LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> Engine Controls - Self-Diagnostics - EEC-V - CNG, Flex-Fuel & Gasoline >> System Tests >> Test He: EGR System >> Diagnostic Aids

Diagnostic Aids

NOTE: After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST  procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

Perform this test when instructed by QUICK TEST. This test is only intended to diagnose:

Fig 1: Identifying DPFEGR System Components
G96C29134Courtesy of FORD MOTOR CO.
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
P0401      HE70
P0402    HE20  HE20
P1400  HE1  HE1  HE1
P1401  HE10  HE10  HE10
P1405      HE50
P1406      HE60
P1408    HE71  
P1409  HE110  HE110  HE120

  1. 1) DTC P1400: Check DPFEGR Sensor Voltage

    This DTC indicates DPFEGR circuit input fault. Possible causes for this fault are:
    • Leaking Upstream Pressure Hose
    • DPFEGR Circuit Shorted To GND Or SIG RTN Circuit
    • VREF Shorted To GND Or SIG RTN Circuit
    • Faulty DPFEGR Sensor
    • Faulty PCM

    Turn ignition switch to ON position. Using scan tool, select DPFEGR PID from PID/DATA MONITOR & RECORD menu. If PID voltage is less than .2 volt, DPFEGR sensor voltage is less than minimum. Go to next step. If voltage is .2 volt or more, inspect DPFEGR sensor vacuum hoses. Repair as necessary and retest. If vacuum hoses are okay, fault is intermittent. Go to step  5).

  2. 2) Generate Opposite DPFEGR Sensor Signal

    Turn ignition switch to OFF position. Disconnect DPFEGR sensor connector. Connect a jumper wire between DPFEGR and VREF terminals at DPFEGR sensor harness connector. See Fig 2-Fig 4 . Turn ignition switch to ON position. Using scan tool, select DPFEGR PID. If PID voltage is not 4-6 volts, remove jumper wire and go to next step. If PID voltage is 4-6 volts, replace DPFEGR sensor.
    Fig 2: Identifying DPFEGR Sensor Wiring Harness Connector Terminals (Taurus 3.0L 4V)
    G00013267Courtesy of FORD MOTOR CO.
    Fig 3: Identifying DPFEGR Sensor Wiring Harness Connector Terminals (LS)
    G00013268Courtesy of FORD MOTOR CO.
    Fig 4: Identifying DPFEGR Sensor Wiring Harness Connector Terminals (All Others)
    G99J02602Courtesy of FORD MOTOR CO.

  3. 3) Measure VREF Voltage At DPFEGR Sensor

    Measure voltage between SIG RTN and VREF terminals at DPFEGR sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, go to TEST C .

  4. 4) Check DPFEGR Circuit For Short To Ground

    Disconnect scan tool from Data Link Connector (DLC). Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between PCM harness connector DPFEGR and SIG RTN terminals. See WIRING DIAGRAMS. See Figure or Figure . Using a DVOM, measure resistance between negative battery terminal and PCM harness connector DPFEGR terminal. If either resistance measurement is 10 k/ohms or less, repair short to ground or SIG RTN circuit. If both resistance measurements are more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  5. 5) Wiggle Test Sensor & Harness

    Turn ignition switch to ON position. Using scan tool, select DPFEGR PID. Observe DPFEGR PID voltage for indication of fault while shaking and bending DPFEGR sensor wiring harness and connector. Tap lightly on DPFEGR sensor to simulate road shock. An indication of fault is a sudden change in DPFEGR PID voltage. If fault is indicated, isolate and repair as necessary. If no fault is indicated, go to TEST Z .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 5) to step 10). No test procedures have been omitted.

  6. 10) DTC P1401: Check DPFEGR Sensor Voltage

    This DTC indicates PCM has detected DPFEGR circuit input above maximum. Possible causes for this fault are:
    • Open In DPFEGR Circuit Or SIG RTN Circuit
    • DPFEGR Circuit Shorted To VREF Or PWR Circuit
    • VREF Circuit Shorted To PWR Circuit
    • Faulty DPFEGR Sensor
    • Faulty PCM

    Turn ignition switch to ON position. Using scan tool, select DPFEGR PID. If PID voltage is more than 4 volts, go to next step. If PID voltage is 4 volts or less, fault is intermittent. Go to step  19).

