERFORM DTC INSPECTION AND VERIFY IF MALFUNCTIONING PART IS PCM •  Always reconnect all disconnected connectors. •  Clear the DTC from the PCM memory using the M-MDS. (See CLEARING DTC [PCM (SKYACTIV-D 2.2)].) •  Implement the repeatability verification procedure. (See Repeatability Verification Procedure.) •  Perform the Pending Trouble Code Access Procedure. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) •  Is the PENDING CODE for this DTC present?	Yes	Repeat the inspection from Step 1. •  If the malfunction recurs, replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) Go to the next step.
		No	Go to the next step.
6	PURPOSE: VERIFY AFTER REPAIR PROCEDURE •  Perform the “AFTER REPAIR PROCEDURE”. (See AFTER REPAIR PROCEDURE [PCM (SKYACTIV-D 2.2)].) •  Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D 2.2)].)
		No	DTC troubleshooting completed.

Fuel injector (6 pin type), With SCR System

Details on DTCs

System malfunction location	EGR control system: Insufficient amount of EGR
Detection condition	Determination conditions	•  The EGR volume is less than 0.16 g/rev for the target value for a continuous 8.2 s.
	Preconditions	•  During EGR control •  Engine speed: 1,300―6,000 rpm •  Fuel injection amount: 15―50 mm3/st •  Engine torque: 80―240 N·m {8.2―24 kgf·m, 60―177 ft·lbf} •  The following DTCs are not detected ―  MAP sensor No.2: P0106:00, P0107:00, P0108:00 ―  BARO sensor: P2228:00, P2229:00 ―  MAF sensor: P0102:00, P0103:00 ―  EGR valve position sensor: P0405:00, P0406:00 ―  EGR valve DC motor control system: P0404:00 ―  EGR cooler bypass valve position sensor: P2494:00, P2495:00 ―  EGR cooler bypass valve control system: P245A:00, P245B:00 ―  EGR valve control system: P0488:00 ―  Intake shutter valve position sensor: P0122:00, P0123:00 ―  Intake shutter valve control system: P1589:00, P2101:00, P2118:00 ―  IAT sensor No.2: P1118:00, P1119:00, P1147:00 ―  Exhaust gas pressure sensor No.1: P0471:00, P0472:00, P0473:00 ―  Exhaust gas temperature sensor No.1: P0545:00, P0546:00 ―  Constant voltage power supply control system: P0642:00, P0643:00, P0652:00, P0653:00 ―  MAP sensor No.2/BARO sensor: P0105:00 ―  Exhaust gas pressure sensor No.1: P0470:00
	Drive cycle	•  2
	Self-test type	•  CMDTC self test
	Sensor/unit used	•  EGR valve •  EGR cooler bypass valve •  Intake shutter valve •  MAF sensor •  MAP sensor No.2 •  Boost air temperature sensor •  Exhaust gas pressure sensor No.1 •  Exhaust gas temperature sensor No.1
Fail-safe	•  Not applicable
Vehicle status when DTCs are output	•  Check engine light turns on
Possible Cause	•  PCM input signal error ―  MAF sensor ―  MAP sensor No.2 ―  Boost air temperature sensor ―  Exhaust gas pressure sensor No.1 ―  Exhaust gas temperature sensor No.1 ―  Input signal part connector or terminal malfunction ―  Input signal part-related wiring harness malfunction •  Intake shutter valve malfunction •  EGR valve malfunction (stuck closed) •  EGR cooler bypass valve malfunction (stuck closed) •  Air suction from intake-air system piping (between turbocharger and intake manifold) •  EGR malfunction (clogging in EGR piping) •  PCM malfunction

System Wiring Diagram

•  Not applicable

Function Explanation (DTC Detection Outline)

•  The PCM performs diagnosis of the EGR system by comparing the target EGR volume with the actual.

•  The PCM monitors the flow volume during EGR implementation.

•  The PCM calculates the difference between the target EGR flow volume and the actual EGR flow volume during EGR implementation. If the monitored, actual flow volume is lower than the specification for the target flow volume, the PCM determines that there is inadequate flow volume.

•  The PCM performs diagnosis when each of the preconditions during drive cycle is met. If a malfunction is detected, the malfunction detection counter begins counting up. If it is normal, the counter begins counting down.

The value of the malfunction detection counter is maintained while the preconditions are not being met. If the cumulative value of the malfunction detection counter exceeds the threshold during the first drive cycle, a malfunction is determined and a pending code is stored.

•  If the PCM determines that the malfunction recurs from the next drive cycle and thereafter, it stores a DTC and turns on the check engine light.

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Repeatability Verification Procedure

Warning

•  To prevent an accident, work with another person when the vehicle is being driven (one person drives vehicle, other person operates M-MDS).

•  Observe legal speed limits when driving the vehicle and perform the procedure in a location where safety can be assured.

