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HOMESERVICE MANUALSFORD1984RV CUTAWAY 5.8 GREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSIS5.0L/5.8L EEC IV TESTINGCIRCUIT TESTINGTEST H - EGR VALVE POSITION (EVP) SENSOR
1984 Ford RV Cutaway 5.8 G

Test H - EGR Valve Position (EVP) Sensor

1984 Ford RV Cutaway 5.8 GSECTION Test H - EGR Valve Position (EVP) Sensor
  1. Code 31. Turn ignition off and wait 10 seconds. Disconnect and plug EGR vacuum line at EGR valve. Perform KEY ON-ENGINE RUNNING (KOER) SELF-TEST  . If code 31, go to next step. If no code 31, but codes 32 and/or 34 present, go to step 9).
  2. Turn ignition off and wait 10 seconds. EGR vacuum line disconnected and plugged at EGR valve. Disconnect harness connector at EGR valve position (EVP) sensor and inspect terminals for damage. Repair as required. With DVOM on 200,000 ohm scale, measure resistance from EVP signal circuit to voltage reference circuit at EVP sensor. Then measure resistance from signal return circuit to voltage reference circuit at sensor. If both readings are 100-5500 ohms, go to next step. If either reading is less than 100 ohms or more than 5500 ohms, replace sensor and repeat QUICK TEST  .
  3. Ignition off, EGR vacuum line disconnected and plugged and harness disconnected at EVP sensor. Connect vacuum pump to EGR valve. With DVOM on 200,000 ohm scale, measure resistance from EVP signal circuit to voltage reference circuit at EVP sensor while gradually increasing vacuum to 10 in. Hg. If reading gradually decreases from no more than 5500 ohms to no less than 100 ohms as vacuum is increased, go to next step. If reading is less than 100 ohms or more than 5500 ohms as vacuum is increased, replace sensor and repeat QUICK TEST  . If reading does not decrease or sensor does not hold vacuum, go to step 12).
  4. Turn ignition on (engine off). EGR vacuum line disconnected and plugged and harness disconnected at EVP sensor. With DVOM on 20 volt scale, measure voltage from voltage reference circuit to signal return circuit at sensor harness. If reading is 4-6 volts, go to next step. If reading is less than 4 volts, go to step 7). If reading is greater than 6 volts, go to TEST C  .
  5. Ignition on (engine off). Reconnect EGR vacuum line at EGR valve and leave harness disconnected. With DVOM on 20 volt scale, measure voltage from voltage reference circuit to EVP signal circuit at sensor harness. If reading is 4-6 volts, go to next step. If reading is less than 4 volts, go to step 7).
  6. Turn ignition off and wait 10 seconds. Harness disconnected at EVP sensor. Disconnect 60-pin connector at ECA and inspect for damaged terminals. Repair as required. With DVOM on 200,000 ohm scale, measure resistance from EVP signal circuit to signal return circuit at sensor harness and from EVP signal circuit to battery negative terminal. If either reading is less than 10,000 ohms, repair short circuit and repeat QUICK TEST  . If both readings are 10,000 ohms or more, replace ECA and repeat QUICK TEST  .
  7. Turn ignition off and wait 10 seconds. Harness disconnected at EVP and ECA. Connect breakout box and leave ECA disconnected. With DVOM on 200 ohm scale, measure continuity from box pin 46 to signal return circuit of EVP harness; from box pin 26 to voltage reference circuit of EVP harness and from box pin 27 to EVP signal circuit of EVP harness. If all readings less than 5 ohms, go to next step. If any reading 5 ohms or more, repair open circuit and repeat QUICK TEST  .
  8. Ignition off, EVP harness disconnected, breakout box installed and ECA disconnected. With DVOM on 200,000 ohm scale, measure resistance from box pin 27 to pins 37 and 57. If either reading is less than 10,000 ohms, repair short circuit and repeat QUICK TEST  . If both readings are 10,000 ohms or more, replace ECA and repeat QUICK TEST  .
  9. Codes 32, 33 and 34. Turn ignition off and wait 10 seconds. Disconnect harness connectors at EGR control (EGRC) and EGR vent (EGRV) solenoids. Check harness for damaged pins and repair as required. With DVOM on 200 ohm scale, measure resistance of solenoids. If both readings are between 30-70 ohms, reconnect harness and go to next step. If either reading is less than 30 ohms or greater than 70 ohms, replace solenoid assembly, reconnect harness and repeat QUICK TEST  .
