Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSATURN2000LW2 AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS - SELF-DIAGNOSTICSDIAGNOSTIC TESTSDTC P0405: EGR SOLENOID CIRCUIT PERFORMANCE - ACTUAL POSITION GREATER THAN COMMANDEDDIAGNOSTIC PROCEDURES
2000 Saturn LW2 Automatic
Diagnostic Procedures
2000 Saturn LW2 AutomaticSECTION Diagnostic Procedures
- Perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK under SELF-DIAGNOSTIC SYSTEM. After performing OBD system check, go to next step.
- Turn ignition on, with engine off. Using scan tool, monitor EGR sensor. If scan tool reads less than 0.14 volt, go to next step. If scan tool does not read less than 0.14 volt, problem is intermittent. See DIAGNOSTIC AIDS .
- Disconnect EGR solenoid harness connector. Using a jumper wire, jumper EGR solenoid harness connector terminals "C" (Brown wire) and "D" (Gray wire). If voltage reading is not greater than 0.14 volt, go to next step. If voltage reading is greater than 0.14 volt, check for terminal tightness at connector. Repair as necessary. If terminals are okay, replace EGR solenoid.
- Remove jumper wire. Using a DVOM, check voltage at EGR solenoid harness connector terminal "D" (Gray wire). If voltage reading is 4-6 volts, go to next step. If voltage reading is not 4-6 volts, go to step 7.
- Turn ignition off. Disconnect ECM harness connector J1. Check for continuity between ground and EGR solenoid harness connector terminal "C" (Brown wire). Check for continuity between EGR harness connector terminals "C" (Brown wire) and "D" (Gray wire). If continuity does not exist on either circuit, go to next step. If continuity exists on either circuit, check circuit for short to ground or shorted to each other. Repair as necessary.
- Check for open in Brown wire to ECM. Repair as necessary. If circuit is okay, check for terminal tightness at connectors. Repair as necessary. If terminals are okay, replace ECM.
- Turn ignition off. Disconnect ECM harness connector J1. Check for continuity between ground and EGR harness connector terminal "D" (Gray wire). If continuity does not exist, go to next step. If continuity exists, check circuit for short to ground. Repair as necessary.
- Check for open in Gray wire to ECM. Repair as necessary. If circuit is okay, check for terminal tightness at connectors. Repair as necessary. If terminals are okay, replace ECM.
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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.