LBZ, LLY Engine MIL/SES Light On With DTC P0403 Set (Check/Reprogram ECM and Perform EGR Valve Motor Cleaning Procedure)

This bulletin is being revised to remove all part information, update information, change warranty information and add a procedure for cleaning the EGR valve motor. Please discard Corporate Bulletin Number 06-06-04-066B (Section 06 -- Engine/Propulsion System).

Some customers may comment on an illumination of the MIL/SES.

Upon further investigation, the technician may find the following DTCs stored in the ECM:

This condition may be caused by the engine control module (ECM) calibration.

Important: Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2® scan tool.

Check the ECM calibration level and reprogram the ECM with the latest calibrations, if required. An ECM calibration was released in March 2007 to address this concern. This calibration, or any that follow, is designed to address this concern. The ECM calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Engine Control Module Programming and Setup procedure in SI. As always make sure your Tech  2® is updated with the latest software version.

After the calibration check and reprogramming of the ECM (if required), the EGR valve motor cleaning procedure should be performed before returning the vehicle to the customer.

Important: Make sure your Tech  2® is updated with the latest software version to access the EGR Valve Motor Cleaning software.

Technicians should perform the following cleaning procedure to ensure that DTC P0403 has been eliminated:

1. Start the engine. Let the engine idle until the engine coolant temperature is greater than 60°C (140°F). Then shut the engine off.
2. Attach a Midtronics 165-PCS charger or equivalent to maintain proper battery voltage.
3. Turn the ignition key to the ON position with the engine off (engine should not be running).
4. Attach a Tech  2® to the vehicle and clear all the codes.

Important: The cleaning procedure may take up to 75 minutes to complete, it is not necessary for the technician to watch or stay with the vehicle. The EGR Solenoid Command will stop cycling and stay at 0% when the procedure is completed.

5. Request and start the EGR Valve Motor Cleaning procedure with a Tech 2® using the steps below.




5.1.	Select "Powertrain" (1).

Example Shows 6.6L Diesel (VIN D--RPO-LBZ) Selected





5.2.	Select Your Engine Type (1).





5.3.	Select "Special Functions" (1).





5.4.	Select "Engine Output Controls" (1).





5.5.	Select "EGR Valve Motor Cleaning" (1).





5.6.	Select "Start" (1).

Important: The EGR Solenoid Command will stop cycling and stay at 0% when the procedure is completed and the command state should go to "Stop".

6. Once the cleaning cycling is complete, disconnect the Tech 2® and remove the charger from the vehicle.
7. Verify the condition has been corrected by evaluating the vehicle's performance and EGR operation.

Important: For additional information on warranty coverage for emission related reprogramming for Medium Duty trucks, refer to Corporate Bulletin Number 04-06-04-036E.

For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty, use: