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Home >> Ford >> 2004 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> Engine Controls - Pinpoint Test JB: Secondary Ignition (Cop) Through Pinpoint Test KD: Electric Exhaust Gas RECIRCULATION (EEGR) System - CNG, Flex-Fuel & Gasoline >> Pinpoint Test KD: Electric Exhaust Gas Recirculation (EEGR) System >> Test Procedure

Test Procedure

NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION  table of fault code setting condition.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P0400    KD9  KD9
P0403  KD1  KD1  KD1
  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 ON Engine OFF.
    • EEGR Assembly connector disconnected.
    • Measure the voltage between:
    ( + )EEGR Assembly Connector, Harness Side ( - )Vehicle battery
    VPWR - Pin 2, 5 Negative terminal

    Is the voltage greater than 10.5 V? 

    Yes No
    GO to  KD3. KEY OFF. REPAIR open circuit.
  3. KD3 CHECK THE EEGR CIRCUIT(S) FOR AN OPEN IN THE HARNESS 
    • Key OFF.
    • 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
    VPWR - Pin 2, 5 VPWR

    Are the resistances greater than 5 ohms? 

    Yes No
    REPAIR open circuit. GO to  KD4.
  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
    VPWR - Pin 2, 5 Negative terminal

    Are the resistances less than 1K ohms? 

    Yes No
    REPAIR short circuit. GO to  KD5.
  5. KD5 CHECK FOR SHORTS BETWEEN CIRCUITS IN THE EEGR HARNESS 
    NOTE: REFER to the POWERTRAIN CONTROL MODULE (PCM) CONNECTOR  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

    Are the resistances less than 1K ohms? 

    Yes No
    REPAIR short circuit. GO to  KD6.
  6. KD6 CHECK THE EEGR CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • PCM connector connected.
    • Key ON Engine OFF.
    • 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
    KEY OFF. REPAIR short circuit. GO to  KD7.
  7. KD7 CHECK THE EEGR FOR OPEN AND SHORT CIRCUITS 
    • Key OFF.
    • PCM connector disconnected.
    • EEGR Assembly connector connected.
    • Measure the resistance between:
    ( + )PCM Connector, Harness Side ( - )PCM Connector, Harness Side
    EGRMC1 VPWR
    EGRMC2 VPWR
    EGRMC3 VPWR
    EGRMC4 VPWR

    Are the resistances between 15 ohms - 24 ohms? 

    Yes No
    GO to  KD8. INSTALL a new EEGR assembly and retest vehicle.
  8. KD8 CHECK THE EEGR FOR SHORTS TO GROUND 
    • Measure the resistance between:
    ( + )PCM Connector, Harness Side ( - )Vehicle battery
    EGRMC1 Negative terminal
    EGRMC2 Negative terminal
    EGRMC3 Negative terminal
    EGRMC4 Negative terminal

    Are the resistances greater than 1K ohms? 

    Yes No
    INSTALL a new PCM.
    Refer to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .    		 INSTALL a new EEGR assembly and retest vehicle.
  9. KD9 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 OFF.
    • MAP/TMAP Sensor connector disconnected.
    • Connect a 5 amp fused jumper wire between the following:
    Point A MAP/TMAP Sensor Connector, Harness Side Point B MAP/TMAP Sensor Connector, Component Side
    VREF - Pin 3 VREF - Pin 3
    SIGRTN - Pin 1 SIGRTN - Pin 1
    • Key ON Engine RUN.
    • Measure the voltage between:
    ( + )MAP/TMAP Sensor Connector, Component Side ( - )Vehicle battery
    MAP - Pin 4 Negative terminal

    Is the voltage between 1 V - 2 V? 

    Yes No
    Note 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  KD10.    		 KEY OFF.
    CHECK the MAP/TMAP harness for open and short circuits
  10. KD10 COMPARE ACTUAL MAP VOLTAGE TO MAP_V PID VOLTAGE EGR 
    • Key ON Engine OFF.
    • Access the PCM -MAP_V PID.
    • Note the MAP_V PID voltage.
    • Key ON Engine RUN.
    • Note the MAP_V PID voltage.
    • Increase engine speed to 1000 RPM.
    • Note the MAP_V PID voltage.
    • Increase engine speed to 2000 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
    The fault is not present at this time
    Be sure the MAP is properly seated and the vacuum source is not blocked.    		 GO to  KD11.
  11. KD11 PERFORM THE KOER SELF-TEST 

    Does DTC P1408 reappear? 

    Yes No
    INSTALL a new EEGR assembly. Concern is elsewhere. RETURN to SYMPTOM CHARTS - CNG, FLEX-FUEL & GASOLINE for further direction.
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