  7. 11) Check DPFEGR Circuit For Short To Power

    Turn ignition switch to OFF position. Disconnect DPFEGR sensor connector. Turn ignition switch to ON position. Measure voltage between DPFEGR terminal at DPFEGR sensor harness connector and negative battery terminal. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, go to step  13).

  8. 12) Check For Short To Power

    Ensure ignition switch is turned to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and PCM harness connector DPFEGR terminal. See WIRING DIAGRAMS. See Figure or Figure . If voltage is more than 10.5 volts, repair short to PWR in DPFEGR circuit. If voltage is 10.5 volts or less, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  9. 13) Generate Opposite DPFEGR Signal

    Turn ignition switch to OFF position. Connect a jumper wire between DPFEGR and SIG RTN terminals at DPFEGR sensor harness connector. See Fig 4. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID. If scan tool error occurs, disconnect jumper wire and go to step  18). If PID voltage is .05 volt or more, disconnect jumper wire and go to step  16). If PID voltage is less than .05 volt, disconnect jumper wire and go to next step.

  10. 14) Verify VREF Is Within Range

    Turn ignition switch to ON position. Measure voltage between SIG RTN terminal and VREF terminal at DPFEGR sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, go to TEST C .
    11. NOTE: On LS models, measure to both VREF circuit terminals.

  11. 15) Check DPFEGR Circuit For Short To VREF In Harness
    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between PCM harness connector DPFEGR and VREF circuit terminals. See Fig 2-Fig 4 . If resistance is more than 10 k/ohms, replace DPFEGR sensor. If resistance is 10 k/ohms or less, repair short between DPFEGR and VREF circuits.

  12. 16) Check DPFEGR Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Ensure DPFEGR sensor is disconnected. Using a DVOM, measure resistance of DPFEGR circuit between PCM harness connector and DPFEGR sensor harness connector. See Fig 2-Fig 4 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in DPFEGR circuit.

  13. 17) Check SIG RTN Circuit For Open In Harness

    Using a DVOM, measure resistance of SIG RTN circuit between PCM harness connector and DPFEGR sensor harness connector. See Fig 2-Fig 4 . If resistance is less than 5 ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If resistance is 5 ohms or more, repair open in SIG RTN circuit.

  14. 18) Check DPFEGR Circuit For Short To VREF In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between PCM harness connector DPFEGR and VREF terminals. See WIRING DIAGRAMS. See Figure or Figure . If resistance is more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If resistance is 10 k/ohms or less, repair short between DPFEGR and VREF circuits.

  15. 19) Wiggle Test Sensor & Harness

    Turn ignition switch to ON position. Using scan tool, select DPFEGR PID. Observe PID voltage for indication of fault while shaking and bending DPFEGR sensor wiring harness and connector. An indication of fault is a sudden change in DPFEGR PID voltage. Tap lightly on DPFEGR sensor to simulate road shock. If fault is indicated, isolate and repair as necessary. If no fault is indicated, go to TEST Z .

  16. 20) KOER & Continuous Memory DTC P0402: Check EGR Flow At Idle (Vacuum Hose Disconnected)

    This DTC indicates PCM has detected EGR flow at idle. Possible causes for this fault are:
    • EGR Valve Stuck Open
    • EGR Vacuum Regulator (VR) Solenoid Vent Plugged
    • EGRVR Circuit Shorted To Ground
    • EGRVR Circuit Shorted To VREF Circuit
    • Pinched, Plugged Or Damaged Vacuum Hose
    • Faulty EGRVR Solenoid
    • Faulty PCM
    NOTE: If Continuous Memory DTC P1405 is present, go to step  50).

    Disconnect and plug EGR vacuum hose. Perform KOER on-demand self-test. See KOER ON-DEMAND SELF-TEST  under QUICK TEST. If KOER DTC P0402 is present, KOER self-test is unable to be performed, engine stalls or will not start, check EGR tube, EGR valve and hoses. Repair as necessary and retest. If DTC P0402 is not present, engine starts and does not stall, go to next step.

