2018 Ford Fusion Energi PlatinumFACTORY OEM SERVICE PROCEDURE

Test Procedure

  1. KD1 CHECK FOR DTCS 
    NOTE: Diagnose any cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, mass airflow (MAF) sensor, manifold absolute pressure (MAP) sensor or throttle position (TP) sensor DTCs before diagnosing any EGR DTCs.

    Are DTCs P0400, P0403, or P1408 present? 

    Yes No
    GO to  KD2. For symptoms without DTCs, GO to  KD2.
    For all others, RETURN to SYMPTOM CHARTS for further direction.
  2. KD2 CHECK THE EEGR CONNECTOR 
    NOTE: If the DTC is intermittent, wiggle the harness and connectors when taking measurements.
    • Check the connection of the EEGR connector.

    Are the connector contacts clean and correctly seated? 

    Yes No
    GO to  KD3. REPAIR as necessary.
    Clear the PCM DTCs. REPEAT the self-test.
  3. KD3 CHECK THE EEGR COILS FOR AN OPEN 
    • Ignition OFF.
    • EEGR Assembly connector disconnected.
    • Measure the resistance between:
    (+) EEGR Assembly Connector, Component Side (-) EEGR Assembly Connector, Component Side
    EGRMC1 - Pin 1 VPWR - Pin 2
    EGRMC2 - Pin 3 VPWR - Pin 2
    EGRMC3 - Pin 4 VPWR - Pin 5
    EGRMC4 - Pin 6 VPWR - Pin 5

    Are the resistances between 12 - 24 ohms? 

    Yes No
    GO to  KD4. INSTALL a new EEGR assembly. REFER to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.
  4. KD4 CHECK THE VPWR CIRCUITS FOR AN OPEN 
    • Ignition ON, engine OFF.
    • Measure the voltage between:
    (+) EEGR Assembly Connector, Harness Side (-) Vehicle Battery
    VPWR - Pin 2 Negative terminal
    VPWR - Pin 5 Negative terminal

    Are the voltages greater than 10.5 V? 

    Yes No
    GO to  KD5. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  5. KD5 CHECK THE EEGR CIRCUITS FOR AN OPEN 
    • Ignition OFF.
    • PCM connector disconnected.
    • Measure the resistance between:
    (+) EEGR Assembly Connector, Harness Side (-) PCM Connector, Harness Side
    EGRMC1 - Pin 1 EGRMC1 - Pin E12
    EGRMC2 - Pin 3 EGRMC2 - Pin E41
    EGRMC3 - Pin 4 EGRMC3 - Pin E40
    EGRMC4 - Pin 6 EGRMC4 - Pin E11

    Are the resistances less than 5 ohms? 

    Yes No
    GO to  KD6. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  6. KD6 CHECK THE EEGR CIRCUITS FOR A SHORT TO GROUND 
    • 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

    Are the resistances greater than 10K ohms? 

    Yes No
    GO to  KD7. REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  7. KD7 CHECK FOR A SHORT BETWEEN EEGR CIRCUITS 
    • Measure the resistance between:
    (+) EEGR Assembly Connector, Harness Side (-) EEGR Assembly Connector, Harness Side
    EGRMC3 - Pin 4 EGRMC1 - Pin 1
    EGRMC3 - Pin 4 EGRMC2 - Pin 3
    EGRMC3 - Pin 4 EGRMC4 - Pin 6
    EGRMC1 - Pin 1 EGRMC2 - Pin 3
    EGRMC1 - Pin 1 EGRMC4 - Pin 6
    EGRMC2 - Pin 3 EGRMC4 - Pin 6

    Are the resistances greater than 10K ohms? 

    Yes No
    GO to  KD8. REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  8. KD8 CHECK THE EEGR CIRCUITS FOR A SHORT TO VOLTAGE 
    • Ignition 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

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.    		 For DTC P1408, GO to  KD9.
    For all others, GO to  KD11.
  9. KD9 COMPARE THE MAP PID VOLTAGE 
    • Ignition ON, engine OFF.
    • Access the PCM and monitor the MAP_V (VOLT) PID.
    • Record the MAP PID voltage.
    • Ignition ON, engine running.
    • Record the MAP PID voltage.

    Does the MAP PID value change? 

    Yes No
    GO to  KD10. GO to PINPOINT TEST DM .
  10. KD10 CARRY OUT THE KOER SELF-TEST 
    • Carry out the PCM KOER self-test.

    Is DTC P1408 retrieved again? 

    Yes No
    INSTALL a new EEGR assembly. REFER to the appropriate Engine Emission Control article.
    Clear the PCM DTCs. REPEAT the self-test.    		 RETURN to SYMPTOM CHARTS for further direction.
  11. KD11 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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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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