Inspection and verification
1. Make sure the customer's complaint is valid.
2. Visually inspect for obvious mechanical and electrical problems.
Mechanical factors | Electrical Factors |
3. If an obvious cause of a problem you identified or described by a customer is found, resolve it before proceeding to the next steps (if possible).
4. Use an approved diagnostic system or scan tool (tester), to retrieve all DTCs before referring to the symptom table or DTC index (DTC).
Clear all DTCs after troubleshooting.
Symptom table
Symptom (specific) | Possible reason | Action |
EGR valve stuck open. | Check the EGR valve. | |
Engine stops/stops | Check the EGR valve. Check engine ventilation system. Check oil separator. Check for EGR related DTCs. | |
Check the EGR valve. Check engine ventilation system. Check oil separator. Check for EGR related DTCs. | ||
Increased gas breakthrough | Decrease in air flow / blockage of the ventilation system | Check engine ventilation hoses. Check oil separator. |
Engine oil leaks | Decrease in air flow / blockage of the ventilation system | Check engine ventilation hoses. Check oil separator. |
DTC index
NOTE: Universal Scan Tools cannot read the listed codes or can only read 5-digit codes. Match the 5 digits from the scan tool with the first 5 digits of the listed 7 digit code to identify the problem (the last 2 digits give additional information read by the diagnostic system approved by the manufacturer).
NOTE: See section 303-14 for a more complete symptom table "Electronic engine management system" in the workshop manual.
DTC | Description | Possible reason | Action |
P040100 | Insufficient flow registered in EGR system A | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by turning the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040200 | Excessive flow registered in EGR system A | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by switching the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040300 | Electrical circuit A for controlling the exhaust gas recirculation system | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by turning the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040400 | Problems with the operating range/characteristics of the electrical circuit A of the exhaust gas recirculation control system | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by switching the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040500 | Low Voltage EGR Sensor Circuit A | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by switching the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040600 | High Voltage EGR Sensor Circuit A | Refer to the relevant section in the workshop manual. Check the EGR valve, coolers and piping. Refer to the electrical manual and check the MAF sensor and circuits. Allow the engine to warm up by switching the ignition off and on. Using the data logging function, check the EGR valve angle. Command the valve actuator to control pulse width modulated 0% then 100% and check the reading again. The angle must be between 5% and 95%. If not, install a new valve if necessary. Clear DTCs and check for correct operation. | |
P040700 | Low voltage in the electrical circuit of the sensor B of the exhaust gas recirculation system | Check EGR throttle position sensor and circuits. Refer to the electrical manual. If no electrical fault is found, install a new EGR valve. Clear DTCs and check for correct operation. | |
P040800 | High voltage in the electrical circuit of the sensor B of the exhaust gas recirculation system | Check EGR throttle position sensor and circuits. Refer to electrical manuals. If no electrical fault is found, install a new EGR valve. Clear DTCs and check for correct operation. | |
P048700 | Break in the electrical circuit A of the throttle valve control of the exhaust gas recirculation system | Check EGR throttle position sensor and circuits. Refer to the electrical manual. Using the data logging function, check the EGR throttle position with the ignition on and the engine off and record the reading. Give the actuator a command for a control pulse width modulated (PWM) 100% and check the position reading. The reading should be between 80 and 95%. Give the actuator a command for a control pulse width modulated (PWM) 0% and check the position reading. The reading should be between 5 - 20%. Manually close and open the throttle and check for resistance. The resistance should be between 300 and 2500 ohms. If the values are not within this range, install a new EGR valve. Clear DTCs and check for correct operation. If the problem still persists, the ECM is suspected. If an ECM malfunction is suspected, refer to the Warranty Policy and Procedures Manual. | |
P048800 | Problems with the operating range/characteristics of the electrical circuit A of the throttle control of the exhaust gas recirculation system | Check EGR throttle position sensor and circuits. Refer to the electrical manual. Using the data logging function, check the EGR throttle position with the ignition on and the engine off and record the reading. Give the actuator a command for a control pulse width modulated (PWM) 100% and check the position reading. The reading should be between 80 and 95%. Give the actuator a command for a control pulse width modulated (PWM) 0% and check the position reading. The reading should be between 5 - 20%. Manually close and open the throttle and check for resistance. The resistance should be between 300 and 2500 ohms. If the values are not within this range, install a new EGR valve. Clear DTCs and check for correct operation. If the problem still persists, the ECM is suspected. If an ECM malfunction is suspected, refer to the Warranty Policy and Procedures Manual. | |