  17. 21) Check EGR Flow At Idle With Vacuum Hose Connected

    Turn ignition switch to OFF position. Reconnect EGR vacuum hose. Perform KOER on-demand self-test. See KOER ON-DEMAND SELF-TEST  under QUICK TEST. If KOER DTC P0402 is present, KOER self-test is unable to be performed, engine stalls or will not start, go to next step. If DTC P0402 is not present, engine starts and does not stall, fault is intermittent. Check for pinched vacuum hoses. Repair as necessary and retest. If vacuum hoses are okay, go to step  30).

  18. 22) Check EGR System

    A pinched or plugged EGR vacuum hose can trap vacuum between EGR vacuum regulator solenoid and EGR valve not allowing EGR valve to close. Using vehicle's vacuum diagram label, check EGR system vacuum hoses for damage, tight connections and correct routing. If hoses are okay, reconnect vacuum hoses and go to next step. If hoses are not okay, repair as necessary.

  19. 23) Check DPFEGR Sensor Output

    Turn ignition switch to OFF position. Disconnect pressure hoses at DPFEGR sensor. Connect vacuum pump to DPFEGR sensor port marked REF. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID from PID/DATA MONITOR & RECORD menu. Note PID voltage. PID voltage should be .2-1.3 volts with switch to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg (27-30 kPa). PID voltage should be more than 4 volts. When vacuum is quickly released, PID voltage should drop to less than 1.5 volts within 3 seconds. If PID voltage is not as specified, replace DPFEGR sensor. If PID voltage is as specified, reconnect DPFEGR sensor and go to next step.

  20. 24) Check EGR Flow At Idle With EGRVR Solenoid Disconnected

    Turn ignition switch to OFF position. Disconnect EGR valve vacuum hose. Connect vacuum gauge to hose. Start engine and allow to idle. While observing vacuum gauge, disconnect EGRVR solenoid connector. If vacuum gauge reading stays at more than 1.6 in. Hg (5.4 kPa), check for fault in EGRVR solenoid. Go to next step. If vacuum gauge reading is 1.6 in. Hg (5.4 kPa) or less, go to step  26).

  21. 25) Check EGRVR Solenoid Vent

    Turn ignition switch to OFF position. Disconnect EGRVR solenoid vacuum hoses. Remove EGRVR solenoid vent cap (if removable). Remove EGRVR filter and inspect for restriction. Plug EGRVR solenoid vacuum supply port. See Fig 5. Using a vacuum pump, apply 10-15 in. Hg (34-51 kPa) to EGRVR solenoid source port. If vacuum holds or is slow to release, EGRVR solenoid is plugged or restricted. Repair or replace EGRVR solenoid as necessary. If vacuum releases (solenoid not plugged or restricted), replace EGRVR solenoid.
    Fig 5: Testing EGRVR Solenoid
    G98G00204Courtesy of FORD MOTOR CO.

  22. 26) Check EGR VR Solenoid Coil Resistance

    Turn ignition switch to OFF position. Disconnect EGR VR solenoid connector. Measure resistance between EGRVR solenoid terminals. If resistance is 26-40 ohms, go to next step. If resistance is not 26-40 ohms, replace EGRVR solenoid.

  23. 27) Check EGRVR Circuit For Short To Ground In Harness

    Disconnect scan tool from DLC. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between negative battery terminal and PCM harness connector EGRVR circuit terminal. See WIRING DIAGRAMS article. See Figure or Figure . If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in EGRVR circuit.

  24. 28) Check EGRVR Circuit For Short To VREF

    Using a DVOM, measure resistance between PCM harness connector EGRVR and VREF circuit terminals. See WIRING DIAGRAMS. See Figure or Figure . If resistance is more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If resistance is 10 k/ohms or less, repair short between EGRVR and VREF circuits.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 28) to step 30). No test procedures have been omitted.

