DTC    P0401    Exhaust Gas Recirculation Flow Insufficient Detected

for Preparation Click here


DESCRIPTION

Based on the driving conditions, the ECM regulates the volume of exhaust gas that is recirculated to the engine's combustion chambers and thus lowers the combustion temperature to reduce Nitrogen Oxides emissions. The ECM monitors signals such as engine speed, coolant temperature, electric load, and vehicle speed. When the EGR permission conditions are fulfilled, the ECM controls the opening of the EGR valve linearly through signals to the EGR step motor.
The ECM opens and closes the EGR valve during fuel-cut and monitors changes in the manifold absolute pressure to detect poor movement or sticking of the EGR valve.

DTC No.
DTC Detection Condition
Trouble Area
P0401
Change in intake manifold pressure is small when the EGR valve opened and closed during fuel cut operation
(2 trip detection logic)
  1. Open or short in EGR circuit
  2. EGR valve assembly
  3. EGR passage
  4. Manifold absolute pressure sensor
  5. ECM

HINT:
DTC P0401 is set while the engine is in fuel cut condition and the brake pedal is pressed for 5 seconds.


CONFIRMATION DRIVING PATTERN


A219133E02

  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to ON.
  3. Turn the tester on.
  4. Clear the DTCs (Click here).
  5. Turn the ignition switch off and wait for at least 30 seconds.
  6. Turn the ignition switch to ON and turn the tester on. [A]
  7. Start the engine and warm it up (until the engine coolant temperature 75°C (167°F)). [B]

    HINT:
    1. The A/C switch and all accessory switches should be off.
    2. Shift lever in P or N (for CVT).

  8. Drive the vehicle at between 60 km/h (37 mph) for 5 minutes or more. [C]

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

  9. Idle the engine for 30 seconds or more. [D]
  10. Accelerate the vehicle at between 60 km/h (37 mph) then select the shift lever in B or 2nd gear. [E]

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

  11. Perform the fuel cut operation for 5 seconds or more, with the accelerator pedal fully released. [F]

    HINT:
    When the fuel cut is operating, "Idle Fuel Cut" in Data List is ON.

  12. Enter the following menus: Powertrain / Engine and ECT / Data List / EGR/VVT Monitor.
  13. Check that the item EGR/VVT Monitor displays is Compl (Complete).

    HINT:
    If the EGR/VVT Monitor is Incmpl (Incomplete), perform the driving pattern again.

  14. If the EGR/VVT Monitor is still Incmpl (Incomplete), perform the following procedure.
    1. Enter the following menus: Powertrain / Engine and ECT / DTC / Pending. [G]
    2. Read the Pending DTC.
    3. If a pending DTC is output, the system is malfunctioning.

      HINT:
      If a pending DTC is not output, perform the following procedure.

  15. Enter the following menus: Powertrain / Engine and ECT / Utility / All Readiness.
  16. Input the DTC P0401.
  17. Check the DTC judgment result.

    Intelligent Tester 
    Tester Display
    		Description
    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 shown ABNORMAL, the system has malfunction.
    2. If the judgment result shows INCOMPLETE or UNKNOWN and no pending DTC is output, accelerate the vehicle again at 60 km/h (37 mph) then select the B or 2nd gear, perform fuel cut operation for 5 seconds or more with the accelerator pedal fully released, and check the DTC judgment result.


WIRING DIAGRAM

Refer to the DTC P0403 (Click here).

INSPECTION PROCEDURE

HINT:
  1. By using the Control the EGR Step Position Active Test, the operation of the EGR valve can be checked.
  2. If the EGR valve is normal, the engine condition is as follows:
    The engine idles steady while the EGR valve is fully closed. When the EGR valve is opened using the Active Test, the Data List values will change as shown in the table below.

    Data List
    		Change
    Engine Speed
    		Idle becomes rough
    MAP
    		Pressure rises
  3. 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.CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P0401)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

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

  1. Read the DTC.

Result 
Result
Proceed to
DTC P0401 is output
A
DTC P0401 and other DTCs are output
B


B
GO TO DTC CHART (Click here)
A


2.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

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

    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.

  1. Check the MAP and Engine Speed in Date List at the idling condition while performing Active Test.

    OK:
    MAP and idling condition change in response to EGR step position.


    Standard:

    -
    		EGR Step Position (Active Test)
    0 Steps
    		0 to 30 Steps
    Idling condition
    		Steady idling
    		Idling changes from steady to rough idling
    MAP
    (Data List)
    		-
    		MAP value is at least +10 kPa (75 mmHg) higher than when EGR valve is fully closed

    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 Active Test is completed.



NG
Go to step 4
OK


3.INSPECT EGR VALVE ASSEMBLY

  1. Remove the EGR valve assembly (Click here).

  1. Check for contamination between the EGR valve and housing.

    OK:
    No leaks or blockage

    Result 
    Result
    		Proceed to
    NG
    		A
    OK
    		B

  1. Reinstall the EGR valve assembly (Click here).



B
Go to step 5
A


4.REPLACE EGR VALVE ASSEMBLY

  1. Replace the EGR valve assembly (Click here).


NEXT


5.CHECK FOR DEPOSIT (EXHAUST MANIFOLD CONVERTER TO EGR VALVE)

  1. Check for cracks, damage, and clogs in the pipes between the exhaust manifold converter and the EGR valve assembly.

  1. Check for exhaust leaks at each connection point.

HINT:
This check may require the removal of components (Click here).

OK:
No deposit



NG
REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENTS AND AREAS
OK


6.CHECK FOR DEPOSIT (EGR VALVE TO INTAKE PORT)

  1. Check for cracks, damage, and clogs in the pipes between the exhaust manifold converter and the EGR valve assembly.

  1. Check for exhaust leaks at each connection point.

HINT:
This check may require the removal of components (Click here).

OK:
No deposit



NG
REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENTS AND AREAS
OK


7.READ VALUE USING INTELLIGENT TESTER (MANIFOLD ABSOLUTE PRESSURE SENSOR)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAP.

  1. Read the MAP value.

    Standard:
    Engine condition
    		Tester Display
    Ignition switch ON
    		80 to 110 kPa (600 to 825 mmHg)

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

  1. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAP.

  1. Read the MAP value with the engine at idle, and with the A/C and all accessory switches off and with the shift lever in P, N or neutral.

    Standard:
    Engine condition
    		Tester Display
    Idling
    		20 to 40 kPa (150 to 300 mmHg)

    Result 
    Result
    		Proceed to
    NG
    		A
    OK
    		B



B
Go to step 10
A


8.CHECK INTAKE SYSTEM

  1. Check the intake system for vacuum leaks (Click here).

    OK:
    No leaks in intake system.



NG
REPAIR OR REPLACE INTAKE SYSTEM
OK


9.REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

  1. Replace the manifold absolute pressure sensor (Click here).


NEXT


10.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Perform the confirmation drive pattern.

    HINT:
    Refer to the CONFIRMATION DRIVE PATTERN.


NEXT

END