Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
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25.
DTC
P0401
Actual fresh air inflow is larger than target air inflow set by EGR system.
P0402
Actual fresh air inflow is smaller than target air inflow set by EGR system.
P0403
ECU internal drive module of EGR valve actuator control wire is
overheated.
P0404
EGR valve actuator control wire is open.
P0405
Voltage of EGR valve position sensor is below the lower limit (Connection is
short to ground).
P0406
Voltage of EGR valve position sensor is above the upper limit (Connection is
open short to high level).
P0489
EGR valve actuator control wire is open.
P0490
EGR valve actuator control wire is short to high level.
Fault Description: Exhaust gas recirculation system is applied in reduction of Nitrogen oxides emission due to high
temperature combustion. Main component of the system is electronic control exhaust gas recirculation valve. Exhaust
gas recirculation valve delivers a small amount of exhaust gas into intake manifold to reduce combustion temperature.
Recirculation gas flow is controlled by ECU according to changes in engine load. In the case of deceleration, gas flow
test for exhaust gas recirculation (EGR) system is carried out by ECU. Therefore, ECU gives a transient command to
open exhaust gas recirculation valve and simultaneously monitors signals of intake manifold air pressure (MAP)
sensor and exhaust gas recirculation position sensor. In the case of inconformity of intake manifold absolute pressure
signals with exhaust gas recirculation valve spool shaft position, ECU records measured D-value of intake manifold
absolute pressure and adjust calibrated failure counter to failure technical threshold value. For error quantities of
detected exhaust gas recirculation flow are different, required test times for exhaust gas recirculation flow concerned
excessive failure technical threshold value of may be different, too. When ECU detects incorrect control signals, DTC
occurs.
Diagnosis Hint: Carry out inspection to engine control system; check engine for historical faults; check exhaust gas
recirculation system for faults as follows—vacuum leaks between exhaust gas recirculation valve and intake manifold.
In the case of carbon deposition or exhaust gas noise around component faying surface, it is indicated there is external
leakage. Check passage and exhaust gas recirculation valve for clogging; check exhaust system for relevant faults
(such as leakage due to exhaust component damage, clogging due to excessive back pressure and too low engine
vacuum and etc.); finally, carry out inspection to mechanical system.
EGR5V Power supply
EGR position signal
EGR ground signal
EGR actuator power supply
EGR actuator ground
EGR position sensor
EGR actuator