  25. 30) Check DPFEGR Sensor Output

    Turn ignition switch to OFF position. Disconnect pressure hoses at DPFEGR sensor. Connect vacuum pump to DPFEGR sensor downstream port marked REF. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and note voltage reading. PID voltage should be .2-1.3 volts with switch to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg (27-30 kPa). PID voltage should be more than 4 volts. When vacuum is quickly released, PID voltage should drop to less than 1.5 volts within 3 seconds. If PID voltage is not as specified, replace DPFEGR sensor. If PID voltage is as specified, reconnect DPFEGR sensor and go to next step.
    26. NOTE: A higher voltage reading with engine idling could be due to an EGR valve not seating fully.

  26. 31) Check DPFEGR Sensor Voltage
    Reconnect DPFEGR sensor connector. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and note voltage reading. PID voltage should be .2-1.3 volts. Disconnect vacuum hose at EGR valve and plug hose. Connect a vacuum pump to EGR valve. Start engine and allow to idle. Observe DPFEGR PID voltage at idle and compare to PID voltage reading taken with switch to ON position. Apply only enough vacuum (2-3 in. Hg) to open EGR valve without stalling engine and release vacuum. Repeat several times while observing DPFEGR PID voltage on scan tool. DPFEGR PID voltage should increase as EGR valve begins to open and return to initial voltage value as vacuum is released. A slow return to voltage is an indication of a slow closing EGR valve. If DPFEGR PID voltage does not indicate a fault, go to next step. If DPFEGR PID voltage indicates a fault (an open, binding or slow closing EGR valve), service or replace EGR valve.

  27. 32) Check EGR Valve Vacuum While Wiggling EGRVR Solenoid Circuit

    Turn ignition switch to OFF position. Remove vacuum pump from EGR valve vacuum hose and connect a vacuum gauge to hose. Turn ignition switch to ON position. Observe vacuum gauge for indication of fault while wiggling EGRVR solenoid wiring harness and connector. Fault is indicated by a sudden jump in vacuum reading. Tap lightly on EGRVR solenoid to simulate road shock. If no faults are indicated, go to next step. If fault is indicated, isolate and repair fault as necessary.

  28. 33) Check EGRVR Solenoid For Restriction

    Turn ignition switch to OFF position. Remove EGRVR solenoid vent filter. Inspect for contamination or water. Remove EGR vacuum hose and inspect for restriction. Repair or replace as necessary. If no faults can be found, problem is intermittent and cannot be identified at this time. Go to TEST Z .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 33) to step 50). No test procedures have been omitted.

  29. 50) DTC P1405: Check For Upstream Pressure Hose Connection

    Check upstream hose at DPFEGR sensor and orifice tube for clean, tight connection. See Fig 6. Repair as necessary. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure EGR MONITOR PROCEDURE is performed to verify repair. If hose is okay, go to next step.
    Fig 6: Identifying DPFEGR Sensor Vacuum Circuits
    G98H00205Courtesy of FORD MOTOR CO.

  30. 51) Inspect Upstream Pressure Hose

    Check upstream hose routing and for a clean, tight connection. Ensure hose is not plugged, pinched, wet or contaminated. Repair as necessary. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure EGR MONITOR PROCEDURE is performed to verify repair. If hose is okay, go to next step.

  31. 52) Inspect Orifice Tube Assembly & DPFEGR Sensor

    Check DPFEGR sensor port marked HI for restriction or damage. Inspect exhaust manifold side pressure pick-up tube (port) at orifice tube assembly for restriction or damage. Repair or replace DPFEGR sensor or orifice tube as necessary. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure EGR MONITOR PROCEDURE is performed to verify repair. If no faults are found, go to next step.

  32. 53) Check DPFEGR Sensor Output

    Disconnect pressure hoses at DPFEGR sensor. Connect vacuum pump to DPFEGR sensor port marked REF. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and note voltage reading. PID voltage should be .2-1.3 volts with switch to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg (27-30 kPa). PID voltage should be more than 4 volts. When vacuum is quickly released, PID voltage should drop to less than 1.5 volts within 3 seconds. If PID voltage is not as specified, replace DPFEGR sensor. If PID voltage is as specified, fault is intermittent and cannot be identified at this time. Go to TEST Z .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 53) to step 60). No test procedures have been omitted.

