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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 681 (Engine Controls - Pinpoint Tests - Diesel 6.0L (99P E-Series & 99P F450/550)) >> PINPOINT TEST W: Exhaust Gas Recirculation (EGR) Systems >> Test Procedure

Test Procedure

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  1. W1 DTCS P0401, P0402, P0403, P0404, P0405, P0406, P1335 AND P1408: PRELIMINARY DIAGNOSIS 
    • Carry out a visual inspection.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record the freeze frame data.
    • Clear the DTCs.
    • Carry out the self-test.
    • Are any DTCs retrieved? 
    Yes No
    For DTC P0403 alone, GO to  W4.
    For DTC P0405 alone, GO to  W10.
    For DTC P0406 alone, GO to  W14.
    For DTCs P0401, P0402, P0404, P1335 or P1408 alone or in combination, GO to  W2.    		 GO to  W3.
  2. W2 DTCS P0401, P0402, P0404, P1335 OR P1408: CHECK FOR OTHER DTCS 
    NOTE: Visually inspect the vehicle for aftermarket accessories and performance modifications (air filter, exhaust system, intake system, performance chip, turbocharger). Refer toDIESEL ELECTRONIC ENGINE CONTROL (EEC) SYSTEM , Modifications to OBD Vehicles.
    • Carry out the self-test.
    • Are other DTCs present? 
    Yes No
    REPAIR all other DTCs. REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS . GO to  W3.
  3. W3 CARRY OUT THE EGR SYSTEM TEST 
    • Engine at normal operating temperature.
    • Key ON, engine OFF.
    • Access the PCM and the EGR System Test.
    • Carry out the EGR System Test while following the directions on the scan tool.
    • Did the EGR System Test pass all tests? 
    Yes No
    Unable to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the concern. REPAIR as necessary. REFER toNO DTCS PRESENT SYMPTOM CHART , if a driveability concern exists. If the EBP and MAP PIDS are both out of range, refer to PINPOINT TEST KA .
    For all other non EGR PIDS that are out of range, REFER to the appropriate pinpoint test to continue diagnosis.
    If DTC P0403 was retrieved, GO to  W4.
    If DTC P0405 was retrieved, GO to  W10.
    If DTC P0406 was retrieved, GO to  W14.
    If DTC P1335 was retrieved, GO to  W9.
    For DTCs P0401, P0402, P0404 or P1408 alone, CLEAN or INSTALL a new EGR actuator as necessary. REFER to appropriate EXHAUST EMISSION CONTROL article. RESET the keep alive memory (KAM), REFER toRESETTING THE KEEP ALIVE MEMORY (KAM) . CLEAR the DTCs. REPEAT the self-test.
  4. W4 DTC P0403: CHECK THE VPWR CIRCUIT FOR VOLTAGE 
    NOTE: Refer to the PCM connector pin numbers at the beginning of this pinpoint test.
    • Key in OFF position.
    • EGR Actuator connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) EGR Actuator Connector, Harness Side ( - )
      VPWR - Pin E Ground
    • Is the voltage greater than 11 V? 
    Yes No
    GO to  W5. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  5. W5 CHECK THE EGRMC CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key in OFF position.
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) EGR Actuator Connector, Harness Side ( - )
      EGRMC - Pin A Ground
    • Is the voltage greater than 0.2 V? 
    Yes No
    GO to  W6. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  6. W6 CHECK THE EGRMC CIRCUIT FOR A SHORT TO GROUND 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) EGR Actuator Connector, Harness Side ( - )
      EGRMC - Pin A Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    GO to  W7. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  7. W7 CHECK THE EGRMC CIRCUIT FOR AN OPEN 
    • Measure the resistance between:
      ( + ) EGR Actuator Connector, Harness Side ( - ) PCM Connector, Harness Side
      EGRMC - Pin A EGRMC - Pin E23
    • Is the resistance less than 5 ohms? 
    Yes No
    GO to  W8. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  8. W8 CHECK THE EGR ACTUATOR 
    • Measure the resistance between:
      ( + ) EGR Actuator Connector, Component Side ( - ) EGR Actuator Connector, Component Side
      EGRMC - Pin A VPWR - Pin E
    • Is the resistance between 4 - 10 ohms? 
    Yes No
    GO to  W17. INSTALL a new EGR actuator. REFER to appropriate EXHAUST EMISSION CONTROL article. RESET the KAM, REFER toRESETTING THE KEEP ALIVE MEMORY (KAM) .
    CLEAR the DTCs. REPEAT the self-test.
  9. W9 DTC P1335: CHECK THE EGRVP PID VOLTAGE 
    NOTE: DTC P1335 is set when the EGR closed position voltage is greater than 1.20 volts at initial key ON which can be caused by excessive carbon buildup on the EGR valve.
    • Key ON, engine OFF.
    • Access the PCM and monitor the EGRVP PID.
    • Is the EGRVP PID voltage under 1.20 volts? 
    Yes No
    The system is operating correctly at this time. The concern may have been caused by carbon buildup on the EGR valve that has since been removed.
    CLEAR the DTCs. REPEAT the self-test.    		 CLEAN or INSTALL a new EGR actuator as necessary. REFER to appropriate EXHAUST EMISSION CONTROL article. RESET the KAM, REFER toRESETTING THE KEEP ALIVE MEMORY (KAM) . CLEAR the DTCs. REPEAT the self-test.
  10. W10 DTC P0405: CHECK THE VREF CIRCUIT FOR VOLTAGE 
    NOTE: Refer to the PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Key in OFF position.
    • EGR Actuator connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) EGR Actuator Connector, Harness Side ( - ) EGR Actuator Connector, Harness Side
      VREF - Pin D SIGRTN - Pin B
    • Is the voltage between 4.5 - 5.5 V? 
    Yes No
    GO to  W11. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  11. W11 CHECK THE EGR CIRCUIT FOR A SHORT TO GROUND 
    • Key in OFF position.
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) EGR Actuator Connector, Harness Side ( - )
      EGR - Pin C Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    GO to  W12. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  12. W12 CHECK THE EGR CIRCUIT FOR AN OPEN 
    • Measure the resistance between:
      ( + ) PCM Connector, Harness Side ( - ) EGR Actuator Connector, Harness Side
      EGR - Pin E33 EGR - Pin C
    • Is the resistance less than 5 ohms? 
    Yes No
    GO to  W13. REPAIR the open 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:
      EGR ACTUATOR CONNECTOR