1.  Start the engine and warm it up.

2.  Drive the vehicle at the constant speed of 70 km/h or morefor 1 min.

3.  Repeat Step 2 2 times or more.

PID Item/Simulation Item Used in Diagnosis

PID

Function Inspection Using M-MDS

Step	Inspection	Results	Action
1	PURPOSE: VERIFY DTC CAUSING FREEZE FRAME DATA •  Is DTC P0401:00 causing the freeze frame data?	Yes	Go to the next step.
		No	Inspect the DTC causing the freeze frame data. (See DTC TABLE [PCM (SKYACTIV-D 2.2)].)
2	PURPOSE: RECORD VEHICLE STATUS AT TIME OF DTC DETECTION TO UTILIZE WITH REPEATABILITY VERIFICATION Note •  Recording can be facilitated using the screen capture function of the PC. •  Record the freeze frame data/snap shot data.	―	Go to the next step.
3	PURPOSE: VERIFY OTHER RELATED DTCs •  Switch the ignition OFF, and then switch it ON (engine off). •  Display the DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) •  Has any DTC other than P0401:00 been stored?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting. (See DTC TABLE [PCM (SKYACTIV-D 2.2)])
		No	Go to the next step.
4	PURPOSE: VERIFY RELATED SENSOR INPUT SIGNAL •  Start the engine and warm it up. •  Display the following PIDs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) ―  EXHPRES1 ―  EXHTEMP1 ―  CACT12 ―  MAF ―  MAP •  Are the monitoring values normal?	Yes	Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 1.
		No	Go to the next step.
5	PURPOSE: INSPECT WIRING HARNESSES AND CONNECTORS FOR RELATED-SENSOR •  Display the following PIDs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) ―  EXHPRES1 ―  EXHTEMP1 ―  CACT12 ―  MAF ―  MAP •  When the PCM, MAF sensor, MAP sensor No.2, boost air temperature sensor, exhaust gas pressure sensor No.1, and exhaust gas temperature sensor No.1 connectors are shaken, does the PID value include a PID item which has changed?	Yes	Inspect the related wiring harnesses and connectors. •  Repair or replace the malfunctioning location. Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 6.
		No	Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 1.

Troubleshooting Diagnostic Procedure

Intention of troubleshooting procedure

•  Steps 1 to 3

―  Perform inspection of each separate part.

•  Step 4

―  Perform the inspection of piping for the intake air system.

•  Step 5

―  Perform the EGR piping inspection.

•  Steps 6 to 7

―  Verify that primary malfunction is resolved and there are no other malfunctions.

Step	Inspection	Results	Action
1	PURPOSE: INSPECT INTAKE SHUTTER VALVE •  Inspect the intake shutter valve. (See INTAKE SHUTTER VALVE INSPECTION [SKYACTIV-D 2.2].) •  Is the intake shutter valve normal?	Yes	Go to the next step.
		No	Replace the intake shutter valve, then go to the Step 6. (See INTAKE SHUTTER VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
2	PURPOSE: VERIFY EGR VALVE OPERATION CONDITION •  Perform the EGR control inspection. (See EGR VALVE INSPECTION [SKYACTIV-D 2.2].) •  Is the EGR valve operation normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location, then go to Step 6. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
3	PURPOSE: VERIFY EGR COOLER BYPASS VALVE OPERATION CONDITION •  Perform the EGR control inspection. (See EGR COOLER BYPASS VALVE INSPECTION [SKYACTIV-D 2.2].) •  Is the EGR cooler bypass valve operation normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location, then go to Step 6. (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
4	PURPOSE: INSPECT INTAKE AIR SYSTEM FOR AIR SUCTION •  Visually inspect the following parts of the intake air system for looseness or damage. ―  Turbocharger and intake manifold •  Is the intake air system normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location, then go to Step 6.
5	PURPOSE: INSPECT EGR PASSAGE FOR CLOGGING •  Switch the ignition OFF. •  Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) •  Is the gasket correctly installed? Visually inspect the EGR passage for clogging. •  Is the EGR passage normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location, then go to the next step. (If there is clogging caused by soot in the EGR valve, inspect around the EGR piping and clean or replace it)
6	PURPOSE: VERIFICATION OF VEHICLE REPAIR COMPLETION •  Reconnect all disconnected connectors and hoses. •  Refer to the [MEMORY CLEARING PROCEDURE] and clear the DTC. (See CLEARING DTC [PCM (SKYACTIV-D 2.2)].) •  Implement the repeatability verification procedure. (See Repeatability Verification Procedure.) •  Display the DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 2.2)].) •  Is DTC P0401:00 displayed?	Yes	Repeat the inspection from Step 1. •  If the malfunction recurs, replace the PCM, then go to the next step. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
		No	Go to the next step.
7	PURPOSE: VERIFY IF THERE IS ANY OTHER MALFUNCTION •  Has any other DTC or pending code been stored?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting. (See DTC TABLE [PCM (SKYACTIV-D 2.2)].)
		No	DTC troubleshooting completed.