  33. 60) DTC P1406: Check For Downstream Pressure Hose Connection

    Check downstream hose at DPFEGR sensor and office tube for clean, tight connection. See Fig 1. Repair as necessary. If hose is okay, go to next step.

  34. 61) Inspect Downstream Pressure Hose

    Check downstream hose routing and for a clean, tight connection. Ensure hose is original equipment. Ensure hose is not pinched, wet or contaminated. Repair or replace hose as necessary. If hose is okay, go to next step.

  35. 62) Inspect Orifice Tube Assembly & DPFEGR Sensor

    Check DPFEGR sensor ports for restriction or damage. Inspect intake manifold side pressure pick-up tube (port) and orifice tube assembly for restriction or damage. Repair or replace DPFEGR sensor or orifice tube as necessary. If no faults are found, go to next step.

  36. 63) Check DPFEGR Sensor Output

    Disconnect pressure hoses at DPFEGR sensor. Connect vacuum pump to DPFEGR sensor port marked REF. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and note voltage reading. PID voltage should be .2-1.3 volts with switch to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg (27-30 kPa). PID voltage should be more than 4 volts. When vacuum is quickly released, PID voltage should drop to less than 1.5 volts within 3 seconds. If PID voltage is not as specified, replace DPFEGR sensor. If PID voltage is as specified, fault is intermittent and cannot be identified at this time. Go to TEST Z .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 63) to step 70). No test procedures have been omitted.

  37. 70) Continuous Memory DTC P0401: Perform KOER Self-Test

    This DTC indicates EGR MONITOR failed due to PCM detecting EGR flow while driving is less than desired minimum. Possible causes for this fault are:
    • EGR valve stuck closed.
    • EGR valve diaphragm leak.
    • EGR flow plugged or restricted.
    • Faulty EGR hose.
    • EVR VPWR Circuit Open
    • EVR VPWR Circuit To PCM Open Or Shorted To PWR
    • DPFEGR Sensor VPWR Circuit Open
    • Faulty DPFEGR Sensor Hoses
    • Faulty DPFEGR Sensor
    • Faulty EGRVR Solenoid
    • Faulty PCM

    If fault is currently present, KOER DTC P1408 should be present. Perform KOER ON-DEMAND SELF-TEST . If DTC P1408 is present, go to next step. If DTC P1408 is not present, go to step  90).

  38. 71) KOER DTC P1408: Retrieve Continuous Memory DTCs

    This DTC indicates KOER ON-DEMAND SELF-TEST failed due to measured EGR flow falling below or exceeding required calibration. Possible causes are:
    • EGR Valve Stuck Closed
    • EGR Valve Diaphragm Leak
    • EGR Flow Plugged Or Restricted
    • Faulty EGR Hose
    • EGRVR Circuit To PCM Open
    • EGRVR Circuit To PCM Open Or Shorted To PWR
    • DPFEGR Sensor VPWR Circuit Open
    • DPFEGR Sensor Hoses Faulty Or Reversed
    • Downstream Pressure Hoses Plugged Or Removed
    • Faulty Orifice Tube Assembly
    • Faulty DPFEGR Sensor
    • Faulty EGRVR Solenoid
    • Faulty PCM

    Retrieve Continuous Memory DTCs. If DTC P1406 is present, go to step  60). If DTC P1406 is not present, go to next step. If any other DTCs are present, record DTCs and service after completing this test.

  39. 72) Perform KOER Self-Test While Monitoring EGR Vacuum

    Disconnect vacuum hose from EGR valve and connect hose to vacuum gauge. Perform KOER on-demand self-test. See KOER ON-DEMAND SELF-TEST  under QUICK TEST while monitoring gauge. Disregard any DTCs set during this test. During test, if EGR vacuum increased to 3 in. Hg or more, go to next step. If vacuum stays less than 3 in. Hg, vacuum is insufficient to open EGR valve. Go to step  80).