  10. Turn ignition off and wait 10 seconds. Enter Output State Check and perform Key On-Engine Off Self-Test until end of Continuous code display. DVOM will indicate zero volts. Depress and release throttle and observe DVOM. If DVOM registered high voltage, remain in Output State Check and go to next step. If DVOM did not register high voltage, depress throttle to wide open position and release. If voltage still does not register high reading, go to TEST D, step 13).
  11. Turn ignition on (engine off). Remain in Output State Check. With DVOM on 20 volt scale, connect leads to vehicle power and EGRV signal circuits on back of EGRV harness. While observing DVOM, depress and release throttle (cycle outputs on and off). Repeat process on EGRC by connecting leads to vehicle power and EGRC signal circuits. If both solenoid outputs cycle on and off, remain in Output State Check and go to next step. If either output does not cycle on and off, exit Output State Check and go to step 16).
  12. Turn ignition on (engine off). Remain in Output State Check. Disconnect and plug vacuum line at bottom port of EGRC solenoid and connect vacuum pump. Connect vacuum gauge to top output vacuum line on EGR valve. Disconnect and allow vacuum vent line to draw air on EGRV solenoid. While applying vacuum and observing vacuum gauge, depress and release throttle several times to cycle outputs on and off. If vacuum output cycles on and off in less than 2 seconds, reconnect vacuum lines and go to next step. If vacuum output does not cycle on and off in less than 2 seconds, replace solenoid assembly and repeat QUICK TEST  .
  13. Turn ignition off and wait 10 seconds. Remove all test equipment and reconnect all vacuum lines. Check EEC system vacuum lines for proper routing, leaks and obstructions. Repair as required. If vacuum lines are okay, service EGR system.
  14. Ignition off. Disconnect harness at EVP sensor and inspect for damage. Repair as required. Disconnect vacuum line at EGR valve and connect vacuum pump. Set DVOM on 200,000 ohm scale. While increasing vacuum to 10 in. Hg to EGR valve, measure resistance between EVP signal circuit to voltage reference circuit on EVP sensor. If reading does not decrease gradually as vacuum increases, go to next step. If reading gradually decreases from no more than 5500 ohms to no less than 100 ohms as vacuum increases, replace ECA, reconnect vacuum lines and repeat QUICK TEST  .
  15. Ignition off and harness disconnected at EVP sensor. Remove EVP sensor from EGR valve. With DVOM on 200,000 ohm scale, measure resistance from signal return circuit to voltage reference circuit at EVP sensor. Observe DVOM while slowly pushing EVP sensor shaft inward. If reading smoothly decreases from no more than 5500 ohms to no less than 100 ohms, replace EGR valve assembly and repeat QUICK TEST  . If reading does not decrease smoothly or changes suddenly, replace EVP sensor and repeat QUICK TEST  .
  16. Disconnect harness at EGRV and EGRC solenoids. Turn ignition on (engine off). With DVOM on 20 volt scale, measure voltage from vehicle power circuit to battery negative terminal on both solenoids. If either reading is less than 10.5 volts, repair open circuit and repeat QUICK TEST  . If both readings are 10.5 volts or greater, go to next step.
  17. Turn ignition off and wait 10 seconds. Harness disconnected at EGRC and EGRV solenoids. Disconnect 60-pin connector at ECA and inspect for damage. Repair as required. Install breakout box and leave ECA disconnected. With DVOM on 200 ohm scale, measure continuity from box pin 33 to EGRV signal circuit on EGRV solenoid harness connector. Then measure from box pin 52 to EGRC signal circuit on EGRC solenoid harness connector. If both readings less than 5 ohms, go to next step. If either reading is 5 ohms or greater, repair open circuit and remove test equipment and repeat QUICK TEST  .
  18. Ignition off. Breakout box installed (ECA, EGRC and EGRV disconnected). With DVOM on 200,000 ohm scale, measure resistance from box pin 33 to pins 40, 46 and 57 and then from box pin 52 to pins 40, 46 and 57. If any reading is less than 10,000 ohms, repair short circuit and repeat QUICK TEST  . If all readings are 10,000 ohms or greater, replace ECA and repeat QUICK TEST  .
  19. Code 35 (RPM too low for EGR test). Before continuing, check for code 12. If code 12 present, go to TEST J  . If no code 12, go to next step.
  20. Turn ignition off and wait 10 seconds. Install tachometer and perform Key On-Engine Running Self-Test while maintaining engine speed at 1500 RPM. Record service codes. If code 35 is present, replace ECA and repeat QUICK TEST  . If no code 35, repeat QUICK TEST  and repair codes as required.
  21. Turn ignition off and wait 10 seconds. Disconnect EVP sensor and inspect harness and connector terminals. Repair as required. Turn ignition on (engine off). With DVOM on 20 volt scale, measure voltage from voltage reference circuit at EVP sensor harness connector to battery ground. If reading is 4-6 volts, go to next step. If reading is less than 4 volts, go to step 7). If reading is 6 volts or more, go to TEST C  .
