DTC P0403:00 [PCM (SKYACTIV-G 2.5T)]

id0102s8704300

DTC P0403:00	EGR valve control circuit problem
DETECTION CONDITION	• The PCM monitors the input voltage from the EGR valve. If the voltage remain low or high, the PCM determines that the EGR valve circuit has a malfunction. Diagnostic support note • This is a continuous monitor (CCM). • The check engine light does not illuminate. • FREEZE FRAME DATA is not available. • Snapshot data is available. • DTC is stored in the PCM memory.
FAIL-SAFE FUNCTION	• Inhibits the EGR control.
POSSIBLE CAUSE	• EGR valve connectors or terminals malfunction • Short to ground or open circuit in EGR valve power supply circuit ? Short to ground in wiring harness between the following terminals: • ENGINE1 15 A fuse—EGR valve terminal C • ENGINE1 15 A fuse—EGR valve terminal D ? ENGINE1 15 A fuse malfunction ? Open circuit in wiring harness between the following terminals: • Main relay terminal C—EGR valve terminal C • Main relay terminal C—EGR valve terminal D • Short to ground in wiring harness between the following terminals: ? EGR valve terminal A—PCM terminal 1J ? EGR valve terminal E—PCM terminal 1Y ? EGR valve terminal B—PCM terminal 1O ? EGR valve terminal F—PCM terminal 1T • PCM connector or terminals malfunction • Short to power supply in wiring harness between the following terminals: ? EGR valve terminal A—PCM terminal 1J ? EGR valve terminal E—PCM terminal 1Y ? EGR valve terminal B—PCM terminal 1O ? EGR valve terminal F—PCM terminal 1T • EGR valve circuits are shorted to each other • Open circuit in wiring harness between the following terminals: ? EGR valve terminal A—PCM terminal 1J ? EGR valve terminal E—PCM terminal 1Y ? EGR valve terminal B—PCM terminal 1O ? EGR valve terminal F—PCM terminal 1T • EGR valve malfunction • PCM malfunction

Diagnostic Procedure

STEP	INSPECTION		ACTION
1	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 snapshot data on the repair order.	—	Go to the next step.
2	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.
2		No	Go to the next step.
3	INSPECT EGR VALVE CONNECTOR CONDITION • Switch the ignition off. • Disconnect the EGR valve connector. • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction?	Yes	Repair or replace the connector and/or terminals, then go to Step 11.
3		No	Go to the next step.
4	INSPECT EGR VALVE POWER SUPPLY CIRCUIT FOR SHORT TO GROUND OR OPEN CIRCUIT • Verify that the EGR valve connector is disconnected. • Switch the ignition ON (engine off). Note • Another DTC may be stored by the PCM detecting an open circuit. • Measure the voltage at the following terminals (wiring harness-side): ? EGR valve terminal C ? EGR valve terminal D • Is the voltage B+?	Yes	Go to the next step.
4		No	Inspect the ENGINE1 15 A fuse. • If the fuse is blown: ? Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • ENGINE1 15 A fuse—EGR valve terminal C • ENGINE1 15 A fuse—EGR valve terminal D If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to ground. • Replace the fuse. • If the fuse is damaged: ? Replace the fuse. • If the fuse is normal: ? Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • Main relay terminal C—EGR valve terminal C • Main relay terminal C—EGR valve terminal D If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 11.
5	INSPECT EGR VALVE CIRCUIT FOR SHORT TO GROUND • Verify that the EGR valve connector is disconnected. • Switch the ignition off. • Inspect for continuity between the following terminals (wiring harness-side) and body ground: ? EGR valve terminal A ? EGR valve terminal E ? EGR valve terminal B ? EGR valve terminal F • Is there continuity?	Yes	Disconnect the PCM connector and inspect the wiring harness for short to ground. • If the short to ground circuit could be detected in the wiring harness: ? Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • EGR valve terminal A—PCM terminal 1J • EGR valve terminal E—PCM terminal 1Y • EGR valve terminal B—PCM terminal 1O • EGR valve terminal F—PCM terminal 1T If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to ground. • If the short to ground circuit could not be detected in the wiring harness: ? Replace the PCM (short to ground in the PCM internal circuit). (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) Go to Step 11.
5		No	Go to the next step.
6	INSPECT PCM CONNECTOR CONDITION • Disconnect the PCM connector. • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction?	Yes	Repair or replace the connector and/or terminals, then go to Step 11.
6		No	Go to the next step.
7	INSPECT EGR VALVE CIRCUIT FOR SHORT TO POWER SUPPLY • Verify that the EGR valve and PCM connectors are disconnected. • Switch the ignition ON (engine off). Note • Another DTC may be stored by the PCM detecting an open circuit. • Measure the voltage at the following terminals (wiring harness-side): ? EGR valve terminal A ? EGR valve terminal E ? EGR valve terminal B ? EGR valve terminal F • Is the voltage 0 V?	Yes	Go to the next step.
7		No	Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • EGR valve terminal A—PCM terminal 1J • EGR valve terminal E—PCM terminal 1Y • EGR valve terminal B—PCM terminal 1O • EGR valve terminal F—PCM terminal 1T If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to power supply. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to power supply. Go to Step 11.
8	INSPECT EGR VALVE CIRCUITS FOR SHORT TO EACH OTHER • Verify that the EGR valve and PCM connectors are disconnected. • Switch the ignition off. • Inspect for continuity EGR valve terminals A, E, B and F (wiring harness-side). • Is there continuity?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • EGR valve terminal A—PCM terminal 1J • EGR valve terminal E—PCM terminal 1Y • EGR valve terminal B—PCM terminal 1O • EGR valve terminal F—PCM terminal 1T If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to each other. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to each other. Go to Step 11.
8		No	Go to the next step.
9	INSPECT EGR VALVE CIRCUIT FOR OPEN CIRCUIT • Verify that the EGR valve and PCM connectors are disconnected. • Inspect for continuity between the following terminals (wiring harness-side): ? EGR valve terminal A—PCM terminal 1J ? EGR valve terminal E—PCM terminal 1Y ? EGR valve terminal B—PCM terminal 1O ? EGR valve terminal F—PCM terminal 1T • Is there continuity?	Yes	Go to the next step.
9		No	Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • EGR valve terminal A—PCM terminal 1J • EGR valve terminal E—PCM terminal 1Y • EGR valve terminal B—PCM terminal 1O • EGR valve terminal F—PCM terminal 1T If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 11.
10	INSPECT EGR VALVE • Inspect the EGR valve. (See EGR VALVE INSPECTION [SKYACTIV-G 2.5T].) • Is there any malfunction?	Yes	Replace the EGR valve, then go to the next step. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
10		No	Go to the next step.
11	VERIFY DTC TROUBLESHOOTING COMPLETED • Always reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the M-MDS. (See CLEARING DTC [PCM (SKYACTIV-G 2.5T)].) • Perform the KOEO or KOER self test. (See KOEO/KOER SELF TEST [PCM (SKYACTIV-G 2.5T)].) • Is the same DTC present?	Yes	Repeat the inspection from Step 1. • If the malfunction recurs, replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) Go to the next step.
11		No	Go to the next step.
12	VERIFY AFTER REPAIR PROCEDURE • Perform the “AFTER REPAIR PROCEDURE”. (See AFTER REPAIR PROCEDURE [PCM (SKYACTIV-G 2.5T)].) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-G 2.5T)].)
12		No	DTC troubleshooting completed.