  40. 73) Inspect DPFEGR Sensor Pressure Hoses

    Check both DPFEGR sensor hoses for correct routing. See Fig 6. Ensure hoses are not restricted or plugged or leaking. Inspect DPF EGR sensor and orifice tube assembly for restriction or damage at pick-up tubes (ports). If no faults are found, go to next step. If faults are found, repair pressure hoses as necessary.

  41. 74) Check VREF Voltage At DPFEGR Sensor

    Disconnect pressure hoses at DPFEGR sensor. Connect vacuum pump to DPFEGR sensor port marked REF. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and note voltage reading. PID voltage should be .2-1.3 volts with switch to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg (27-30 kPa). PID voltage should be more than 4 volts. When vacuum is quickly released, PID voltage should drop to less than 1.5 volts within 3 seconds. If PID voltage is not as specified, replace DPFEGR sensor. If PID voltage is as specified, reconnect hoses and go to next step.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 74) to step 76). No test procedures have been omitted.

  42. 76) Check EGR Valve Function

    Turn ignition switch to OFF position. Disconnect and plug hose at EGR valve. Connect vacuum pump to EGR valve. Start engine and allow to idle. Using scan tool, select DPFEGR and RPM PIDs. Slowly apply 5-10 in. Hg to EGR valve and hold for 10 seconds. It may be necessary to increase engine speed to obtain 1000 RPM. As vacuum increases, PID voltage should increase (up to 2.5 volts). When vacuum is held steady, PID voltage should also hold steady. If PID voltage is as specified, reconnect all components and go to step  85). If PID voltage is not as specified, check EGR valve for deposits, contamination or unusual wear. Service or replace EGR valve.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 76) to step 80). No test procedures have been omitted.

  43. 80) Check EGRVR Solenoid Vacuum

    Inspect vacuum hoses between EGRVR solenoid and EGR valve for leaks, restrictions, damage or incorrect routing. Repair as necessary. If hoses are okay, disconnect vacuum hoses at EGRVR solenoid. Connect vacuum pump to EGRVR solenoid vacuum supply hose. Start engine and allow to idle. If vacuum gauge reading is 15 in. Hg or more at idle and vacuum lines are okay, go to next step. If vacuum gauge reading is less than 15 in. Hg, isolate fault and repair as necessary.

  44. 81) Check VPWR To EGRVR Solenoid

    Turn ignition switch to OFF position. Disconnect EGRVR solenoid connector. Turn ignition switch to ON position. Measure voltage between ground and VPWR terminal at EGRVR solenoid harness connector. See Fig 7-Fig 8 . If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit.
    Fig 7: Identifying EGRVR Solenoid Wiring Harness Connector Terminals (LS)
    G00013269Courtesy of FORD MOTOR CO.
    Fig 8: Identifying EGRVR Solenoid Wiring Harness Connector Terminals (All Others)
    G99D02604Courtesy of FORD MOTOR CO.

  45. 82) Check Resistance At EGRVR Solenoid

    Turn ignition switch to OFF position. Measure resistance between EGRVR solenoid terminals. If resistance is 26-40 ohms, go to next step. If resistance is not 26-40 ohms, replace EGRVR solenoid.

  46. 83) Check EGRVR Circuit For Short To PWR In Harness

    Ensure ignition switch is turned to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and appropriate PCM harness connector EGRVR terminal. See Fig 7 or Fig 8 . If voltage is one volt or less, go to next step. If voltage is more than one volt, repair short to PWR in EGRVR circuit.

  47. 84) Check EGRVR Circuit For Open In Harness

    Turn ignition switch to OFF position. Using a DVOM, measure resistance of EGRVR circuit between PCM harness connector and EGRVR solenoid harness connector. See Fig 7 or Fig 8 . If resistance is less than 5 ohms, reconnect EGRVR solenoid and PCM harness connectors and go to next step. If resistance is 5 ohms or more, repair open in EGRVR circuit.

  48. 85) Check EGRVR Solenoid Vacuum Output Capability By Grounding EGRVR Circuit

    Disconnect hose from EGR valve and connect vacuum gauge to EGR vacuum hose. Start engine and allow to idle. Backprobe PCM harness connector to connect a jumper wire between chassis ground and PCM harness connector EGRVR circuit terminal. See Fig 7 or Fig 8 . If vacuum gauge reading is 4 in. Hg or more, replace PCM. If vacuum gauge reading is less than 4 in. Hg, replace EGRVR solenoid.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 85) to step 90). No test procedures have been omitted.

