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Old 09-23-2011, 10:15 AM   #1 (permalink)
BrianP
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EGR code P0403

I was looking for feedback from anyone that has knowledge in this EGR code or function. First some background.

A few weeks ago the engine light came on, scantool told me P0403 EGR recirculating failure, always 2 codes set same number (I think thats how it was stated). I reset both code events but it came back on. I took it to the dealer (with my mods in place, yes I know) and they did an ECM upgrade for the EGR and cleared it but said unless I replaced the 4" exhaust back to stock they wouldn't proceed any further. I debated with the service writer that the exhaust had been in place for 2 years without issue. He of course didn't care. I took the truck on vacation anyway with the light on and it got normal MPG's, 18-19 hwy. The truck has 57k miles on the clock now.

My initial thought is to block it and stick it. I believe there is a problem but they said the EGR was working properly, I would debate this since nothing has changed in my set up for over two years.

So my questions are, what is the most effective way to eliminate or disable this code without changing my current set up? Also, what blocker kits have you guys used and will it effectively block all EGR codes? I'm cool with leaving it non functional, I considered it anyway.

Any feedback would be greatly appreciated.
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Old 09-23-2011, 10:23 AM   #2 (permalink)
osky
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My lbz was doing the same thing. I put the blocker plate and finger stick in at 7k miles. At about 35k it started throwing codes that you are getting. We have a diesel performance shop near me, Husker Diesel. I didn't take it to the dealer because I knew they would bitch at me with my exhaust, so I took it to Husker and they put me a very nice EFI Live tow tune with turbo brake and eliminated all my egr functions. I don't have a bit of trouble now. I see you already have the banks. If you didn't, this would be the way to go. Block it and tune it. Hope this helps. I'm not sure if the finger stick will help you with egr problems??? It didn't me. It only helped me from throwing a code due to my exhuast if I remember right.
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Old 09-23-2011, 06:48 PM   #3 (permalink)
BrianP
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Egr p0403

Thx Osky,

If you don't mind, about what did your custom EFIlive tune cost you? I considered it, maybe get a decent tow tune in place and if I can stack my Banks I could always tune in another few HP's if thats possible. Although, I rarely change the setting, my level 4 seems to do just about everything I need unless I tow heavy then I'll de-tune it one level.

But anyway, I plan to use a blocker plate regardless, I haven't done much research on who does EFIlive setups in my area (pittsburgh/greensburg PA) but even if I have to drive a little ways I will if it's not too terribly expensive.

The check engine light is killing me, I'll need to do something soon. I'll have to do a little more research but I appreciate your response. I don't want to buy the stick if it doesn't block the code I'm getting.
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Old 09-24-2011, 10:26 AM   #4 (permalink)
70runR
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I have an '06 LBZ with the EGR blocker and finger stick and last year towed my 32' race trailer (20,000 lbs combined truck & trailer) out to Vegas and the check engine light came on that signified EGR / coolant. Also about that time the #5 glow plug set of the CEL. I ended up by passing the coolant line to the EGR and everything seems to be fine. Been several thousand miles since. Truck has 158K on it now.
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Old 09-24-2011, 12:05 PM   #5 (permalink)
Canadian Cowboy
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P0403 is an indication of a problem with the EGR Servo motor electronics.
Here is a GM PI regarding the EGR.

Models: 2006-2008 Chevrolet Kodiak C4500/C5500 Series, Silverado, Silverado Classic Models

2006-2008 GMC Sierra, Sierra Classic Models, TopKick C4500/C5500 Series

with 6.6L Duramax Diesel Engine (VINs D, 2, 6 -- RPOs LBZ, LLY, LMM)




--------------------------------------------------------------------------------

This bulletin is being revised to add the 2008 model year and update the information. Please discard Corporate Bulletin Number 06-06-04-063B (Section 06 -- Engine/Propulsion System).


--------------------------------------------------------------------------------

The EGR Valve Motor is now serviceable separately from the EGR valve assembly. If published diagnostics indicate a concern with the motor, order P/N 98057041.

The complete EGR valve assembly with the motor should be replaced if there is a concern with the EGR valve motor on the following models:

2006-2008 Chevrolet Express

2006-2008 GMC Savana





The EGR valve motor assembly (1).

