Test KD: Electric Exhaust Gas RECIRCULATION: Testing

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NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

FAULT CODE SETTING CONDITION

Fault Code	KOEO	KOER	Continuous Memory
P0400	KD9	KD9	KD9
P0403	KD1	KD1	KD1
P1408		KD9

NOTE: For additional testing information, see DIAGNOSTIC AIDS .

NOTE: If DTC P0403 was set due to an intermittent condition, perform wiggle test on wiring harness and connectors while performing the following test procedures.

1) For KOEO, KOER & Continuous Memory DTC P0403: Check EEGR Connection To Harness
DTC P0403 indicates a malfunction has been detected in one or more of 4 EEGR motor coils or circuits, and/or PCM is detecting an open, short to PWR or GND. Possible causes for this fault are:
- EEGR Motor Windings Open
- EEGR Motor Connector Not Properly Seated
- Open Or Short To PWR Or GND In Circuit Between PCM To EEGR
- Open Or Short Circuit In PCM
- Short To PWR Or GND In EEGR Motor
Ensure EEGR motor harness connector is fully seated. Repair as necessary. If connector is okay, go to next step.

2) Check For VPWR At Harness Connector To EEGR Motor

Turn ignition switch to OFF position. Disconnect EEGR harness connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and EEGR motor harness connector terminals No. 2 and 5 (VPWR circuits). See Figure. If both voltage measurements are more than 10.5 volts, go to next step. If either voltage measurement is 10.5 volts or less, check for blown fuse No. 9 (20-amp) for Focus, or fuse No. 41 (20-amp) for Ranger in battery junction box. Battery junction box is located in left rear of engine compartment. If fuse is blown, repair short to ground in B+ circuit to EEGR motor. If fuse is okay, repair open in VPWR circuit between battery junction box and appropriate EEGR motor terminal. See WIRING DIAGRAMS .

3) Check For Open Circuits In EEGR Harness

Ensure ignition switch is turned to OFF position. Disconnect PCM harness connector. Using a DVOM, measure resistance of each EGRM(1-4) circuit between specified EEGR motor and PCM harness connector terminals. See PCM CONNECTOR IDENTIFICATION and Figure. See EEGR CIRCUIT IDENTIFICATION (FOCUS) or EEGR CIRCUIT IDENTIFICATION (RANGER) table. If all resistance measurements are less than 5 ohms, go to next step. If any resistance measurement is 5 ohms or more, repair open in appropriate EGRM circuit.

4) Check EEGR Harness Circuit For Shorts To Ground

Turn ignition switch to OFF position. Using a DVOM, measure resistance between negative battery terminal and each EGRM(1-4) circuit at PCM harness connector. See PCM CONNECTOR IDENTIFICATION and Figure. See EEGR CIRCUIT IDENTIFICATION (FOCUS) EEGR CIRCUIT IDENTIFICATION (RANGER) table. If each resistance measurement is more than 10 k/ohms, go to next step. If any resistance measurement is 10 k/ohms or less, repair short to ground in affected EGRM circuit.

EEGR CIRCUIT IDENTIFICATION (FOCUS) ⁽¹⁾

EEGR Harness Connector Terminal No. (Wire Color) ⁽²⁾

PCM Harness Connector Terminal No.

1 (Black/Orange)

3 (Black/Green)

4 (Black/Red)

E10

6 (Black/White)

E11

⁽¹⁾	For EEGR harness connector terminal identification, see Figure.

⁽²⁾	EEGR harness connector terminals No. 2 and 5 (Green/Red and Green/Black wires) are fused VPWR circuits. See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

EEGR CIRCUIT IDENTIFICATION (RANGER) ⁽¹⁾

EEGR Harness Connector Terminal No. (Wire Color) ⁽²⁾

PCM Harness Connector Terminal No.

1 (Tan/Red)

3 (Gray/Red)

4 (Violet/Orange)

6 (Dark Green)

⁽¹⁾	For EEGR harness connector terminal identification, see Figure.

⁽²⁾	EEGR harness connector terminals No. 2 and 5 (Light Blue/Orange wires) are fused VPWR circuits. See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

5) Check EEGR Harness Circuits For Shorts To Each Other

Ensure ignition switch is turned to OFF position. Using a DVOM, measure resistance between circuits EGRM3 and EGRM1, and between circuits EGRM2 and EGRM4 at PCM harness connector. Also, measure resistance between EGRM1, and EGRM2 and EGRM4 at PCM harness connector. See PCM CONNECTOR IDENTIFICATION and Figure. If each resistance measurement is more than 10 k/ohms, go to next step. If any resistance measurement is 10 k/ohms or less, repair short between EGRM circuits.

6) Check For Shorts To PWR In EEGR Harness

Reconnect PCM connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and EEGR motor harness connector terminals No. 1, 3, 4 and 6. If all voltage measurements are less than 0.1 volt, go to next step. If any voltage measurement is 0.1 volt or more, repair short to PWR in affected EGRM circuit.

7) Check EEGR Motor Windings For Open Or Short Circuits

Turn ignition switch to OFF position. Disconnect PCM connector and reconnect EEGR motor connector. Using a DVOM, measure resistance between VPWR, and EGRM1, EGRM3, EGRM4 and EGRM2 at PCM harness connector. See PCM CONNECTOR IDENTIFICATION and Figure. Each resistance measurement should be 20-24 ohms. If all resistance measurements are within specification, go to next step. If any resistance measurement is not within specification, repair or replace EEGR motor as necessary.

8) Check EEGR Motor Windings For Shorts To Ground

Ensure ignition switch is turned to OFF position. Ensure PCM is disconnected. Using a DVOM, measure resistance between negative battery terminal and EGRM1, EGRM2, EGRM3 and EGRM4 at PCM harness connector. If all resistances are more than 10 k/ohms, replace PCM. If any resistance is 10 k/ohms or less, repair or replace EEGR motor as necessary.

NOTE: For additional testing information, see DIAGNOSTIC AIDS .

NOTE: During the following procedure, DTCs may be set in PCM. After performing test, clear DTCs and repeat QUICK TEST procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

9) For KOEO, KOER & Continuous Memory DTC P0400 &/Or P1408: Check For Stuck EEGR Valve Operation
If DTCs P0102, P0103, P0107, P0108, P1100 or P1101 are also present, service prior to continuing with this test step. DTCs P0400 and P1408 indicate KOER self-test failed due to measured EEGR flow is less than or is more than required calibration. Possible causes are:
- EEGR Valve Stuck Closed Or Open
- Connector To EEGR Not Seated
- EEGR Motor Windings Open Or Shorted
- No Power To EEGR
- Harness Open Or Shorted To PWR Or GND
- Vacuum Signal To MAP Restricted Or Leaking
- MAF Sensor Signal Error
- Faulty PCM
- Carbon Build-Up In EEGR Valve Seat Area
- One Or More Sensor Not Responding Or Out Of Range
Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. See OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS. Select EGRMDSD and MAP PIDs. Start engine and allow to reach normal operating temperature. Raise engine speed to 1200 RPM to prevent engine stalling. Engine RPM must remain steady during test. Using scan tool, introduce EGR function in small increments (about 8-12 steps), while monitoring MAP PID. MAP PID value should increase as EGR function is introduced with scan tool. If MAP PID does not increase as specified, replace EEGR motor assembly. If MAP PID value increases as specified, fault cannot be duplicated at this time. Ensure MAP connector is seated correctly and vacuum source is not blocked.