  49. 90) Check EGR System

    Turn ignition switch to OFF position. Check entire EGR system for deterioration or signs of intermittent failure. Repair as necessary. If no faults are found, go to next step.

  50. 91) Inspect DPFEGR Pressure Hoses

    Check both DPFEGR sensor hoses for correct routing. See Fig 6. Ensure downstream and upstream hoses are not pinched and that hose routing does not have low spots where water may collect, freeze and plug hose in colder climates. Inspect DPFE sensor and orifice tube assembly for restriction or damage at pick-up tubes (ports). If no faults are found, go to next step. If faults are found, repair as necessary.

  51. 92) Check DPFEGR Sensor Output While Applying Vacuum

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Disconnect pressure hoses at DPFEGR sensor. Connect hand vacuum pump to DPFEGR sensor downstream intake manifold (smaller diameter) port. DO NOT apply vacuum to sensor. See Fig 6. Turn ignition switch to ON position. Using scan tool, select DPFEGR PID from PID/DATA MONITOR & RECORD menu. Record DPFEGR PID voltage reading without vacuum applied.

    DPFEGR PID voltage reading should be .2-1.3 volts with ignition switch turned to ON position and no vacuum applied. Using vacuum pump, apply 8-9 in. Hg. DPFEGR PID voltage reading should increase to more than 4 volts with vacuum applied. Quickly release vacuum. DPFEGR PID voltage reading should drop to less than 1.5 volts within 3 seconds of releasing vacuum. If DPFEGR PID voltage reading does not operate as specified, replace DPFEGR sensor. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure EGR MONITOR PROCEDURE is performed to verify repair. If DPFEGR PID voltage reading operates as specified, reconnect pressure hoses and go to next step.

  52. 93) Check EGR Valve Operation

    Turn ignition switch to OFF position. Disconnect and plug vacuum hose at EGR valve. Connect hand vacuum pump to EGR valve. Start engine and allow to idle. Using scan tool, select DPFEGR and RPM PIDs. Slowly apply 5-10 in. Hg to EGR valve and hold for 10 seconds. It may be necessary to increase engine speed to obtain 800 RPM. Check for the following:
    • EGR valve should start opening at about 1.6 in Hg, which is indicated by DPFEGR PID voltage reading increasing.
    • As vacuum increases, DPFEGR PID voltage reading should increase (up to 2.5 volts with full vacuum applied). As DPFEGR voltage reading increases, EGR valve should open fully.
    • When vacuum is held steady, DPFEGR PID voltage reading should also hold steady.

    If DPFEGR PID voltage reading operates as specified, reconnect all components and go to next step. If DPFEGR PID voltage reading does not operate as specified, remove EGR valve and check for contamination, wear, carbon deposits, binding, leaking diaphragm or other damage. If EGR valve is okay, check for obstructed EGR port in intake manifold. Repair as necessary.

    NOTE: In cold climate, EGR valve may freeze shut and thaw when engine warms, causing intermittent DTC to be set in PCM memory.

  53. 94) Check Vacuum Signal For Intermittent Fault

    Connect vacuum pump to EGR valve vacuum supply hose. Start engine and allow to idle. Connect a jumper wire between PCM connector terminal C16 (EGRVR) on LS or terminal No. 47 (EGRVR) and chassis ground to turn EGRVR solenoid on. Vacuum gauge reading should be more than 4 in. Hg. Observe vacuum gauge for fault while tapping lightly on EGRVR solenoid. Fault will be indicated by a sudden drop of vacuum. Wiggle EGRVR solenoid vacuum hoses, wiring harness and connector. If fault is indicated, isolate and repair as necessary. If no faults are indicated, symptom cannot be identified at this time. Go to TEST Z .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 94) to step 100). No test procedures have been omitted.

