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Home >> Chrysler >> 2011 >> 300 C, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 75 (3.7L/4.7L/5.7L - DTCS P0196 To P0501 - NGC - 1500 & 2500) >> Diagnosis and Testing >> P0404-EGR Position Sensor Performance >> Diagnostic Test

Diagnostic Test

WARNING: This page is about a different car, the 2011 RAM Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. ACTIVE DTC 
    NOTE:

    Diagnose and repair any EGR signal circuit high or low DTCs before continuing with this procedure.

    1. Turn the ignition on.
    2. With the scan tool, select View DTCs. Record DTC and Freeze Frame information.
    3. Start the engine and allow it to reach 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 may result in possible serious or fatal injury.

      WARNING:

      The normal operating temperature of the EGR system is very high. Never work around or attempt to service any part of the EGR system until it has cooled. Failure to follow these instructions can result in possible serious or fatal injury.

      NOTE:

      Attempt to operate the vehicle under conditions similar to which the DTC was set.

      NOTE:

      It may be necessary to test drive the vehicle within the DTC monitoring conditions in order for this DTC to set.

    4. With the scan tool, select View DTCs.

      Is the DTC Active or Pending at this time?

      Yes 

      • Go To  2.

      No 

  2. (F856) 5-VOLT SUPPLY CIRCUIT HIGH RESISTANCE 
    Fig 1: Measuring Resistance Of 5-volt Supply Circuit From EGR Solenoid Harness Connector To Appropriate Terminal Of PCM Pinout Box 8815
    GC0090801Courtesy of CHRYSLER LLC
    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 the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis.

    2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5-volt Supply circuit at the EGR Valve Assembly harness connector and probing the appropriate terminal of the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position). Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter.
      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 may result in possible serious or fatal injury.

    3. Start the engine.

      Is the voltage below 0.5 of a volt?

      Yes 

      • Go To  3.

      No 

      • Repair the (F856) 5-volt Supply circuit for high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  3. (K34) EGR SIGNAL CIRCUIT HIGH RESISTANCE 
    Fig 2: Performing Voltage Drop Test On (K34) EGR Signal Circuit
    GC0090802Courtesy of CHRYSLER LLC
    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 the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis.

    2. Using a voltmeter, perform a voltage drop test by backprobing the (K34) EGR Signal circuit at the EGR Valve Assembly harness connector and probing the appropriate terminal of the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position). Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter.
      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 may result in possible serious or fatal injury.

    3. Start the engine.

      Is the voltage below 0.5 of a volt?

      Yes 

      • Go To  4.

      No 

      • Repair the (K34) EGR Signal circuit for high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  4. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 
    Fig 3: Performing Voltage Drop Test (K900) Sensor Ground Circuit
    GC0090803Courtesy of CHRYSLER LLC
    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 the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis.

    2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the EGR Valve Assembly harness connector and probing the appropriate terminal of the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position). Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter.
      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 may result in possible serious or fatal injury.

    3. Start the engine.

      Is the voltage below 0.5 of a volt?

      Yes 

      • Go To  5.

      No 

      • Repair the (K900) Sensor Ground circuit for high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  5. (Z908) GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 4: Using 12-volt Test Light Connected To 12 Volts To Check Ground Circuit In EGR Valve Assembly Harness Connector
    GC0090798Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the EGR Valve Assembly harness connector.
    3. Using a 12-volt test light connected to the 12 Volts, check the (Z908) Ground circuit in the EGR Valve Assembly harness connector.
      NOTE:

      The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

      Is the test light illuminated and bright?

      Yes 

      • Go To  6.

      No 

      • Repair the (Z908) Ground circuit for an open circuit of high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  6. (K35) EGR CONTROL CIRCUIT HIGH RESISTANCE 
    1. Turn the ignition off.
    2. Connect the EGR Valve Assembly connector.
      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 the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis.

    3. Using a voltmeter, perform a voltage drop test by backprobing the (K35) EGR Control circuit at the EGR Valve Assembly harness connector and probing the appropriate terminal of the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position). Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter.
    4. Start the engine and allow it to reach 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 may result in possible serious or fatal injury.

    5. With the scan tool, perform the EGR System Test.
    6. Select OPEN to open the EGR valve.
    7. Monitor the circuit voltage on the voltmeter.

      Is the voltage below 0.5 of a volt when the valve was opened during the system test?

      Yes 

      • Go To  7.

      No 

      • Repair the (K35) EGR Control circuit for excessive resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  7. EGR VALVE ASSEMBLY 
    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. Verify that there is good pin to terminal contact in the Solenoid and the Powertrain Control Module connectors.
    3. Look for any chafed, pierced, pinched or partially broken wires.
    4. Look for broken, bent, pushed out or corroded terminals.
    5. Refer to any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

      • Replace the EGR Valve Assembly in accordance with the Service Information if no problems were found with the connectors.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
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