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Home >> Ford >> 2005 >> Focus ZX3 SES, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Pinpoint Test JE: Integrated Ignition Coil Pack A, B, Or C Failure Through Pinpoint Test KP: Charge Air Cooler (CAC) Pump - (Except Diesel & Hybrid) >> Pinpoint Test KD: Electric Exhaust Gas Recirculation (EEGR) System >> Test Procedure

Test Procedure

  1. KD1 DTC P0403: EGR CONTROL CIRCUIT - CHECK THE CONNECTION OF THE EEGR HARNESS CONNECTOR TO THE EEGR 
    NOTE: If the DTC is intermittent, wiggle the harness and connectors when taking measurements.
    • Check the connection of the EEGR harness connector to the EEGR.

    Are the connector contacts clean and properly seated? 

    Yes No
    GO to  KD2. REPAIR as necessary.
  2. KD2 CHECK FOR VPWR AT THE EEGR HARNESS CONNECTOR 
    • Key in ON position.
    • EEGR Assembly connector disconnected.
    • Measure the voltage between:
      (+) EEGR Assembly Connector, Harness Side (-) Vehicle Battery
      VPWR - Pin 2, 5 Negative terminal

    Are the voltages greater than 10.5 volts? 

    Yes No
    GO to  KD3. REPAIR the open circuit.
  3. KD3 CHECK THE EEGR CIRCUIT(S) FOR AN OPEN IN THE HARNESS 
    • Key in OFF position.
    • PCM connector disconnected.
    • Measure the resistance between:
      (+) EEGR Assembly Connector, Harness Side (-) PCM Connector, Harness Side
      EGRMC1 - Pin 1 EGRMC1
      EGRMC2 - Pin 3 EGRMC2
      EGRMC3 - Pin 4 EGRMC3
      EGRMC4 - Pin 6 EGRMC4

    Are the resistances less than 5 ohms? 

    Yes No
    GO to  KD4. REPAIR the open circuit.
  4. KD4 CHECK THE EEGR CIRCUIT(S) FOR A SHORT TO GROUND IN THE HARNESS 
    • Measure the resistance between:
      (+) EEGR Assembly Connector, Harness Side (-) Vehicle Battery
      EGRMC1 - Pin 1 Negative terminal
      EGRMC2 - Pin 3 Negative terminal
      EGRMC3 - Pin 4 Negative terminal
      EGRMC4 - Pin 6 Negative terminal

    Are the resistances greater than 10K ohms? 

    Yes No
    GO to  KD5. REPAIR the short circuit to GND.
  5. KD5 CHECK FOR SHORTS BETWEEN CIRCUITS IN THE EEGR HARNESS 
    NOTE: REFER to the POWERTRAIN CONTROL MODULE (PCM) CONNECTOR  PCM connector pin numbers in the beginning of this pinpoint test.
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-) PCM Connector, Harness Side
      EGRMC3 EGRMC1
      EGRMC3 EGRMC2
      EGRMC3 EGRMC4
      EGRMC1 EGRMC2
      EGRMC1 EGRMC4
      EGRMC2 EGRMC4

    Are the resistances greater than 10K ohms? 

    Yes No
    GO to  KD6. REPAIR the short circuit.
  6. KD6 CHECK THE EEGR CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • Key in ON position.
    • Measure the voltage between:
      (+) EEGR Assembly Connector, Harness Side (-) Vehicle Battery
      EGRMC1 - Pin 1 Negative terminal
      EGRMC2 - Pin 3 Negative terminal
      EGRMC3 - Pin 4 Negative terminal
      EGRMC4 - Pin 6 Negative terminal

    Are the voltages greater than 0.1 V? 

    Yes No
    REPAIR the short circuit. GO to  KD7.
  7. KD7 CHECK THE EEGR COILS FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between:
      (+) EEGR Assembly Connector, Component Side (-) EEGR Assembly Connector, Component Side
      EGRMC1 - Pin 1 VPWR - Pin 2, 5
      EGRMC2 - Pin 3 VPWR - Pin 2, 5
      EGRMC3 - Pin 4 VPWR - Pin 2, 5
      EGRMC4 - Pin 6 VPWR - Pin 2, 5

    Are the resistances between 15 ohms - 24 ohms? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . INSTALL a new EEGR assembly.
  8. KD8 DTCS P0400 AND P1408: CHECK FOR STUCK OR STICKY EGR VALVE OPERATION BY COMPARING ACTUAL MAP VOLTAGE TO MAP_V PID VOLTAGE 
    NOTE: Repair the following DTCs first, if present:
    • P0102, P0103, P0107, P0108, P1100, P1101.
    • Key in OFF position.
    • MAP Sensor connector disconnected.
    • Connect a 5 amp fused jumper wire between the following:
      Point A MAP Sensor Connector, Harness Side Point B MAP Sensor Connector, Component Side
      VREF VREF
      SIGRTN SIGRTN
    • Key on engine running.
    • Measure the voltage between:
      (+) MAP Sensor Connector, Component Side (-) Vehicle Battery
      MAP Negative terminal

    Is the voltage between 1 V - 2 V? 

    Yes No
    RECORD the actual MAP voltage values at KOEO, idle, 1, 000 and 2, 000 RPM. You will use the values for comparison in the following test step.
    GO to  KD9.    		 Key in OFF position.
    CHECK the MAP harness for open and short circuits.
  9. KD9 COMPARE ACTUAL MAP VOLTAGE TO MAP_V PID VOLTAGE EGR 
    • Key in ON position.
    • Access the PCM and monitor the MAP_V PID.
    • Note the MAP_V PID voltage.
    • Key on engine running.
    • Note the MAP_V PID voltage.
    • Increase engine speed to 1, 000 RPM.
    • Note the MAP_V PID voltage.
    • Increase engine speed to 2, 000 RPM.
    • Note the MAP_V PID voltage.

    Does the MAP_V PID voltage stay within 0.5 volt of the actual MAP voltage? 

    Yes No
    Key in OFF position.
    The fault is not present at this time.
    Be sure the MAP is properly seated and the vacuum source is not blocked.    		 Key in OFF position.
    GO to  KD10.
  10. KD10 CARRY OUT THE KOER SELF-TEST 

    Does DTC P1408 reappear? 

    Yes No
    INSTALL a new EEGR assembly. REFER to STEP 2: NO DTCS PRESENT SYMPTOM CHART INDEX .
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