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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 10 (Engine Controls - Pinpoint Tests (Diesel)) >> Pinpoint Test AZ: Exhaust Gas RECIRCULATION (EGR) Cooler System >> Test Procedure

Test Procedure

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. AZ1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) 

    Are DTCs P0401, P2425, P2426, P2427, P2457, P245A or P24A5 present? 

    Yes No
    For DTCs P0401, P2457 or P24A5, GO to  AZ7.
    For all others, GO to AZ2  .    		 RETURN to ENGINE CONTROLS - SYMPTOM CHARTS (DIESEL) , Symptom Charts for further direction.
  2. AZ2 CHECK THE VPWR CIRCUIT FOR AN OPEN 
    • Ignition OFF.
    • Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Harness Side (-)
      VPWR - Pin 1 Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    GO to AZ3  . REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  3. AZ3 CHECK THE EGRCBV CIRCUIT FOR AN OPEN 
    • Ignition OFF.
    • PCM-E connector disconnected.
    • Measure the resistance between:
      (+) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Harness Side (-) PCM-E Connector, Harness Side
      EGRCBV - Pin 2 EGRCBV - Pin 66

    Is the resistance less than 5 ohms? 

    Yes No
    GO to AZ4  . REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  4. AZ4 CHECK THE EGRCBV CIRCUIT FOR A SHORT TO GROUND 
    • Measure the resistance between:
      (+) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Harness Side (-)
      EGRCBV - Pin 2 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to AZ5  . REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  5. AZ5 CHECK THE EGRCBV CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Harness Side (-)
      EGRCBV - Pin 2 Ground

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test. GO to AZ6  .
  6. AZ6 CHECK THE EGR COOLER BYPASS VALVE SOLENOID FOR THE CORRECT RESISTANCE 
    • Ignition OFF.
    • Measure the resistance between:
      (+) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Component Side (-) Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid Connector, Component Side
      VPWR - Pin 1 EGRCBV - Pin 2

    Is the resistance between 18 - 28 ohms? 

    Yes No
    For DTCs P2425, P2426 or P2427, GO to  AZ14.
    For all others, GO to AZ7  .    		 INSTALL a new Exhaust Gas Recirculation (EGR) Cooler Bypass Valve solenoid. Refer to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.
  7. AZ7 CARRY OUT A VISUAL INSPECTION 
    NOTE: When checking the EGR cooler bypass valve actuator for sticking or binding it is normal to notice some inconsistent movement.
    • Visually inspect for:
      • damaged or leaking vacuum lines
      • damaged EGR cooler bypass valve actuator or linkage
      • damaged EGR cooler bypass valve solenoid
    • Manually move the EGR cooler bypass valve actuator to check for sticking or binding.

    Is a concern present? 

    Yes No
    REPAIR as necessary.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to AZ8  .
  8. AZ8 CHECK THE SECONDARY COOLING SYSTEM 
    • Check the secondary cooling system for a system overheating condition or a low coolant condition. Refer to the appropriate Engine Cooling article, Inspection and Verification.

    Is the secondary cooling system overheating or is a low coolant condition present? 

    Yes No
    REPAIR as necessary. REFER to the appropriate Engine Cooling article, Symptom Chart to diagnose the system overheats symptom or loss of coolant symptom.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to AZ9  .
  9. AZ9 VISUALLY CHECK THE FUNCTIONALITY OF THE EGR COOLER BYPASS VALVE 
    NOTE: When the ignition is OFF, the EGR cooler bypass valve linkage will be fully extended.
    • Ignition OFF.
    • Observe the position of the EGR cooler bypass valve linkage.
    • Ignition ON, engine running.
    • Observe the position of the EGR cooler bypass valve linkage.

    Did the EGR cooler bypass valve linkage change from fully extended to fully retracted? 