  22. Ignition on and EVP sensor disconnected. With DVOM on 20 volt scale, measure voltage from voltage reference circuit to signal return circuit at sensor harness. If reading is 4-6 volts, go to next step. If reading is less than 4 volts, repair open circuit and repeat KEY ON-ENGINE OFF (KOEO) SELF-TEST  .
  23. Turn ignition off and wait 10 seconds. Disconnect 60-pin connector at ECA and inspect. Repair as required. Connect breakout box and reconnect ECA. Connect EVP sensor. Turn ignition on (engine off). With DVOM on 20 volt scale, measure voltage from box pin 27 to pin 46. If less than .5 volt, go to next step. If 1.25 volt or greater, go to step 27).
  24. Turn ignition off and wait 10 seconds. Disconnect ECA and EVP sensor. Breakout box installed. With DVOM on 200 ohm scale, measure resistance from box pin 27 to pins 20, 40, 46 and 60 in turn. If 5 ohms or more, go to next step. If less than 5 ohms, repair short to ground in EVP signal circuit and repeat QUICK TEST  .
  25. Turn ignition off. Breakout box installed and ECA and EVP sensor disconnected. With DVOM on 200 ohm scale, measure resistance from box pin 27 to EVP signal circuit at sensor harness. If 5 ohms or more, repair open in EVP signal circuit and repeat QUICK TEST  . If less than 5 ohms, go to next step.
  26. Turn ignition off. Replace EVP sensor with known good sensor and reconnect harness. Remove breakout box and reconnect ECA. Perform Key On-Engine Off Self-Test. If code 31 present, replace ECA and reinstall original EVP sensor. If no code 31, testing is complete.
  27. Turn ignition off and wait 10 seconds. Disconnect 60-pin connector at ECA and connect breakout box. Leave ECA disconnected. Disconnect EVP sensor. With DVOM on 200 ohm scale, measure resistance from box pin 27 to pins 26, 37 and 57 in turn. If 5 ohms or more, go to next step. If less than 5 ohms, repair short to power and repeat KEY ON-ENGINE OFF (KOEO) SELF-TEST  .
  28. Turn ignition off and wait 10 seconds. Connect electrical harness to a known good EVP sensor and EGR valve assembly. Remove breakout box and reconnect ECA. Perform KEY ON-ENGINE OFF (KOEO) SELF-TEST  .If code 31, replace ECA, reconnect original EVP sensor and EGR valve assembly and repeat QUICK TEST  . If no code 31, go to next step.
  29. Turn ignition off and wait 10 seconds. Install original EVP sensor and connect harness. Perform KEY ON-ENGINE OFF (KOEO) SELF-TEST  . If code 31, install new EVP sensor. If no code 31, testing complete.
  30. Continuous Code 31. Disconnect vacuum line at EGR valve and install vacuum pump. Very slowly apply 6 in. Hg vacuum to sensor, then slowly bleed off vacuum. Enter Continuous Monitor mode and observe volt/ohmmeter for fault indication while doing the following: Lightly tap on EVP sensor to simulate road shock. Wiggle sensor connector. If fault is indicated, go to next step. If no fault indicated, go to step 32).
  31. Turn ignition off and wait 10 seconds. Disconnect 60-pin connector at ECA and inspect. Repair as required. Connect breakout box and reconnect ECA. With volt/ohmmeter still connected to self-test output as in step 30), connect DVOM between box pin 27 and pin 46. Turn ignition on (engine off). With DVOM on 20 volt scale, observe DVOM while repeating step 30). If fault occurs below 4.25 volts, disconnect and inspect harness at EVP sensor. If connector and terminals are okay, replace EVP sensor and repeat QUICK TEST  . If fault does not occur below 4.25 volts, EGR valve "overshoot" may have caused code 31. Sensor service not required. Go to next step to verify harness integrity.
  32. Observe volt/ohmmeter while doing the following: Beginning at EVP, wiggle, shake or bend small sections of harness while working way to dash panel. Then repeating process from panel to ECA. If fault is indicated, isolate and repair problem and repeat QUICK TEST  . If no fault indicated, go to next step.
  33. Turn ignition off and wait 10 seconds. Disconnect 60-pin connector at ECA and inspect connector and terminals for damage. If damaged, service as required and repeat QUICK TEST  . If okay, fault cannot be duplicated at this time. Continuous Code 31 testing is complete.
Fig 1: EGR Valve Position (EVP) Sensor Circuit
G9390
RENDER: 1.0x

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