Engine Controls - MIL ON/DTC's P0403/P0401 Set
TECHNICALBulletin No.: 06-06-04-066D
Date: February 06, 2009
Subject:
Check Engine Light On, DTC P0403 Set (Check/Reprogram ECM and Perform EGR Valve Motor Cleaning Procedure)
Models:
2006-2007 Chevrolet Express, Kodiak C4500/C5500 Series, Silverado, Silverado Classic
2006-2007 GMC Savana, Sierra, Sierra Classic, TopKick C4500/C5500 Series
with 6.6L Duramax Diesel Engine (VINs D, 2 - RPOs LBZ, LLY)
Supercede:
This bulletin is being revised to update the correction information and to reduce the warranty labor time for the cleaning procedure due to the release of new software. Please discard Corporate Bulletin Number 06-06-04-066C (Section 06 - Engine/Propulsion System)
Condition
Some customers may comment on an illumination of the check engine light.
Upon further investigation, the technician may find the following DTCs stored in the ECM:
^ P0403: EGR Solenoid Control Circuit
^ P0401: (Exhaust Gas Recirculation Flow Is Insufficient) may also be present with P0403.
Cause
This condition may be caused by the engine control module (ECM) calibration.
Correction
ECM Reprogramming for DTC P0401 and P0403
Important:
Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool.
Check the ECM calibration level and reprogram the ECM with the latest calibrations, if required. An ECM calibration was released in March 2007 to address this concern. This calibration, or any that follow, is designed to address this concern. The ECM calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Engine Control Module Programming and Setup procedure in SI. As always make sure your Tech 2(R) is updated with the latest software version.
For vehicles that set DTC P0403: After reprogramming of the ECM, the EGR valve motor cleaning procedure should be performed before returning the vehicle to the customer.
EGR Valve Motor Cleaning Procedure (DTC P0403 Only)
Important:
Make sure your Tech 2(R) is updated with version 29.002 or later to access the revised EGR Valve Motor Cleaning software.
Technicians should perform the following cleaning procedure to ensure that DTC P0403 has been eliminated:
Important:
Two scenarios may occur when completing this procedure.
^ There is no EGR Valve Motor Cleaning procedure found in the Tech 2 Special Functions. This can occur on 2006 or 2007 vehicles. If the Tech 2 and the ignition is not turned off after programming, a technician may not find the updated EGR Motor Cleaning special function in output controls. To access the updated special function, turn off the ignition key, power down the Tech 2 (unplug it from the vehicle), power the Tech 2 back up, rebuild the proper vehicle, and then see if the special function is found. Complete the remaining steps in the bulletin.
^ If working with a 2007 model year vehicle, a technician may not be able to find the EGR solenoid command to know when the EGR cleaning procedure has been completed. When following the bulletin and steps 5.4 to 5.5 are reached, technicians are directed to start the EGR Motor Cleaning procedure, and monitor the EGR solenoid command. If the EGR solenoid command is not displayed on the Tech 2, the technician will have to back out of the Tech 2, and build the vehicle as a 2006 model year. When the 2007 vehicle is built as a 2006, the procedure can be completed and monitored.
Note
Only build the vehicle as a 2006 after the new ECM calibration has been installed, and the EGR solenoid command is missing.
1. Start the engine. Let the engine idle until the engine coolant temperature is greater than 60°C (140°F). Then shut the engine off.
2. Attach a Midtronics 165-PCS charger or equivalent to maintain proper battery voltage.
3. Turn the ignition key to the ON position with the engine off (engine should not be running).
4. Attach a Tech 2(R) to the vehicle and clear all the codes.
Important:
The cleaning procedure may take up to 15 minutes to complete, it is not necessary for the technician to watch or stay with the vehicle. The EGR Solenoid Command will stop cycling and stay at 0% when the procedure is completed.
5. Request and start the EGR Valve Motor Cleaning procedure with a Tech 2(R) using the steps 1 - 6 shown above.
6. Once the cleaning cycling is complete, disconnect the Tech 2(R) and remove the charger from the vehicle.
7. Verify the condition has been corrected by evaluating the vehicle's performance and EGR operation.
Warranty Information
Disclaimer