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HOMESERVICE MANUALSFORD2003WINDSTAR BASEREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - SYSTEM TEST DV THROUGH JD - CNG, FLEX-FUEL & GASOLINETEST HE: EGR SYSTEMTESTING
2003 Ford Windstar Base

Test He: EGR System: Testing

2003 Ford Windstar BaseSECTION Testing
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
P0401      HE70
P0402  HE22  HE22  HE22
P0403  HE110  HE110  HE120
P0405  HE1  HE1  HE1
P0406  HE10  HE10  HE10
P1400  HE1  HE1  HE1
P1401  HE10  HE10  HE10
P1405      HE50
P1406      HE60
P1408      HE71
P1409  HE110  HE110  HE120
(1)
For engines equipped with a "Exhaust Gas Recirculation System Module (ESM)" see FAULT CODE SETTING CONDITION .
(2)
For engines equipped with "Electric Exhaust Gas Recirculation (EEGR) Assembly see FAULT CODE SETTING CONDITION .
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) For KOEO, KOER & Continuous Memory DTC P0405 & P1400: Determine Present DPFEGR PID Voltage
    DTC P0405 and P1400 indicates EGR MONITOR failed due to average voltage to PCM dropping below minimum calibrated limit of less than .2 volt. Possible causes for this fault are:
    • DPFEGR Circuit Shorted To GND Or SIG RTN Circuit
    • Faulty DPFEGR Sensor
    • VREF Circuit Shorted To GND Or SIG RTN Circuit
    • Faulty PCM

    Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. If DPFEGR PID voltage is less than .2 volt, fault is currently present. Go to next step. If voltage is .2 volt or more, fault is intermittent. Go to step  5).

  2. 2) Attempt To Induce Opposite DPFEGR Sensor Voltage

    Turn ignition switch to OFF position. Disconnect DPFEGR sensor harness connector. See Figure-Figure . Turn ignition switch to ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. If PID voltage is 4-6 volts, replace DPFEGR sensor. If PID voltage is not 4-6 volts, go to next step.

  3. 3) Check VREF & SIG RTN Circuits For Open To DPFEGR Sensor

    Using a DVOM, measure voltage between SIG RTN and VREF circuits at DPFEGR sensor harness connector. See Figure-Figure . If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, go to TEST C, step 1) .

  4. 4) Check DPFEGR Circuit For Short To Ground & SIG RTN In Harness

    Disconnect scan tool from Data Link Connector (DLC). Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between DPFEGR circuit, and SIG RTN circuit at PCM harness connector, and negative battery terminal. See PCM CONNECTOR IDENTIFICATION and Figure-Figure . If both resistance measurements are more than 10 k/ohms, replace PCM. If either resistance measurement is 10 k/ohms or less, repair short to ground or SIG RTN in DPFEGR circuit.

  5. 5) Perform Wiggle Test On DPFEGR Sensor & Circuit While Monitoring DPFEGR PID For A Sudden Change

    Ensure ignition switch is in ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. Observe DPFEGR PID voltage reading for change while tapping lightly on DPFEGR sensor, and shaking and bending DPFEGR sensor wiring harness and connector to simulate road shock. A sudden change in DPFEGR PID voltage reading indicates a fault. If fault is indicated, isolate and repair as necessary. If no fault is indicated, go to TEST Z, step 1) .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 5) to step 10). No test procedures have been omitted.
    6. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  6. 10) For KOEO, KOER & Continuous Memory DTC P0406 & P1401: Determine Present DPFEGR Sensor PID Voltage
    DTC P0406 and P1401 indicate EGR MONITOR failed due to average voltage to PCM exceeding maximum calibrated limit of 4.5 volts. Possible causes for this fault are:
    • Open In DPFEGR Or SIG RTN circuit.
    • VREF Or DPFEGR circuit shorted To PWR.
    • Faulty DPFEGR sensor.
    • Faulty PCM.

    Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. If DPFEGR PID voltage is more than 4 volts, fault is currently present. Go to next step. If DPFEGR PID voltage is 4 volts or less, fault is intermittent. Go to step  19).

  7. 11) Check DPFEGR Circuit For Short To PWR

    Turn ignition switch to OFF position. Disconnect DPFEGR sensor connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and DPFEGR circuit at DPFEGR sensor harness connector. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, go to step  13).

  8. 12) Check DPFEGR Circuit For Short To PWR In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and DPFEGR circuit at PCM harness connector. See PCM CONNECTOR IDENTIFICATION and Figure-Figure . If voltage is more than 10.5 volts, repair short to PWR in DPFEGR circuit. If voltage is 10.5 volts or less, replace faulty PCM.

  9. 13) Verify Scan Tool Communication

    Connect jumper wire between DPFEGR and SIG RTN circuits at the DPFEGR sensor harness connector. See Figure-Figure . Turn ignition switch to ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. If a scan tool communication concern appears with the jumper wire connected, immediately remove jumper wire. Go to step  19). If a scan tool communication concern does not appear with the jumper wire connected, go to next step.

  10. 14) Induce Opposite DPFEGR Sensor Voltage

    With jumper wire connected between DPFEGR and SIG RTN circuits at DPFEGR sensor harness connector, use scan tool to access DPFEGR PID from PID/DATA MONITOR & RECORD menu. If DPFEGR PID voltage reading is .05 volt or more, disconnect jumper wire and go to step  17). If DPFEGR PID voltage reading is less than .05 volt, disconnect jumper wire and go to next step.

  11. 15) Check VREF Voltage To DPFEGR Sensor

    Turn ignition switch to ON position. Using a DVOM, measure voltage between SIG RTN and VREF circuits at DPFEGR sensor harness connector. See Figure-Figure . If voltage is 4-6 volts, replace DPFEGR sensor. If voltage is not 4-6 volts, go to TEST C, step 1) .