Important:: There is no gasket between the motor and the valve.





Some vehicles may have a thin metal spacer between the motor and the valve that appears to be a gasket (1). This spacer is used to correct for production variances in some valves and should be reinstalled with the new motor.

Removal Procedure -- EGR Valve Motor
Disconnect the negative battery cable.
Remove the air cleaner outlet duct, if necessary. Refer to Air Cleaner Outlet Duct Replacement in SI.
Remove the EGR valve motor harness connector.
Remove the four mounting screws from the EGR valve motor to the EGR valve. Discard the old mounting screws.
Remove the EGR motor and spacer (if equipped) from the engine. Save the spacer.
Installation Procedure -- EGR Valve Motor
Important: The EGR valve motor is packaged with new mounting screws.

Install the spacer (if equipped), the EGR valve motor P/N 98057041 and the new mounting screws to the EGR valve.
Tighten
Tighten the four new mounting screws to 2 Nm (18 lb in).

Install the EGR valve motor harness connector.
Install the air cleaner outlet duct, if removed. Refer to Air Cleaner Outlet Duct Replacement in SI.
Connect the negative battery cable.
Cycle the ignition key to the run position with the engine not running to relearn the new EGR valve motor pintle position.
Parts Information
Part Number
Description

98057041
Motor, EGR Valve

Subject: LBZ LLY Engine with Rough Idle, Poor Performance, Black/White Exhaust Smoke, MIL/SES Light On, DTCs P003A, P060B, P0230, P0403, P0401, P0606, P2146, P2149, P2152, P2155 (Reprogram ECM) #06-06-04-066A - (03/09/2007)



Models: 2006-2007 Chevrolet Express, Kodiak C4500/C5500 Series, Silverado Classic

2006-2007 GMC Savana, Sierra Classic, TopKick C4500/C5500 Series

with 6.6L Duramax Diesel Engine (VINs D, 2 -- RPOs LBZ, LLY)




--------------------------------------------------------------------------------

This bulletin is being revised to add additional warranty information on the EGR learn procedure. Please discard Corporate Bulletin Number 06-06-04-066 (Section 06 -- Engine/Propulsion System).


--------------------------------------------------------------------------------

Condition
Some customers may comment on an illumination of the MIL/SES with one or more of the following symptoms:

Rough Idle

Poor Performance

Black/White Exhaust Smoke

Upon further investigation, the technician may find one or more of the following DTCs stored in the ECM:

P003A: Turbocharger Boost Control Position Not Learned

P060B: Control Module Analog To Digital Performance

P0230: Fuel Pump Relay Control Circuit

P0403: EGR Solenoid Control Circuit

P0401: Exhaust Gas Recirculation Flow Is Insufficient

P0606: Control Module Internal Performance

P2146, P2149, P2152, P2155: Injector Positive Voltage Control Circuit Group 1-4

Cause
This condition may be caused by a calibration issue.

Correction
Important: If the calibration update was for DTC P0403, then follow the service procedure in this bulletin to ensure that the P0403 code has been eliminated.

If routine diagnosis using SI does not reveal any obvious cause for the DTCs setting, then reprogram the ECM.

Reprogram the ECM with the latest calibrations if the above concern is encountered. An updated ECM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern.

The new ECM calibration is available to dealerships in TIS2WEB (website version of TIS) version. If you cannot access the calibration, please call the Techline Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be provided. As always, make sure your Tech 2 is updated with the latest software version.

P0403 EGR SOLENOID CONTROL CIRCUIT LEARN PROCEDURE
After the new calibration is installed for a DTC P0403, the EGR valve learn procedure should be performed four times before returning the vehicle to the customer. The EGR learning cycle occurs on engine shutdown. Technicians should perform the following service procedure to ensure that the DTC P0403 has been eliminated:

Start the engine. Let the engine idle until the engine coolant temperature is greater than 75C (167F). Then shut the engine off for one minute.
Once the engine coolant temperature is greater than 75C (167F), repeat this procedure four separate times, letting the vehicle idle for 30 seconds.
Evaluate the vehicle performance and EGR operation after the learning cycle has been completed.


