P0403

 

DTC    P0403    Exhaust Gas Recirculation Control Circuit


 

DESCRIPTION

Refer to DTC P0401.
 

DTC No.DTC Detection ConditionTrouble Area
P0403Open or short in EGR valve circuit (1 trip detection logic).
  1. Open or short in EGR valve assembly circuit
  2. EGR valve assembly
  3. ECM

HINT:

DTC P0403 is set when the power switch is on (IG).

 

MONITOR DESCRIPTION

This DTC is designed to detect an open or short in the EGR valve assembly circuit.
Example:

  1. If the EGR1, EGR2, EGR3 or EGR4 terminal output voltage is excessively low, but the step motor is still operating, the ECM determines that there is a short in the EGR valve assembly circuit , and sets the DTC.
  2. If the EGR1, EGR2, EGR3 or EGR4 terminal output voltage is excessively low, and the step motor is not operating, the ECM determines that there is an open in the EGR valve assembly circuit, and sets the DTC.

 

MONITOR STRATEGY

Frequency of OperationContinuous


 

CONFIRMATION DRIVING PATTERN


P0403 Exhaust Gas Recirculation Control Circuit CT200h / ZWA10

 

  1. Connect the intelligent tester to the DLC3.
  2. Turn the power switch on (IG) and turn the tester on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC operation).
  4. Turn the power switch off and wait for 30 seconds.
  5. Turn the power switch on (IG) and turn the tester on [A].
  6. Put the engine in inspection mode (maintenance mode).
  7. Start the engine and warm it up [B].
  8. Drive the vehicle at 20 km/h (12.4 mph) or more for 10 minutes [C].

    CAUTION:

    When performing the confirmation driving pattern, obey all speed limits and traffic laws.

     

  9. Enter the following menus: Powertrain / Engine and ECT / DTC [D].
  10. Read the pending DTCs.

    HINT:

    1. If a pending DTC is output, the system is malfunctioning.
    2. If a pending DTC is not output, perform the following procedure.

     

  11. Enter the following menus: Powertrain / Engine and ECT / Utility / All Readiness.
  12. Input the DTC: P0403.
  13. Check the DTC judgment result.

    Tester DisplayDescription
    NORMAL
    1. DTC judgment completed
    2. System normal
    ABNORMAL
    1. DTC judgment completed
    2. System abnormal
    INCOMPLETE
    1. DTC judgment not completed
    2. Perform driving pattern after confirming DTC enabling conditions
    UNKNOWN
    1. Unable to perform DTC judgment
    2. Number of DTCs which do not fulfill DTC preconditions has reached ECU's memory limit

    HINT:

    1. If the judgment result shows NORMAL, the system has a normal.
    2. If the judgment result shows ABNORMAL, the system has a malfunction.

     

 

WIRING DIAGRAM


P0403 Exhaust Gas Recirculation Control Circuit CT200h / ZWA10



 

INSPECTION PROCEDURE

NOTICE:

Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT:

Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

 

1.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION)
  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Turn the tester on.

  1. Put the engine in inspection mode (maintenance mode).

  1. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

    HINT:

    The A/C switch and all accessory switches should be off.
  1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position / Data List / All Data / Throttle Idle Position and MAP.

  1. Confirm that the Throttle Idle Position is ON and check the engine idling condition and MAP values in the Data List while performing the Active Test.

    HINT:
    1. Do not leave the EGR valve open for 10 seconds or more during the Active Test.
    2. Be sure to return the EGR valve to step 0 when the Active Test is completed.
    3. Do not open the EGR valve 30 steps or more during the Active Test.
    OK:
    MAP and idling condition change in response to EGR step position when Throttle Idle Position is ON in Data List.

     

    Standard:

    -EGR Step Position (Active Test)
    0 Steps0 to 30 Steps
    Idling conditionSteady idlingIdling changes from steady to rough idling or stalls
    MAP
    (Data List)
    MAP value is 20 to 40 kPa (150 to 300 mmHg)
    (EGR valve is fully closed)
    MAP value is at least +10 kPa (75 mmHg) higher than when EGR valve is fully closed

     

    Result 
    ResultProceed to
    Within standard rangeA
    Outside of standard rangeB

     

 B
Go to step 2
 
A 
 
CHECK FOR INTERMITTENT PROBLEMS  

 

2.INSPECT EGR VALVE ASSEMBLY
  1. Inspect the EGR valve assembly.

 

 NG
REPLACE EGR VALVE ASSEMBLY 
 
OK 
 

 

3.INSPECT EGR VALVE ASSEMBLY (+B1 OR +B2 VOLTAGE)


 

P0403 Exhaust Gas Recirculation Control Circuit CT200h / ZWA10
  1. Disconnect the EGR valve assembly connector.

  1. Turn the power switch on (IG).

  1. Measure the voltage according to the value(s) in the table below.

    Standard Voltage:
    Tester ConnectionSwitch ConditionSpecified Condition
    D10-2 (+B1) - Body groundPower switch on (IG)11 to 14 V
    D10-5 (+B2) - Body groundPower switch on (IG)11 to 14 V
    Text in Illustration 
    *aFront view of wire harness connector
    (to EGR Valve Assembly)
 NG
REPAIR OR REPLACE HARNESS OR CONNECTOR (EGR VALVE ASSEMBLY - EFI MAIN RELAY)
 
OK 
 

 

4.CHECK HARNESS AND CONNECTOR (ECM - EGR VALVE ASSEMBLY)
  1. Disconnect the EGR valve assembly connector.

  1. Disconnect the ECM connector.

  1. Measure the resistance according to the value(s) in the table below.
     

    Standard Resistance:

    Tester ConnectionConditionSpecified Condition
    D27-45 (EGR1) - D10-4 (EGR1)AlwaysBelow 1 Ω
    D27-44 (EGR2) - D10-3 (EGR2)AlwaysBelow 1 Ω
    D27-43 (EGR3) - D10-6 (EGR3)AlwaysBelow 1 Ω
    D27-42 (EGR4) - D10-1 (EGR4)AlwaysBelow 1 Ω
    D27-45 (EGR1) or D10-4 (EGR1) - Body groundAlways10 kΩ or higher
    D27-44 (EGR2) or D10-3 (EGR2) - Body groundAlways10 kΩ or higher
    D27-43 (EGR3) or D10-6 (EGR3) - Body groundAlways10 kΩ or higher
    D27-42 (EGR4) or D10-1 (EGR4) - Body groundAlways10 kΩ or higher
 NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
 
OK 
 

 

5.CHECK DTC OUTPUT RECORDS (DTC P0403)
  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG) and turn the tester on.

  1. Clear the DTCs.

  1. Drive the vehicle in accordance with the driving pattern described in the Confirmation Driving Pattern.

  1. Enter the following menus: Powertrain / Engine and ECT / DTC.

  1. Read the DTCs.

    Result 
    ResultProceed to
    DTC is not outputA
    DTC P0403 is outputB
 B
REPLACE ECM
 
A 
 
END