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Ford F150 Pickup. Instruction - part 1518

sensor (intake manifold side or smaller diameter port). 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 0.2-
0.8 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 1.0 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 step 85).

80) Check Vacuum Source And Vacuum Hoses To EGR Vacuum Regulator Solenoid

Inspect vacuum hoses between EGRVR solenoid and EGR valve for leaks, restrictions, damage or
incorrect routing. Repair as necessary. If hoses are okay, disconnect vacuum hoses at EGRVR solenoid.
Connect vacuum gauge to EGRVR solenoid vacuum supply hose. Start engine and allow to idle. If
vacuum gauge measurement is 15 in. Hg (51 kPa) or more at idle, go to next step. If vacuum gauge
measurement is less than 15 in. Hg (51 kPa), isolate fault and repair as necessary.

81) Check VPWR Voltage To EGR Vacuum Regulator Solenoid

Turn ignition switch to OFF position. Disconnect EGRVR solenoid (ESM connector). Turn ignition
switch to ON position. Using a DVOM, measure voltage between negative battery terminal and VPWR
circuit at EGRVR solenoid harness connector. See Fig. 195. If voltage is more than 10.5 volts, go to next
step. If voltage is 10.5 volts or less, repair open in VPWR circuit.

82) Check EGR Vacuum Regulator Solenoid Resistance

Turn ignition switch to OFF position. Using a DVOM, measure resistance between EGRVR solenoid
connector terminals. If EGRVR solenoid resistance is 30-36 ohms, go to next step. If EGRVR solenoid
resistance is not 30-36 ohms, replace ESM.

83) Check EGRVR Circuit For Short To PWR In Harness

Ensure ignition switch is in OFF position. Disconnect PCM connector(s). Turn ignition switch to ON
position. Using a DVOM, measure voltage between negative battery terminal and EGRVR circuit at PCM
harness connector. See PCM CONNECTOR IDENTIFICATION. If voltage is one volt or less, go to
next step. If voltage is more than one volt, repair short to PWR in EGRVR circuit.

84) Check EGRVR Circuit For Open In Harness

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 74) to step 80). No test procedures have been omitted.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

Turn ignition switch to OFF position. Measure resistance of EGRVR circuit between PCM harness
connector pin and ESM (vacuum regulator solenoid) harness connector. If resistance is less than 5 ohms,
reconnect EGRVR solenoid and PCM harness connectors and go to next step. If resistance is 5 ohms or
more, repair open in EGRVR circuit.

85) Check EGR Vacuum Regulator Solenoid Vacuum Output Capability By Grounding EGRVR
Circuit

Connect a tachometer to monitor engine RPM. Start engine. With engine at idle, jumper PCM EGRVR
circuit to chassis ground. If engine speed is reduced/stallout with jumper in, replace PCM. If engine speed
is not reduced/stallout with jumper in, replace ESM.

90) Inspect EGR System For An Intermittent Failure

Turn ignition switch to OFF position. Visually inspect entire EGR system for deterioration or signs of
intermittent failure. Repair as necessary. If no faults are found, go to next step.

91) Inspect DPFEGR Sensor Pressure Hoses

Inspect both hoses for improper routing. Hoses should not be pinched or have dips where water could
settle or freeze. Inspect both hoses for leaks and blockage. Inspect DPFEGR sensor for blockage or
damage. Repair as necessary. If no faults are found, go to next step.

92) 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). 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 0.2-
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.

93) Check EGR Valve Function By Applying Vacuum With Hand Pump

Start engine and bring to idle. Using scan tool, access DPFEGR and RPM PIDs from PID/DATA
MONITOR & RECORD menu. Using Output Test Mode function, slowly apply EGR and hold it for 10
seconds. If engine wants to stall, increase RPM with throttle to maintain a minimum of 800 RPM. Look
for the following:

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

EGR valve starts opening by increasing DPFEGR PID voltage.

DPFEGR PID voltage increasing until EGR valve is fully open. DPFEGR PID should read 2.5
volts minimum with full vacuum applied.

DPFEGR PID voltage steady when vacuum is held. If voltage drops within a few seconds, the EGR
valve or vacuum source could be leaking.

If the DPFEGR PID voltage indicates that the EGR valve is operating as described in this test, go to next
step. If the DPFEGR PID voltage does not indicate that the EGR valve is operating as described in this
test, replace ESM.