CC
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Old 09-24-2011, 08:26 PM   #6 (permalink)
TheJDMan
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Well I had the EGR blocked and sticked at first but I never liked that setup. I installed one of All Seasons EGR delete kit that is when I started getting the P0403 code. I contacted Duramax Tuner about building a tune which killed the EGR and Intake air heater codes but they never replied. Does anyone know of a diesel shop in the Richmond VA area that can do EFI Live tunes?
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Old 09-25-2011, 09:51 AM   #7 (permalink)
BrianP
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This is all good information. After reading the service bulletin cowboy posted, it is clear to me the dealer did not do their due dilligence. The oversize exhaust excuse was just a bunch of crap. P0403 leans toward the servo motor or issues related to it, if I read and understood that correctly.

I looked at the paperwork and it says they performed ECM reflash under bulletin number 06-06-04-066D. They spent .4 hours on the reflash but no comments on whether they did the sync process for the EGR. I would assume not? Or maybe it's part of the reflash process???

Is there a way I can perform this EGR sync myself?

Oddly, all I get is the code. I am not experiencing any other conditions, no rough idle, no smoke or anything odd. I had just checked my MPG on an all HWY miles after 350 miles and got 18.6 mpg hand calc. Thats pretty typical for my truck, tank before that was 17mpg even with a some city driving. I typically see 15 to 15.5 city unless I tow. None of that changed.

Anyway, everything else seems normal. Thanks for all the great info.
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Last edited by BrianP; 09-25-2011 at 09:58 AM. Reason: additional comment
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Old 09-25-2011, 10:03 AM   #8 (permalink)
Canadian Cowboy
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The dealer should have preformed the relearn after reflashing the new calibration,there is a separate labor code for the procedure they may not of but you would have to ask them.
You need a tech 2 scanner to preform the relearn.

Quote:
P0403 EGR SOLENOID CONTROL CIRCUIT LEARN PROCEDURE
After the new calibration is installed for a DTC P0403, the EGR valve learn procedure should be performed four times before returning the vehicle to the customer. The EGR learning cycle occurs on engine shutdown. Technicians should perform the following service procedure to ensure that the DTC P0403 has been eliminated:

Start the engine. Let the engine idle until the engine coolant temperature is greater than 75C (167F). Then shut the engine off for one minute.
Once the engine coolant temperature is greater than 75C (167F), repeat this procedure four separate times, letting the vehicle idle for 30 seconds.
Evaluate the vehicle performance and EGR operation after the learning cycle has been completed.
CC
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Old 09-25-2011, 11:18 PM   #9 (permalink)
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Quote:
Originally Posted by TheJDMan View Post
Well I had the EGR blocked and sticked at first but I never liked that setup. I installed one of All Seasons EGR delete kit that is when I started getting the P0403 code. I contacted Duramax Tuner about building a tune which killed the EGR and Intake air heater codes but they never replied. Does anyone know of a diesel shop in the Richmond VA area that can do EFI Live tunes?
I don't know anybody there, but Husker Diesel in Gretna, NE did mine. My truck doesn't even know an egr exist! No more codes! I am local so I just drove there. They can do things for you over the phone and mail. Talk to Jess if you call there. Drop my name and he will hook you up. www.huskerdiesel.com
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Old 09-25-2011, 11:22 PM   #10 (permalink)
osky
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Quote:
Originally Posted by BrianP View Post
Thx Osky,

If you don't mind, about what did your custom EFIlive tune cost you? I considered it, maybe get a decent tow tune in place and if I can stack my Banks I could always tune in another few HP's if thats possible. Although, I rarely change the setting, my level 4 seems to do just about everything I need unless I tow heavy then I'll de-tune it one level.

But anyway, I plan to use a blocker plate regardless, I haven't done much research on who does EFIlive setups in my area (pittsburgh/greensburg PA) but even if I have to drive a little ways I will if it's not too terribly expensive.

The check engine light is killing me, I'll need to do something soon. I'll have to do a little more research but I appreciate your response. I don't want to buy the stick if it doesn't block the code I'm getting.
My one tune was $300. Way cheaper than having things fixed at the dealer and I have more power, turbo brake, and 2mpg better mileage. Call Jess at Husker Diesel. He can give you some options on getting EFI Live to you. He does it all the time. I am very happy with my tow tune. Let him know I sent you and he may offer a discount...?
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