  12. 17) Check DPFEGR Circuit For Open In Harness

    Turn ignition switch to OFF position. Ensure DPFEGR sensor is disconnected. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance of DPFEGR circuit between PCM harness connector and DPFEGR sensor harness connector. See PCM CONNECTOR IDENTIFICATION and Figure-Figure . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in DPFEGR circuit.

  13. 18) Check SIG RTN Circuit For Open In Harness

    Using a DVOM, measure resistance of SIG RTN circuit between PCM harness connector and DPFEGR sensor harness connector. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in SIG RTN circuit.

  14. 19) Check DPFEGR Circuit For Short To VREF In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance between DPFEGR and VREF circuits at PCM harness connector (both VREF circuits on 150-pin PCM). See PCM CONNECTOR IDENTIFICATION and Figure-Figure . If resistance is more than 10 k/ohms, replace PCM. If resistance is 10 k/ohms or less, repair short between DPFEGR and VREF circuits.

  15. 20) Perform Wiggle Test On DPFEGR Sensor & Circuit While Monitoring DPFEGR PID For A Sudden Change

    Turn ignition switch to ON position. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. Observe DPFEGR PID value for a sudden change while tapping lightly on DPFEGR sensor, and shaking and bending DPFEGR sensor wiring harness and connector to simulate road shock. A sudden change in DPFEGR PID value indicates a fault. If fault is indicated, isolate and repair as necessary. If no fault is indicated, go to TEST Z, step 1) .

  16. 21) Check For Presence Of DTC P1405 With DTC P0402

    If DTC P1405 is present with DTC P0402, go to step  50). If DTC P1405 is not present with P0402, go to next step.
    17. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  17. 22) For KOER & Continuous Memory Only DTC P0402: Check EGR Flow At Idle (Vacuum Hose Disconnected)
    DTC P0402 indicates EGR MONITOR failed due to PCM detecting EGR signal at idle is more than at KOEO by a calibrated amount of .5 volt. Possible causes for this fault are:
    • EGR Valve Stuck Open
    • EGR Vacuum Regulator (VR) Solenoid Vent Plugged
    • EGR Tube Plugged
    • DPFEGR Sensor Slow To Respond
    • Faulty DPFEGR Sensor
    • Pinched, Plugged, Damaged Or Improperly Connected Vacuum Hose
    • EGRVR Circuit Shorted To Ground
    • EGRVR Circuit Shorted To VREF Circuit
    • Faulty EGRVR Solenoid
    • Faulty PCM

    Disconnect and plug EGR valve vacuum hose. Perform KOER ON-DEMAND SELF-TEST . If KOER DTC P0402 is present, KOER self-test is unable to be performed, engine stalls or will not start, check EGR tube, EGR valve and hoses. Repair as necessary and retest. If DTC P0402 is not present, engine starts and does not stall, reconnect EGR valve vacuum hose and go to next step.

  18. 23) Check For EGR Flow At Idle With Vacuum Hose Connected

    Ensure EGR valve vacuum hose is reconnected. Perform KOER ON-DEMAND SELF-TEST . If DTC P0402 is present, engine stalls or will not start, there may be EGR flow at idle. Go to next step. If DTC P0402 is not present, engine starts and does not stall, fault is intermittent. Check vacuum hoses for pinching and icing. Repair as necessary and retest. If vacuum hoses are okay, go to step  31).
    19. NOTE: A pinched or plugged EGR vacuum hose will not allow EGR valve to close if vacuum becomes trapped between EGR vacuum regulator solenoid and EGR valve.

  19. 24) Check EGR System Vacuum Hoses For Integrity & Proper Connection
    Using vehicle's vacuum diagram label, check EGR system vacuum hoses for damage, tight connections and correct routing. Repair as necessary. If hoses are okay, go to next step.

  20. 25) Check DPFEGR Sensor Output By Applying Vacuum With Hand Pump

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Disconnect pressure hoses at DPFEGR sensor. Connect hand vacuum pump to downstream connection at DPFEGR sensor (intake manifold side or smaller diameter port). See Figure. Using scan tool, access DPFEGR PID from PID/DATA MONITOR & RECORD menu. Read the following DPFEGR PID values with ignition switch in ON position:
    • DO NOT apply vacuum to sensor. Record DPFEGR PID value. DPFEGR PID value should be .2-1.3 volts.
    • Using vacuum pump, apply 8-9 in. Hg (27-30 kPa) for a few seconds. DPFEGR PID value should increase to more than 4 volts.
    • Quickly release vacuum. DPFEGR PID value should drop to less than 1.5 volts within 3 seconds of releasing vacuum.

    If any DPFEGR PID values are not as specified, replace DPFEGR sensor. If all DPFEGR PID values are as specified, reconnect DPFEGR sensor and go to next step.

    21. NOTE: EGR valve requires more than 1.6 in. Hg (5.4 kPa) of vacuum to begin to open. If vacuum reading stays at more than 1.6 in. Hg (5.4 kPa) after EGRVR solenoid connector is disconnected, this indicates a mechanical fault in EGRVR solenoid.

  21. 26) Check For EGR Flow At Idle With EGRVR Solenoid Disconnected
    Disconnect EGR valve vacuum hose and connect vacuum gauge to hose. Start engine and allow to idle. While observing vacuum gauge, disconnect EGRVR solenoid harness connector. If vacuum gauge measurement stays at more than 1.6 in. Hg (5.4 kPa), go to next step. If vacuum gauge measurement is 1.6 in. Hg (5.4 kPa) or less, go to step  28).
    22. NOTE: A plugged EGRVR solenoid vent will not allow EGR vacuum to vent to atmosphere.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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