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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 6 (Engine Controls - Self-Diagnostics - 2.2L) >> Diagnostic Tests >> DTC P0404: Exhaust Gas RECIRCULATION System - Range/Performance Malfunction >> Diagnostic Procedure

Diagnostic Procedure

WARNING: This page is about a different car, the 2002 Isuzu Rodeo Sport and 2002 Isuzu Rodeo. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform ON-BOARD DIAGNOSTIC II SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM. After performing OBD-II system check, go to next step.
  2. Turn ignition on. Using scan tool, select EXHAUST GAS RECIRCULATION VALVE CONTROL TEST  under MISCELLANEOUS TESTS. From scan tool, command EGR valve open to 25, 50, 75 and 100 percent while observing actual EGR valve position. If actual EGR valve position follows commanded EGR position, go to step  19 . If EGR actual position is different than EGR commanded position, go to next step.
  3. Turn ignition off. Disconnect EGR valve 5-pin harness connector. EGR valve is located at top rear of engine. Turn ignition on. Using a test light connected to battery voltage, probe EGR valve harness connector terminal No. 2 (Blue/Yellow wire). See WIRING DIAGRAMS article. If test light illuminates, leave harness connector disconnected and go to next step. If test light does not illuminate, go to step  5 .
  4. Using a test light connected to ground, probe EGR valve harness connector terminal No. 1 (Yellow wire) EGR control circuit. Observe test light while using scan tool to, command EGR valve open to 25, 50, 75 and 100 percent. If test light got brighter with each command, flashed or maintained a steady glow, go to step  6 . If test light does not illuminate as specified, go to step  7 .
  5. Repair open or poor connection in Blue/Yellow wire (EGR valve ground) between PCM and EGR valve. See WIRING DIAGRAMS article. After repair, go to step  19 .
  6. Using test light connected to ground, probe EGR valve harness connector No. 3 (Yellow/Red wire) EGR signal. If test light illuminates, go to step  8 . If test light does not illuminate, go to step  9 .
  7. Using test light connected to ground, probe EGR valve harness connector No. 1 (Yellow wire) EGR control circuit. Do not command EGR valve to open. If test light illuminates, go to step  10 . If test light does not illuminate, go to step  11 .
  8. Check for short to voltage in Yellow/Red wire (EGR signal circuit) between PCM and EGR valve. See WIRING DIAGRAMS article. If problem is found, repair as necessary. After repair, go to step  19 . If no problem was found, go to step  12 .
  9. Using DVOM measure voltage between ground and EGR valve harness connector terminal No. 4 (Gray/Red wire). Voltage reading should be about 5 volts. If voltage reading is as specified, go to step  13 . If voltage reading is not as specified, go to step  14 .
  10. Check for short to voltage in Yellow wire (EGR valve control circuit) between PCM and EGR valve. See WIRING DIAGRAMS article. If problem is found, repair as necessary. After repair, go to step  19 . If no problem is found, go to step  12 .
  11. Using a test light connected to battery voltage, probe EGR valve harness connector terminal No. 1 (Yellow wire). If test light illuminates, go to step  15 . If test light does not illuminate, go to step  16 .
  12. Replace and reprogram PCM. See POWERTRAIN CONTROL MODULE REPLACEMENT  under POWERTRAIN CONTROL MODULE. After repair is complete, go to step  19 .
  13. Check for poor, loose or damaged terminal connections at PCM harness connector C-2 terminal D9 (EGR ground circuit). See Figure . If problem is found, repair as necessary. After repair, go to step  19 . If no problem was found, go to step  17 .
  14. Check for short to voltage in Gray/Red wire (5-volt reference) between PCM and EGR valve. See WIRING DIAGRAMS article. If problem is found, repair as necessary. After repair, go to step  19 . If no problem was found, repeat test starting in step  12 .
  15. Check for short to ground in Yellow wire (EGR control circuit) between PCM and EGR valve. See WIRING DIAGRAMS article. If problem is found, repair as necessary. After repair, go to step  19 . If no problem was found, repeat test starting in step  12 .
  16. Check for an open or poor connection in Yellow wire at EGR valve harness connector. If problem is found, repair as necessary. After repair, go to step  19 . If no problem was found, go to step  18 .
  17. Replace EGR valve. See REMOVAL, OVERHAUL & INSTALLATION article. After repair, go to step  19 .
  18. Check for poor, loose or damaged terminal connections in all PCM harness connectors. If problem is found, repair as necessary. After repair, go to next step. If no problem was found, repeat test starting in step  12 .
  19. Using scan tool, clear DTCs. Start engine and idle at normal operating temperature of 167-203°F (75-95°C). Operate vehicle within CODE ENABLE CRITERIA  . If scan tool indicates DTC P0404 RAN AND PASSED, system is okay. See VERIFYING VEHICLE REPAIR  under SELF-DIAGNOSTIC SYSTEM. If scan tool indicates diagnostic did not pass, repeat test starting in step  2 .
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