94) Inspect EGR Vacuum Signal Supply For Intermittent Failure
Tee a vacuum gauge into the vacuum hose at EGRVR valve. Start engine and allow to idle. Connect a
jumper wire between EGRVR circuit and ground to activate the solenoid to full on (note that the vacuum
reading will briefly drop as the EGRVR is turned ON and OFF). Observe vacuum gauge for an indication
of a fault while lightly taping on the EGR vacuum regulator solenoid and wiggling the EGR vacuum
regulator solenoid connector, vacuum lines and vehicle harness between the solenoid and PCM. A fault is
indicated by a sudden drop in vacuum reading. If a fault is indicated, isolate fault and repair as necessary.
If a fault is not indicated, unable to duplicate or identify fault at this time. Go to TEST Z, step 1).

100) EGR Diagnosis By Symptom: Check For EGR Flow With EGR Vacuum Hose Disconnected
And Plugged
A POOR FUEL ECONOMY symptom has indicated possible EGR flow at idle with no EGR DTCs
stored. Possible causes are:

EGR Valve Not Fully Seated

EGRVR Solenoid Vent Restricted

Faulty EGRVR Solenoid

Perform KOER ON-DEMAND SELF-TEST and service any other DTCs that are present. If no other
DTCs are present, disconnect and plug EGR valve vacuum supply hose. Leave scan tool connected to
Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access DPFEGR PID
and record voltage reading (KOEO). Start engine, allow to idle and record DPFEGR PID voltage reading

NOTE:

In cold climates, the EGR valve may temporarily freeze shut and thaw
when the engine warms up causing the intermittent DTC.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 94) to step 100). No test procedures have been omitted.

NOTE:

Diagnostic step 100) is performed when directed here from POOR FUEL
ECONOMY symptom under SYMPTOMS in TROUBLE SHOOTING - NO
CODES - CNG & GASOLINE article.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 100) to step 110). No test procedures have been omitted.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

(KOER). Compare KOER DPFEGR PID voltage reading to KOEO DPFEGR PID voltage reading. An
increase in voltage at idle indicates that DPFEGR sensor is sensing EGR flow. If KOER DPFEGR PID
voltage reading is .15 volt or more than that of KOEO reading, DPFEGR sensor is sensing EGR flow and
most likely cause is EGR valve. Remove the ESM and check EGR valve for contamination, wear, carbon
deposits, binding or damage. Repair as necessary. If DPFEGR PID voltage reading at idle is within .15
volt of KOEO reading, this indicates a fault in EGR valve vacuum supply. Check EGR valve vacuum
supply hoses, EGRVR solenoid vent and vent filter for restriction. If vacuum supply hoses, EGRVR
solenoid vent and vent filter are okay, replace ESM.

110) For KOEO & KOER Only DTC P1409: Check EGR Vacuum Regulator Solenoid Resistance

DTC P0403 and P1409 indicates self-test failed due to EGRVR circuit voltage reading too high or too
low when compared to expected voltage range. EGR system must be enabled for test to be completed.
Possible causes are:

EGRVR Circuit Open Or Shorted To VPWR Or GND

VPWR Circuit Open To EGRVR Solenoid

Faulty EGRVR Solenoid

Faulty PCM

Turn ignition switch to OFF position. Disconnect EGRVR solenoid (ESM connector). Using a DVOM,
measure resistance between EGRVR solenoid terminals. If resistance is 30-36 ohms, go to next step. If
resistance is not 30-36 ohms, replace ESM.

111) Check VPWR Voltage To EGR Vacuum Regulator Solenoid

Turn ignition switch to ON position. Using a DVOM, measure voltage between VPWR circuit at EGRVR
solenoid (ESM) harness connector and negative battery terminal. See Fig. 195. If voltage is more than
10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit.

112) Check EVR Circuit For Open In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance
of EGRVR circuit between PCM harness connector and EGRVR solenoid (ESM) harness connector. See
PCM CONNECTOR IDENTIFICATION and Fig. 195. If resistance is less than 5 ohms, go to next
step. If resistance is 5 ohms or more, repair open in EGRVR circuit.

113) Check EVR Circuit For Short To Power In Harness

Turn ignition switch to ON position. Using a DVOM, measure voltage between EGRVR circuit at PCM
harness connector and negative battery terminal. If voltage is less than one volt, go to next step. If voltage
is one volt or more, repair short to PWR in EGRVR circuit.

114) Check EVR Circuit For Short To Ground In Harness

Turn ignition switch to OFF position. Using a DVOM, measure resistance between EGRVR and PWR
GND circuits at PCM harness connector. If resistance is 10 k/ohms or less, repair short between circuits.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

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