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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 14 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - DTC P0700 TO DTC P2463)DTC P2463CIRCUIT/SYSTEM TESTING
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Circuit/System Testing

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Circuit/System Testing
WARNING: This page is about a different variant/trim than selected.
    IMPORTANT: Perform the Repair Verification after completing the Circuit/System Testing.
  1. Visually inspect the exhaust differential pressure system for any of the following conditions:
    • Modifications
    • Damaged components
    • Bends or kinks
    • Loose or improperly installed components
    • Improperly routed differential pressure lines

      The exhaust differential pressure line should have a continuous downward gradient from the sensor.

  2. Test for water in fuel contamination. Refer to Contaminants-in-Fuel Diagnosis .
  3. Remove and visually inspect the flexible part of the exhaust differential pressure lines for internal restrictions.
    • If a condition is found, replace the exhaust differential pressure lines.
  4. Ignition ON, observe the scan tool EGR Position Sensor and Desired EGR Position parameters while commanding the EGR solenoid to 20 percent and 0 percent. The values should remain equal to or less than 3 percent.
    • If greater than the specified range, replace the EGR valve.
  5. Test the EGR valve gaskets and cooler gaskets for leaks. Apply a soap solution to the gaskets while commanding the TC Vane Pos. Ctrl. Solenoid ON, and inspect for excessive air bubbles at the EGR valve gaskets and cooler gaskets.
    • If an air leak is found, replace the EGR valve gaskets or EGR cooler gasket.
  6. Test the fuel system for leaking, restricted or sticking fuel injectors, high fuel pressures, or high fuel injector flow rates. Refer to Fuel Injector Balance Test with Tech 2 .
  7. Test the charge air cooler (CAC) for leaks. Refer to Charge Air Cooler Diagnosis (Full System Air Leak Test) or Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test) or Charge Air Cooler Diagnosis (Induction System Smoke Test) .
  8. Ignition OFF, disconnect the harness connector at the exhaust differential pressure sensor.
  9. Ignition OFF for 90 seconds, test for less than 5 ohms between the low reference circuit terminal 1 and ground.
    • If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the ECM.
  10. Disconnect the harness connector X1 at the ECM.
  11. Test for less than 5 ohms on the differential pressure sensor circuits between the following terminals:
    • ECM X1 5-volt reference circuit terminal 14 to exhaust differential pressure sensor terminal 3.
    • ECM X1 signal circuit terminal 43 to exhaust differential pressure sensor terminal 2.
    • If greater than the specified range, repair the affected circuit for an open/high resistance.
  12. If all circuits and engine control components test normal, test or replace the exhaust differential pressure sensor.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.