    Yes No
    GO to AZ10  . For EGR cooler bypass valve linkage is always retracted. GO to AZ10  .
    For all others, GO to  AZ12.
  10. AZ10 CHECK FOR A STUCK OPEN EGR COOLER BYPASS VALVE SOLENOID 
    NOTE: The EGR cooler bypass valve is normally closed with the engine OFF or when commanded to 0% duty cycle. EGR flow is directed through the EGR cooler when the EGR cooler bypass valve is closed.
    • Ignition OFF.
    • Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Solenoid connector disconnected.
    • Ignition ON, engine running.

    Is the EGR cooler bypass valve linkage fully retracted? 

    Yes No
    INSTALL a new Exhaust Gas Recirculation (EGR) Cooler Bypass Valve solenoid. Refer to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to AZ11  .
  11. AZ11 CHECK THE EGR FLOW THROUGH THE EGR COOLER 
    NOTE: Verify the engine oil temperature (EOT) is greater than 60°C (140°F) before testing.
    NOTE: The TURBO_WGATE PID will only be available on vehicles equipped with a turbocharger wastegate.
    • Ignition ON, engine running.
    • Access the PCM and monitor the EOT (TEMP) PID.
    • Access the PCM and control the VGTDC (PER) PID.
    • Command the VGTDC PID to 60%.
    • Access the PCM and control the TURBO_WGATE (PER) PID.
    • Command the TURBO_WGATE PID duty cycle to 0%.
    • Access the PCM and control the RPMDSD (RPM) PID.
    • Increase the RPM_DSD PID to approximately 1, 500 RPM.
    • Access the PCM and control the EGR_A_CMD (PER) PID.
    • Command the EGR_A_CMD PID to 60%.
    • Access the PCM and monitor the MAF_A (FLOW) PID.
    • Access the PCM and monitor the EGRT11 (TEMP) PID.
    • Access the PCM and control the EGRCBV (PER) PID.
    • Increase the EGRCBV PID duty cycle to 100%, then decrease the EGRCBV PID duty cycle to 0%.
    • Monitor the MAF_A PID and the EGRT11 PID values while decreasing the EGRCBV PID from 100% to 0%.

    Does the MAF_A PID increase by less than 0.014 kg/s (14 g/s) and does the EGRT11 PID decrease by more than 30° C (55° F)? 

    Yes No
    The system is operating correctly at this time.
    RETURN to section 3, for further direction.    		 REFER to the appropriate Engine Emission Control article, Disassembly and Assembly. INSPECT the EGR cooler bypass valve. INSPECT the EGR cooler core. REPAIR as necessary.
    Clear the PCM DTCs. REPEAT the self-test.
  12. AZ12 CHECK FOR VACUUM AT THE EGR COOLER BYPASS VALVE ACTUATOR 
    • Ignition OFF.
    • Disconnect the EGR cooler bypass valve actuator vacuum hose.
    • Connect the DSL ENG Pressure Test Kit 014-00761 or equivalent to the EGR cooler bypass valve actuator vacuum hose.
    • Ignition ON, engine running.

    Is 67.73 kPa (20 in-Hg) or greater vacuum present at the EGR cooler bypass valve actuator vacuum hose? 

    Yes No
    INSTALL a new EGR cooler bypass valve actuator. Refer to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to AZ13  .
  13. AZ13 CHECK FOR VACUUM AT THE EGR COOLER BYPASS VALVE SOLENOID 
    • Ignition OFF.
    • Disconnect the EGR cooler bypass solenoid vacuum hose from the EGR cooler bypass valve solenoid.
    • Connect the DSL ENG Pressure Test Kit 014-00761 or equivalent to the bypass solenoid vacuum hose.
    • Ignition ON, engine running.

    Is 67.73 kPa (20 in-Hg) or greater vacuum present at the EGR cooler bypass solenoid vacuum hose? 

    Yes No
    INSTALL a new Exhaust Gas Recirculation (EGR) Cooler Bypass Valve solenoid.
    Refer to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.    		 REFER to the appropriate Four-Wheel Drive Systems article, the front axles do not engage/disengage correctly, to diagnose the vacuum concern.
    Clear the PCM DTCs. REPEAT the self-test.
  14. AZ14 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.
    • Verify the concern is still present.

    Is the concern still present? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) , Programming the VID Block for a Replacement PCM. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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