      Pins Pin Minimum Resistance Maximum Resistance
      B C 50 Ohms 2,500 Ohms
      C D 2,000 Ohms 7,000 Ohms
      B D 3,000 Ohms 7,000 Ohms
    • Are the resistances within specifications? 
    Yes No
    GO to  W17. INSTALL a new EGR actuator. REFER to appropriate EXHAUST EMISSION CONTROL article. RESET the KAM, REFER toRESETTING THE KEEP ALIVE MEMORY (KAM) .
    CLEAR the DTCs. REPEAT the self-test.
  14. W14 DTC P0406: CHECK FOR DTC P0405 
    NOTE: Refer to the PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Key in OFF position.
    • EGR Actuator connector disconnected.
    • The EGR actuator is disconnected to simulate the opposite DTC.
    • Key ON, engine OFF.
    • Carry out the self-test.
    • Is DTC P0405 present? 
    Yes No
    INSTALL a new EGR actuator. REFER to appropriate EXHAUST EMISSION CONTROL article. RESET the KAM, REFER toRESETTING THE KEEP ALIVE MEMORY (KAM) .
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  W15.
  15. W15 CHECK THE EGR CIRCUIT FOR A SHORT TO VOLTAGE 
    • Key in OFF position.
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) EGR Actuator Connector, Harness Side ( - )
      EGR - Pin C Ground
    • Is the voltage less than 0.2 V? 
    Yes No
    GO to  W16. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  16. W16 CHECK THE SIGRTN CIRCUIT FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) EGR Actuator Connector, Harness Side ( - ) PCM Connector, Harness Side
      SIGRTN - Pin B SIGRTN - Pin B20, B33, E25
    • Are the resistances less than 5 ohms? 
    Yes No
    GO to  W17. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  17. W17 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect all the PCM connectors.
    • Visually inspect for:
      • pushed out pins
      • corrosion
    • Connect all the PCM connectors and make sure they seat correctly.
    • Carry out the PCM self-test and verify the concern is still present.
    • Is the concern still present? 
    Yes No
    INSTALL a new PCM. REFER toFLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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