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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 747 (Engine Controls - Pinpoint Tests - 6.0L Diesel (99P E-Series & 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, P1335 
    • Perform visual inspection.
    • Connect the scan tool.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record freeze frame data.
    • Clear all DTCs.
    • Perform On-Demand Self Test.

    ARE ANY DTCS RETRIEVED? 

    Yes No
    For P0401, Go to  W2. UNABLE to duplicate condition. CHECK for loose connections, damaged or corroded terminals or pins. WIGGLE harness attempting to recreate fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists.
    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.
  2. W2 DIAGNOSTIC TROUBLE CODE (DTC) P0401, P0402 
    NOTE: Visually inspect the vehicle for aftermarket accessories and performance modifications (air filter, exhaust system, intake system, performance chip, turbocharger, etc.). Refer to Diesel Electronic Engine Control (EC) System, MODIFICATIONS TO OBD VEHICLES .
    NOTE: Refer to the PCM and component connector, Figure and Figure, at the beginning of this pinpoint test.
    • 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
    • Perform On-Demand Self Test.

    ARE OTHER DTCS PRESENT? 

    Yes No
    REPAIR all other DTCs before diagnosing DTC P0401 or P0402. Go to  W3.
  3. W3 CHECK EGR VALVE OPERATION 
    NOTE: Additional DTCs may set during the utilization of output state control (OSC). Clear all PCM and TCM DTCs after diagnostics have been performed. 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, duty cycle can be controlled to 100%.
    • Access the EP, EGRVPDES, EGRDC and EGRVP PIDS.
    • Record readings.
    • Start engine.
    • Activate Output State Control for the EGR valve.
    • Monitor EP while increasing and decreasing EGRDC.

    DOES EP READING INDICATE EGR VALVE MOVEMENT? 

    Yes No
    CLEAR DTCs and RETEST the system. If other DTCs are present, Go to the appropriate pinpoint test. If a driveability concern is present or DTC P0401 or P0402 is present, REFER to DIAGNOSTIC SUBROUTINES - 6.0L DIESEL , Performance Testing of EGR System. INSTALL a new EGR valve. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  4. W4 DIAGNOSTIC TROUBLE CODE (DTC) P0403 
    NOTE: Refer to the PCM and component connector, Figure and Figure, 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
    • Disconnect the EGR actuator electrical harness connector.
    • Key on.
    • Measure the voltage between EGR actuator valve harness connector pin E and ground.

    IS THE VOLTAGE ABOVE 11.0 VOLTS? 

    Yes No
    Go to  W5. REPAIR open in VPWR circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  5. W5 CHECK EGR ACTUATOR CONTROL VALVE CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key off.
    • Disconnect the PCM engine harness connector.
    • Key on.
    • Measure the voltage between EGR actuator valve harness connector pin A and ground.

    IS THE VOLTAGE LESS THAN 0.2 VOLTS? 

    Yes No
    Go to  W6. REPAIR short to voltage. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  6. W6 CHECK EGR ACTUATOR CONTROL VALVE CIRCUIT FOR A SHORT TO GROUND 
    • Key off.
    • Measure the resistance between EGR actuator valve harness connector pin A and ground.

    IS THE RESISTANCE GREATER THAN 10,000 OHMS? 

    Yes No
    Go to  W7. REPAIR short to ground. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  7. W7 CHECK EGR CONTROL CIRCUIT FOR AN OPEN 
    • Measure the resistance between EGR actuator harness connector pin A and PCM engine harness connector pin 23.

    IS THE RESISTANCE LESS THAN 5 OHMS? 

    Yes No
    Go to  W8. REPAIR open in control circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  8. W8 CHECK EGR ACTUATOR 
    • Measure the resistance between EGR actuator (component side) pins A and E.

    IS THE RESISTANCE BETWEEN 4.0 AND 10.0 OHMS? 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR DTCs and RETEST the system. INSTALL a new EGR actuator. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  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 other DTCs before diagnosing DTC P0404 or P1335. REFER to DIAGNOSTIC SUBROUTINES - 6.0L DIESEL . PERFORM the EGR Position Test. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  10. W10 DIAGNOSTIC TROUBLE CODE (DTC) P0405 
    NOTE: Refer to the PCM and component connector, Figure and Figure, at the beginning of this pinpoint test.
    • Possible causes:
      • position signal circuit shorted to ground
      • position signal circuit open
      • actuator
      • PCM
    • Disconnect the EGR actuator valve electrical connector.
    • Key on.
    • Measure the voltage between EGR harness connector pin D and pin B.

    IS THE VOLTAGE BETWEEN 4.5-5.5 VOLTS? 

    Yes No
    Go to  W11. REPAIR open in VREF or signal return circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  11. W11 CHECK EGR POSITION SIGNAL CIRCUIT FOR A SHORT TO GROUND 
    • Key off.
    • Disconnect the PCM engine harness connector.
    • Measure the resistance between EGR harness connector pin C and ground.

    IS THE RESISTANCE GREATER THAN 10,000 OHMS? 

    Yes No
    Go to  W12. REPAIR short to ground in position signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  12. W12 CHECK EGR POSITION SIGNAL CIRCUIT FOR AN OPEN 
    • Measure the resistance between PCM engine harness connector pin 33, and EGR actuator connector pin C.

    IS THE RESISTANCE LESS THAN 5 OHMS? 

    Yes No
    Go to  W13. REPAIR open in EGR position signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  13. W13 CHECK EGR INTERNAL CIRCUITS FOR AN OPEN OR SHORT 
    • Measure the resistance of EGR (component) internal circuits.
      • 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 ALL MEASUREMENTS WITHIN RANGE? 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR DTCs and RETEST the system. INSTALL a new EGR actuator. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  14. W14 DIAGNOSTIC TROUBLE CODE (DTC) P0406 
    NOTE: Refer to the PCM and component connector, Figure and Figure, at the beginning of this pinpoint test.
    • Possible causes:
      • position signal shorted to voltage
      • open in signal return circuit
      • sensor
      • PCM
    • Induce opposite failure.
    • Disconnect EGR actuator harness connector.
    • Perform On-Demand Self Test.

    IS DTC P0405 PRESENT? 

    Yes No
    INSTALL a new EGR actuator. RESTORE the vehicle. CLEAR DTCs and RETEST the system. Go to  W15.
  15. W15 CHECK EGR POSITION SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key off.
    • Disconnect the PCM engine harness connector.
    • Key on.
    • Measure the voltage between EGR actuator connector pin C and ground.

    IS THE VOLTAGE LESS THAN 0.2 VOLTS? 

    Yes No
    Go to  W. REPAIR short to voltage in EGR position signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  16. W16 CHECK EGR POSITION SIGNAL CIRCUIT SIGNAL RETURN FOR AN OPEN 
    • Key off.
    • Reconnect PCM.
    • Measure the resistance between EGR harness connector pin B and PCM engine connector pin 25.

    IS THE RESISTANCE LESS THAN 5 OHMS? 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR DTCs and RETEST the system. REPAIR open in signal return circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
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