  54. 100) EGR Diagnosis By Symptom: Check For EGR Flow With EGR Vacuum Hose Disconnected & Plugged

    If directed to this test step for a poor fuel economy symptom and no DTCs are present, possible causes are:
    • EGR Valve Not Fully Seated
    • EGRVR Solenoid Vent Restricted
    • Faulty EGRVR Solenoid

    Perform KOER ON-DEMAND SELF-TEST  and service any other DTCs that are present. If no other DTCs are present, disconnect and plug EGR valve vacuum supply hose. Leave scan tool connected to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, select DPFEGR PID and record voltage reading. Start engine and allow to idle. Observe and record DPFEGR PID voltage reading. Compare DPFEGR PID voltage readings. If DPFEGR PID voltage reading at idle is more than .15 volt of KOEO reading, DPFEGR sensor is sensing EGR flow and most likely cause is EGR valve. Check EGR valve for contamination, wear, carbon deposits, binding or damage. Repair as necessary. If DPFEGR PID voltage reading at idle is within .15 volt of KOEO reading, check EGR valve vacuum supply, EGRVR solenoid vent and vent filter for restriction. If no restrictions are found, replace EGRVR solenoid.

    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 100) to step 110). No test procedures have been omitted.

  55. 110) KOEO Or KOER DTC P1409: Check EGRVR Solenoid Resistance

    This DTC indicates self-test failed due to EGRVR circuit voltage reads too high or too low when compared to expected voltage range. Possible causes are:
    • EGRVR Circuit Open Or Shorted To VPWR Or GND
    • VPWR Circuit Open To EGRVR Solenoid
    • Faulty EGRVR Solenoid
    • Faulty PCM

    Turn ignition switch to OFF position. Disconnect EGRVR solenoid harness connector. Using a DVOM, measure resistance between EGRVR solenoid terminals. If resistance is 26-40 ohms, go to next step. If resistance is not 26-40 ohms, replace EGRVR solenoid.

  56. 111) Check VPWR To EGRVR Solenoid

    Turn ignition switch to ON position. Measure voltage between VPWR terminal at EGRVR solenoid harness connector and chassis ground. See Fig 7-Fig 8 . If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit.

  57. 112) Check EGRVR Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance of EGRVR circuit between PCM harness connector and EGRVR solenoid harness connector. See WIRING DIAGRAMS article. See Figure, Figure, Fig 7 or Fig 8 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in EGRVR circuit.

  58. 113) Check EGRVR Circuit For Short To PWR In Harness

    Turn ignition switch to ON position. Using a DVOM, measure voltage between PCM harness connector EGRVR circuit terminal and negative battery terminal. See Figure, Figure, Fig 7 or Fig 8 . If voltage is less than one volt, go to next step. If voltage is one volt or more, repair short to PWR in EGRVR circuit.

  59. 114) Check EGRVR For Short To PWR GND

    Turn ignition switch to OFF position. Using a DVOM, measure resistance between PCM harness connector EGRVR and PWR GND terminals. See Figure or Figure . See WIRING DIAGRAMS article. If resistance is less than 10 k/ohms, repair short circuit. If resistance is 10 k/ohms or more, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 114) to step 120). No test procedures have been omitted.

  60. 120) Continuous Memory DTC P1409: Wiggle EGRVR Solenoid While Monitoring VPWR

    This DTC indicates self-test failed due to EGRVR circuit voltage reads too high or too low when compared to expected voltage range. Possible causes are:
    • EGRVR Circuit Open Or Shorted To VPWR Or GND
    • VPWR Circuit Open To EGRVR Solenoid
    • Faulty EGRVR Solenoid
    • Faulty PCM

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure resistance between PCM harness connector EGRVR and PWR GND terminals. See Figure, Figure, Fig 7 or Fig 8 . See WIRING DIAGRAMS article. Voltage should be more than 10.5 volts. Observe DVOM for indication of fault while tapping lightly on EGRVR solenoid, and wiggling EGRVR solenoid wiring harness and connector to simulate road shock. Fault is indicated by a sudden drop in voltage reading. If fault is indicated, isolate and repair as necessary. If no faults are indicated, unable to duplicate or identify fault at this time. Go to TEST Z .

scientia non olet · About LEMON Manuals