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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1059 (Engine Controls - Pinpoint Tests - 6.0L Diesel (99P F450/550)) >> Pinpoint Test W: Exhaust Gas Recirculation (EGR) >> Test Procedure

Test Procedure

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  1. W1 PRELIMINARY DIAGNOSIS FOR DTCS P0401, P0402, P0403, P0404, P0405, P0406, AND P1335 
    • Carry out a visual inspection.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record the freeze frame data.
    • Clear all DTCs.
    • Carry out the on-demand self-test.

    Are any DTCs retrieved? 

    Yes No
    For P0401, GO to  W2.
    For P0402, GO to  W2.
    For P0403, GO to  W4.
    For P0404 or P1335, GO to  W9.
    For P0405, GO to  W10.
    For P0406, GO to  W14.    		 UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists.
  2. W2 DIAGNOSTIC TROUBLE CODE (DTC) P0401 OR P0402 
    NOTE: Visually inspect the vehicle for aftermarket accessories and performance modifications (air filter, exhaust system, intake system, performance chip, turbocharger). Refer to DIESEL ELECTRONIC ENGINE CONTROL (EEC) SYSTEM , MODIFICATIONS TO OBD VEHICLES .
    • Possible causes:
      • restricted air flow (intake or exhaust)
      • charge air cooler (CAC) system leaks (hoses/cooler)
      • EGR valve stuck or sticking
      • EGR valve O-rings
      • restricted EGR cooler
      • EGR valve position sensor bias
      • EP sensor bias
    • Carry out the on-demand self-test.

    Are other DTCs present? 

    Yes No
    REPAIR all other DTCs. REFER to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS . GO to  W3.
  3. W3 CHECK THE EGR VALVE OPERATION 
    NOTE: Additional DTCs may set during the use of output state control (OSC). Clear all PCM and TCM DTCs after the diagnostics have been completed. Repeat the self-test to verify all DTCs have been cleared.
    NOTE: EGR valve override control with the engine running is 75% maximum duty cycle. With the KOEO, the duty cycle can be controlled to 100%.
    • Access the EP, EGRVPDES, EGRDC, and EGRVP PIDs.
    • Record the PID values.
    • Key ON, engine running.
    • Access Output State Control for the EGR valve.
    • Monitor the EP PID while increasing and decreasing the EGRDC.

    Does EP reading indicate any EGR valve movement? 

    Yes No
    CLEAR the DTCs. REPEAT the self-test. If other DTCs are present, REFER to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS . If a driveability concern is present or DTC P0401 or P0402 is present, REFER to EXHAUST GAS RECIRCULATION (EGR) POSITION TEST . INSTALL a new EGR valve. CLEAR the DTCs. REPEAT the self-test.
  4. W4 DIAGNOSTIC TROUBLE CODE (DTC) P0403 
    NOTE: Refer to the PCM connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • open in control circuit
      • control circuit shorted to voltage
      • control circuit shorted to ground
      • EGR actuator
      • PCM
    • Key OFF.
    • Disconnect the EGR actuator.
    • Key ON, engine OFF.
    • Measure the voltage between EGR actuator connector pin E, harness side and ground.

    Is the voltage greater than 11.0 volts? 

    Yes No
    Go to  W5. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  5. W5 CHECK THE EGR ACTUATOR CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key OFF.
    • Disconnect the PCM engine connector.
    • Key ON, engine OFF.
    • Measure the voltage between the EGR actuator pin A, harness side and ground.

    Is the voltage less than 0.2 volts? 

    Yes No
    GO to  W6. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  6. W6 CHECK THE EGR ACTUATOR CIRCUIT FOR A SHORT TO GROUND 
    • Key OFF.
    • Measure the resistance between the EGR actuator pin A, harness side and ground.

    Is the resistance greater than 10,000 ohms? 

    Yes No
    GO to  W7. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  7. W7 CHECK THE EGR CONTROL CIRCUIT FOR AN OPEN 
    • Measure the resistance between the EGR actuator pin A, harness side and the PCM engine connector pin 23, harness side.

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  W8. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  8. W8 CHECK THE EGR ACTUATOR 
    • Measure the resistance between the EGR actuator pin A, component side and the EGR actuator pin E, component side.

    Is the resistance between 4 and 10 ohms? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. INSTALL a new EGR actuator. CLEAR the DTCs. REPEAT the self-test.
  9. W9 DIAGNOSTIC TROUBLE CODE (DTC) P0404 OR P1335 
    NOTE: DTC P1335 is set when the EGR closed position voltage is greater than 1.20 volts at initial key on.
    • Possible causes:
      • EGR valve
      • PCM

    Are other DTCs present? 

    Yes No
    REPAIR all other DTCs. REFER to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS . CARRY OUT the EXHAUST GAS RECIRCULATION (EGR) POSITION Test. CLEAR the DTCs. REPEAT the self-test.
  10. W10 DIAGNOSTIC TROUBLE CODE (DTC) P0405 
    NOTE: Refer to Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • position signal circuit shorted to ground
      • position signal circuit open
      • actuator
      • PCM
    • Key OFF.
    • Disconnect the EGR actuator.
    • Key ON, engine OFF.
    • Measure the voltage between EGR actuator pin D, harness side and the EGR actuator pin B, harness side.

    Is the voltage between 4.5 - 5.5 volts? 

    Yes No
    GO to  W11. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  11. W11 CHECK THE EGR POSITION SIGNAL CIRCUIT FOR A SHORT TO GROUND 
    • Key OFF.
    • Disconnect the PCM engine connector.
    • Measure the resistance between the EGR actuator pin C, harness side and ground.

    Is the resistance greater than 10,000 ohms? 

    Yes No
    GO to  W12. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  12. W12 CHECK THE EGR POSITION SIGNAL CIRCUIT FOR AN OPEN 
    • Measure the resistance between the PCM engine connector pin 33, harness side and the EGR actuator pin C, harness side.

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  W13. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  13. W13 CHECK THE EGR ACTUATOR 
    • Measure the resistance between the EGR actuator pins, component side as follows:
      • Pins B and C: 50-2,500 ohms
      • Pins C and D: 2,000-7,000 ohms
      • Pins B and D: 3,000-7,000 ohms

    Are the resistances within specifications? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. INSTALL a new EGR actuator. CLEAR the DTCs. REPEAT the self-test.
  14. W14 DIAGNOSTIC TROUBLE CODE (DTC) P0406 
    NOTE: Refer to Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • position signal shorted to voltage
      • signal return circuit open
      • sensor
      • PCM
    • Simulate the opposite DTC.
    • Key OFF.
    • Disconnect the EGR actuator.
    • Key ON, engine OFF.
    • Carry out the on-demand self-test.

    Is DTC P0405 present? 

    Yes No
    INSTALL a new EGR actuator. CLEAR the DTCs. REPEAT the self-test. GO to  W15.
  15. W15 CHECK THE EGR POSITION SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key OFF.
    • Disconnect the PCM engine harness connector.
    • Key ON, engine OFF.
    • Measure the voltage between the EGR actuator pin C, harness side and ground.

    Is the voltage less than 0.2 volts? 

    Yes No
    GO to  W16. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  16. W16 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN 
    • Key OFF.
    • Measure the resistance between EGR actuator pin B, harness side and the PCM engine connector pin 25, harness side.

    Is the resistance less than 5 ohms? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
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