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HOMESERVICE MANUALSSATURN1999SL2 AUTOMATIC, MP6REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROL SYSTEM - TESTS W/CODES - DTC P0352-P0452DTC P0404DTC P0404: EGR VALVE OPEN PINTLE POSITION (4.8L, 5.3L & 6.0L "C" & "K" SERIES)DIAGNOSTIC PROCEDURES
1999 Saturn SL2 Automatic, MP6

Diagnostic Procedures

1999 Saturn SL2 Automatic, MP6SECTION Diagnostic Procedures
  1. Perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS INTRODUCTION article. After performing OBD system check, go to next step.
  2. Turn ignition on, with engine off. Using scan tool, command EGR valve to 50 percent. If engine runs rough or stall, go to next step. If engine does not run rough or stall, go to step  6.
  3. Operate engine at idle. Command EGR valve to 50 percent. Monitor actual EGR position on scan tool. If actual EGR position is 48-52 percent, see DIAGNOSTIC AIDS . If actual EGR position is not 48-52 percent, go to next step.
  4. Turn ignition off. Disconnect PCM harness connector C2. Disconnect EGR harness connector. Using DVOM, check resistance of EGR valve control circuit. If resistance is 0-2 ohms, go to next step. If resistance is not 0-2 ohms, go to step  14.
  5. Check resistance of EGR valve ground circuit. If resistance is 0-2 ohms, go to step  16. If resistance is not 0-2 ohms, go to step  15.
  6. Turn ignition off. Disconnect EGR valve harness connector. Turn ignition on. Connect a test light between ground and EGR control circuit. Using scan tool, command EGR valve to 100 percent. If test light illuminates, go to next step. If test light does not illuminate, go to step  8.
  7. Connect test light between battery voltage and EGR ground circuit. If test light illuminates, go to step  16. If test light does not illuminate, go to step  11.
  8. Turn ignition off. Disconnect PCM harness connector C2. Disconnect EGR harness connector. Using DVOM, check continuity of EGR valve control circuit. If continuity exists, go to next step. If continuity does not exist, go to step  12.
  9. Check continuity between ground and EGR valve control circuit. If continuity exists, go to step  12. If continuity does not exist, go to next step.
  10. Check continuity from EGR control circuit to all other circuits in the PCM harness connector. If continuity exists, go to step  12. If continuity does not exist, go to step  18.
  11. Turn ignition off. Disconnect PCM harness connector C2. Disconnect EGR harness connector. Using DVOM, check continuity of EGR valve ground circuit. If continuity exists, go to step  18. If continuity does not exist, go to step  13.
  12. Repair open or short to ground in EGR valve control circuit. After repairs, go to step  20.
  13. Repair open in EGR valve ground circuit. After repairs, go to step  20.
  14. Repair high resistance in EGR valve control circuit. After repairs, go to step  20.
  15. Repair high resistance in EGR valve ground circuit. After repairs, go to step  20.
  16. Check for poor connections at EGR valve harness connector. Repair as necessary. After repairs, go to step  20. If connections are okay, go to next step.
  17. Replace EGR valve. After replacing EGR valve, go to step  20.
  18. Check for poor connection at PCM connector. Repair as necessary. After repairs, go to step  20. If connections are okay, go to next step.
  19. Replace PCM. Program replacement PCM using required equipment. After replacing PCM, go to next step.
  20. Using scan tool, select DTC, CLEAR INFO function. Start and warm engine to normal operating temperature. Select DTC, SPECIFIC, then enter this DTC. Operate vehicle within conditions for setting this DTC. If scan tool indicates that this test ran and passed, go to next step. If scan tool did not indicate that this test ran and passed, repeat step  2.
  21. Using scan tool, select CAPTURE INFO, REVIEW INFO function. If any undiagnosed DTCs are displayed, go to applicable DTC test. If no additional DTCs are set, system is okay.
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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.