Ford F150 Pickup. Manual — part 1516

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).

11) Check DPFEGR Circuit For Short To PWR

Turn ignition switch to OFF position. Disconnect ESM harness connector. Turn ignition switch to ON
position. Using a DVOM, measure voltage between chassis ground and DPFEGR circuit at ESM 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,
go to step 13).

12) Check DPFEGR Circuit For Short To PWR In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). 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 Fig. 195. 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.

13) Induce Opposite DPFEGR Sensor Voltage

Turn ignition switch to OFF position. Connect a jumper wire between DPFEGR and SIG RTN circuits at
ESM harness connector. Turn ignition switch to ON position.

Using scan tool, 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 16). If DPFEGR PID voltage
reading is less than .05 volt, disconnect jumper wire and go to next step.

14) Check VREF Voltage To DPFEGR Sensor

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

15) Check DPFEGR Circuit For Short To VREF In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). 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 Fig. 195. If resistance is more than 10 k/ohms,
replace DPFEGR sensor. If resistance is 10 k/ohms or less, repair short between DPFEGR and VREF
circuits.

16) Check DPFEGR Circuit For Open In Harness

NOTE:

If a scan tool communication concern exists, remove jumper wire and go
to step 18).

2003 Ford Pickup F150

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

Turn ignition switch to OFF position. Ensure DPFEGR sensor is disconnected. Disconnect PCM
connector(s). Using a DVOM, measure resistance of DPFEGR circuit between PCM harness connector
and 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 DPFEGR circuit.

17) Check SIG RTN Circuit For Open In Harness

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

18) Check DPFEGR Circuit For Short To VREF In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). 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 Fig. 195. 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.

19) Complete A Wiggle Test On DPFEGR Sensor (On The ESM) & 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).

20) For KOER & Continuous Memory Only DTC P0402: Check For EGR Flow At Idle With EGR
Vacuum Hose Disconnected
If DTC P1405 was output during Continuous Memory self-test, go directly to step 50) to diagnose present
fault. 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:

z

EGR Valve Stuck Open

z

EGR Vacuum Regulator (VR) Solenoid Vent Plugged

z

EGR Tube Plugged

z

DPFEGR Sensor Slow To Respond

z

Faulty DPFEGR Sensor

z

Pinched, Plugged, Damaged Or Improperly Connected Vacuum Hose

z

EGRVR Circuit Shorted To Ground

z

EGRVR Circuit Shorted To VREF Circuit

z

Faulty EGRVR Solenoid

z

Faulty PCM

NOTE:

For additional testing information, see DIAGNOSTIC AIDS.

2003 Ford Pickup F150

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

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, Turn
ignition switch to OFF position. Inspect pressure hoses first for damage and pinching. If okay, remove
ESM and inspect the EGR valve for signs of contamination, unusual wear, carbon deposits, binding and
other damage. Repair as necessary. If DTC P0402 is not present, engine starts and does not stall,
reconnect EGR valve vacuum hose and go to next step.

21) Check For EGR Flow At Idle With EGR 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. There is possible EGR
flow at idle, go to step 23). 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 30).

23) 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
vacuum hose at DPFEGR sensor on the ESM (downstream hose to intake manifold). Connect a hand
vacuum pump to the downstream connection on the ESM. Using scan tool, access DPFEGR PID from
PID/DATA MONITOR & RECORD menu. Read the following DPFEGR PID values with ignition
switch in ON position:

z

DO NOT apply vacuum to sensor. Record DPFEGR PID value. DPFEGR PID value should be .25-
1.30 volts.

z

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.

z

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.

24) Check For EGR Flow At Idle With EGR Vacuum Regulator Solenoid Connector Off
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 26).

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.

NOTE:

A plugged EGRVR solenoid vent will not allow EGR vacuum to vent to
atmosphere.

2003 Ford Pickup F150

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

25) Inspect EGR Vacuum Regulator Solenoid Vent For Plugging
Turn ignition switch to OFF position. Disconnect EGRVR solenoid vacuum hose. Carefully remove EGR
vacuum regulator solenoid vent cap (if the locking tabs are damaged the filter function may be
compromised). Remove EGRVR solenoid filter and check for blockage or icing. Plug EGRVR solenoid
vacuum supply port to EGR. Connect a hand vacuum pump to the EGR vacuum regulator solenoid
(vacuum source port) and apply 10-15 in. Hg (34-51 kPa). If vacuum holds or is slow to release, EGRVR
solenoid vent may be plugged or restricted. Repair EGRVR solenoid as necessary. If unable to repair
EGRVR solenoid, replace ESM. If vacuum releases (solenoid vent not plugged or restricted), replace
ESM.

26) Measure EGR Vacuum Regulator Solenoid Coil Resistance

Turn ignition switch to OFF position. Ensure EGRVR solenoid is disconnected. 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.

27) Check EGRVR Circuit For Short To Ground In Harness

Disconnect scan tool from DLC. Disconnect PCM connector(s). Using a DVOM, measure resistance
between negative battery terminal and EGRVR circuit at PCM harness connector. See PCM
CONNECTOR IDENTIFICATION and Fig. 195. If resistance is more than 10 k/ohms, go to next step.
If resistance is 10 k/ohms or less, repair short to ground in EGRVR circuit.

28) Check EGRVR Circuit For Short To VREF

Using a DVOM, measure resistance between EGRVR and VREF circuits at PCM harness connector (both
VREF circuits on 150-pin PCM). See PCM CONNECTOR IDENTIFICATION and Fig. 195. If
resistance is more than 10 k/ohms, replace PCM. If resistance is 10 k/ohms or less, repair short between
EGRVR and VREF circuits.

30) 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 hose at DPFEGR sensor (downstream/intake manifold line). Connect hand vacuum pump to
downstream connection at DPFEGR sensor (intake manifold side of sensor). Using scan tool, access
DPFEGR PID from PID/DATA MONITOR & RECORD menu. Read the following DPFEGR PID values
with ignition switch in ON position:

z

DO NOT apply vacuum to sensor. Record DPFEGR PID value. DPFEGR PID value should be .2-
1.3 volts.

z

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.

z

Quickly release vacuum. DPFEGR PID value should drop to less than 1.5 volts within 3 seconds of
releasing vacuum.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 28) to step 30). No test procedures have been omitted.

2003 Ford Pickup F150

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