Expert: Roland Finston - 7/9/2011

Question
I have a '01 Sebring 2.7, the engine was replaced before I bought the vehicle, so I don't know what year 2.7 is in the car now. I have cleared the codes and the 2 above codes keep coming back. I checked on the 1289 and says it's the MTV Solenoid. I went out to the car, and according to the 2.7 illustration I have from Mitchell, it is located just to the right of the MAP Sensor. To my surprise, my car does not have one. The intake is molded to have one but it's not there and I don't see any wiring connectors hanging. However, I don't think this code will fail me for state inspection (NJ). I am looking to find out the procedure for curing the 0406 code. If you could pass along step by step instuctions and a wiring diagram for the EGR system and how to change EGR valve that would be fantastic. Thank you in advance for you time and consideration.

Answer
Hi Gary,
The egr solenoid has 6-pin connector. I described it in my first answer:
"The 0406 is about the voltage signal from the exhaust gas recirculation valve's solenoid being higher than would normally be suspected (more than 5v). The most likely cause is some sort of a short/open in the 5 wires that are connected to the solenoid for example the signal wire could be shorted to the 5V supply wire or the 12v battery supply wire..  The egr and its nearby solenoid are located at the rear of the engine on the right (engine's right) side. Take a close look at all the wires associated with the solenoid and verify that there is no sign of damage. The signal wire is light green/pink on pin 1 of the solenoid, and the 5v supply wire is violet/white on pin 2. There is 12v on the orange/dark green at pin 6. So check for any breaks/melts on those three wires and the other two as well."
The signal wire connects to pin 34 of the pcm, the 5v wire to pin 61, the 12v comes from a fuse in the power distribution center (most likely fuse 25), pin 3 is the sensor ground wire to pin 43 of the pcm, and pin 4 is gray/yellow to pin 40 of the pcm. These wirings are based upon the 2.7L diagrams for a '99 model 2.7L used in the LH-body so the assignments to the pcm plugs may not be exactly correct. However the purposes of the 5 wires are identical for sure. I would unplug the solenoid and check the voltage on the wires that carry voltage or signal, and also verify that the ground wire isn't open or shorted to voltage, and that the signal wire is not shorted to a voltage wire. Pin 4 is either going to show 12v (probably at idle) or 0v when revved as that is the wire that deactivates/activates the egr, respectively. That is basically the troubleshoot for this code as somehow the signal wire is showing more than its maximun should be (4.9V) which indicates either a short to higher voltage wire or a ground wire that is open.
If all that checks out, then the solenoid itself may be faulty. And if that proves out you are left with a possible pcm failure. So take the troubleshoot in that order.
I don't have a document scanner or a digital version of the wiring diagram so can't send you that, but what I have described is essentially the wiring diagram for the egr solenoid.
The 2.7L had a manifold tuning valve in some years, but I don't have a detailed wiring diagram for it. If you have the mtv, the manual for '03 lists its control to be on pin 39 of the pcm by a violet/red wire. It also has a 12v supply wire but it is not shown in the '03 wiring diagrams proper.
Roland

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