P133400 | Problems with the minimum / maximum limit positions of the throttle position sensor of the EGR system | Check the EGR valve and electrical circuits. Refer to the electrical manual. Refer to the relevant section in the workshop manual. If a module is suspected, refer to the warranty policy and procedures manual. | |
P133500 | Problems with the minimum / maximum limit positions of the EGR position sensor | Check the EGR valve and electrical circuits. Refer to electrical manuals. Using the data logging function, check the EGR valve angles and command the valve to control pulse width modulation (PWM) 0%. Check the angle again. The reading should be between 0 - 20%. If the value is outside this range, install a new valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P140A00 | Low voltage in the electrical circuit of the sensor C of the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to the electrical manual. Using the data logging function, check the EGR valve angle with the ignition on and the engine off. Send a control pulse width modulation of 0% and then 100% to the valve corner and check the angle values. The angles should be between 0-20% and 80-95%. If not, install a new valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P140B00 | High voltage in the electrical circuit of the sensor C of the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to the electrical manual. Using the data logging function, check the EGR valve angle with the ignition on and the engine off. Send a control pulse width modulation of 0% and then 100% to the valve corner and check the angle values. The angles should be between 0-20% and 80-95%. If not, install a new valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P140C00 | Electrical circuit B for controlling the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to electrical manuals. If a module is suspected, refer to the warranty policy and procedures manual. | |
P140D00 | Problems with the operating range / characteristics of the electrical circuit B of the control of the exhaust gas recirculation system | Check IAT, MAP and MAF sensors and circuits. Refer to the electrical manual. Left bank EGR valve circuit checks are described in the relevant section of the workshop manual. | |
P140E00 | Problems with the minimum / maximum limit positions of the sensor C of the EGR system | Check the EGR valve and electrical circuits. Refer to electrical manuals. Using the data logging function, check the EGR valve angles and command the valve to control pulse width modulation (PWM) 0%. Check the corner again. The value should be 0 - 20%. If the value is outside this range, install a new valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P141A00 | Intermittent / chaotic malfunction in the electrical circuit of the sensor A of the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to electrical manuals. Start the engine and let it warm up. Using the data logging function, check the position of the EGR valve. After another 5 seconds, check the position again. If the value has increased by more than 80% in 10ms, check the circuits again. If no electrical fault is found, install a new EGR valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P141B00 | Intermittent / chaotic malfunction in the electrical circuit of the sensor B of the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to electrical manuals. Start the engine and let it warm up. Using the data logging function, check the position of the EGR valve. After another 5 seconds, check the position again. If the value has increased by more than 80% in 10ms, check the circuits again. If no electrical fault is found, install a new EGR valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P141C00 | Intermittent / chaotic malfunction in the electrical circuit of the sensor C of the exhaust gas recirculation system | Check the EGR valve and electrical circuits. Refer to electrical manuals. Start the engine and let it warm up. Using the data logging function, check the position of the EGR valve. After another 5 seconds, check the position again. If the value has increased by more than 80% in 10ms, check the circuits again. If no electrical fault is found, install a new EGR valve. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P214100 | Low voltage in the electrical circuit A of the throttle control of the exhaust gas recirculation system | Check the EGR sensor circuits. Refer to electrical manuals. Repair if necessary. Clear DTCs and check for correct operation. Using the data logger function, read the difference between the target and actual eGr throttle position and the actual EGR throttle position. Make sure the throttle is open and command the throttle to close. Verify that the throttle position value increases above 90%. Check the difference between target and actual position. This value must not exceed a maximum of 5% or a minimum of -15%. Make sure the EGR throttle is not sticking. Install a new right valve if necessary. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. | |
P214200 | High voltage in the electrical circuit A of the throttle control of the exhaust gas recirculation system | Check the EGR sensor circuits. Refer to electrical manuals. Repair if necessary. Clear DTCs and check for correct operation. Using the data logger function, read the difference between the target and actual eGr throttle position and the actual EGR throttle position. Make sure the throttle is open and command the throttle to close. Verify that the throttle position value increases above 90%. Check the difference between target and actual position. This value must not exceed a maximum of 5% or a minimum of -15%. Make sure the EGR throttle is not sticking. Install a new left valve if necessary. Refer to the relevant section in the workshop manual. Clear DTCs and check for correct operation. |
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