Case Number: S2118000015 REV. B
Release Date: March 2022
Symptom/Vehicle Issue: Malfunction Indicator Lamp (MIL) Illumination. Diagnostic
Trouble Code (DTC) P0403 – EGR Control Circuit Open, Set.
Discussion: Reports have been received from the field of EGR valves being replaced
for DTC P0403 on lower mileage vehicles. An analysis of the returned parts has found
that all were no trouble found (NTF). Further analysis indicates that the DTC may have
set falsely due to slightly higher resistance caused by the internal brushes in the new
EGR valve motor not being fully seated yet. This is not caused by an internal defect in
the EGR valve. As the EGR valve operates, the brushes will set in, lowering the
internal resistance. If you receive a vehicle in with this DTC, please perform the
following repair procedure based on your scenario.
Repair Procedure:
Scenario #1: MIL Illuminated, P0403 Set Stored. Additional PCM DTCs Active.
If the vehicle has P0403 set in stored status along with other PCM active DTCs or
drivability symptoms, diagnose and repair those DTCs/Conditions first before
diagnosing P0403. Once repaired, attempt to duplicate the P0403 by doing the
following.
• Clear all DTCs and turn off the ignition for a minimum of 5 minutes. Restart the
vehicle. Did P0403 reset?
a. Yes >>>. Continue with normal published diagnostics for the DTC.
b. No >>>. Perform the EGR Motor Sweep Routine below to ensure the motor
brushes have fully seated to prevent false failure of P0403.

This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechCONNECT or eCONTACT ticket if no
solution is found
FCA US LLC

Version 4.3 10/29/2020

Scenario #2: MIL Illuminated, P0403 is the only DTC and is set active.
If the vehicle is in with a MIL complaint and DTC P0403 is the only active code,
proceed with normal published diagnostics for the DTC. Closely inspect all connections
for loose, damaged, or pushed out pins and repair as necessary.
Scenario #3: MIL Illuminated condition, P0403 is the only DTC but is currently
stored.
If the vehicle is in with a MIL complaint and DTC P0403 is the only code set but is
stored, perform the following:
• Clear the DTC and allow the vehicle to sit overnight.
• Start the vehicle and see if P0403 returned. Did the P0403 reset?
a. Yes >>> Proceed with normal published diagnostics for P0403, and repair as
necessary.
b. No >>> Perform the EGR Motor Sweep Routine below to ensure the motor
brushes have fully seated to prevent false failure of P0403.
EGR Motor Sweep Routine:
1. Turn the ignition on, engine off
2. Using wiTECH, navigate to the PCM “Actuators” tab, and initiate the “EGR DC
Motor Solenoid Valve/Recirculation Valve” routine. Please see (Figure 1.).

This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechCONNECT or eCONTACT ticket if no
solution is found
FCA US LLC

Version 4.3 10/29/2020

Figure 1.

3. From the available drop-down menu, select 100% and click “Start” to command
the EGR valve to 100%. Please see (Figure 2).

Figure 2.

This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechCONNECT or eCONTACT ticket if no
solution is found
FCA US LLC

Version 4.3 10/29/2020

4. Wait 2-5 seconds and click “Stop”
5. Repeat steps 3 and 4, for a total of 5 times.
6. Perform the above sequence for the remaining selectable positions (0%, 20%,
40%, 60%, and 80%).

This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechCONNECT or eCONTACT ticket if no
solution is found
FCA US LLC

Version 4.3 10/29/2020