Ford F150 Pickup. Manual — part 1517

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.

31) Check DPFEGR Sensor Voltage While Exercising EGR Valve

Ensure DPFEGR sensor is connected. Turn ignition switch to ON position. Using scan tool, access
DPFEGR PID from PID/DATA MONITOR & RECORD menu. View DPFEGR PID and make note of
voltage. Typical DPFEGR sensor voltage (ESM system) with no EGR flow is between 0.3 and 0.6 volts.
Start engine and allow to idle. Observe DPFEGR PID at idle and compare to the key on engine off
voltage. (A higher voltage at idle could be due to a non-seating EGR valve.) Using scan tool output state
control function, apply just enough vacuum to EGR valve to open it 2-3 in. Hg (7-10 kPa) without
stalling engine and release vacuum. Repeat several times while observing DPFEGR PID. DPFEGR PID
voltage must increase as valve begins to open and return to initial value as vacuum is released. A slow to
return voltage could be an indication of a binding or slow-closing EGR valve. Service or replace EGR
valve as necessary. If DPFEGR PID quickly returns to initial voltage reading after releasing vacuum, go
to step 33).

33) Inspect EGR Vacuum Regulator Solenoid Vacuum Hose For Potential Plugging

Inspect EGR vacuum hose for possible blockage or pinching. If EGR vacuum regulator solenoid vacuum
hose is plugged, repair as necessary. If EGR vacuum regulator solenoid vacuum hose is okay, unable to
duplicate or identify fault at this time. Go to TEST Z, step 1).

50) Inspect Upstream Pressure Hose Connections

Inspect upstream hose for disconnect or poor connection. If hose is off or poorly connected, repair as
necessary. Perform DRIVE CYCLES. Ensure EGR MONITOR PROCEDURE is performed to verify
repair. If hose is off okay, go to next step.

51) Inspect Upstream Pressure Hose For Plugging
Visually inspect upstream pressure hose routing. Hose must not be pinched or have dips in it where water
could settle or freeze. Remove upstream pressure hose and carefully inspect for plugging, water or leaks.
If there is a fault detected in the hose, repair or replace upstream pressure hose as necessary. Perform
DRIVE CYCLES. Ensure EGR MONITOR PROCEDURE is performed to verify repair. If hose is okay,

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 31) to step 33). No test procedures have been omitted.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 33) to step 50). No test procedures have been omitted.

NOTE:

It is essential that the DPFEGR pressure hose used is the correct repair
part and not a substitute.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 51) to step 53). No test procedures have been omitted.

2003 Ford Pickup F150

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

go to step 53).

53) 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:

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.

If any DPFEGR PID values are not as specified, replace DPFEGR sensor. Perform DRIVE CYCLES.
Ensure EGR MONITOR PROCEDURE is performed to verify repair. If all DPFEGR PID values are as
specified, unable to duplicate or identify fault at this time. Go to TEST Z, step 1).

60) For KOER & Continuous Memory Only DTC P1406: Inspect Downstream Pressure Hose
Connections

While driving, the EGR monitor commands the EGR valve closed and checks the differential pressure
across the EGR orifice. The test fails when the signal from the DPF EGR sensor continues to indicate
EGR flow even after the EGR valve is commanded closed.

z

Downstream hose is disconnected.

z

Downstream hose is plugged (ice).

z

Plugged or damaged EGR tube.

If the fault is currently present, DTC P1408 will be output in Key On Engine Running (KOER) Self-Test.

Verify EGR valve is securely attached and exhaust gasses are not leaking from the sealing surface.
Inspect downstream hose at DPFEGR sensor for disconnect or poor connection. If hose is off or poorly
connected, repair as necessary. If hose is okay, go to next step.

61) Inspect Downstream Pressure Hose For Plugging

Visually inspect downstream pressure hose routing. Hose must not be pinched or have dips in it where
water can settle or freeze. Remove downstream pressure hose and carefully inspect for plugging, water, or
leaks. If there is a fault detected in the hose, repair or replace as necessary. If hose is okay, go to step 63).

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 53) to step 60). No test procedures have been omitted.

2003 Ford Pickup F150

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

63) Check EGR 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:

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.

If any DPFEGR PID values are not as specified, replace DPFEGR sensor. If all DPFEGR PID values are
as specified, reconnect DPFEGR sensor. Unable to duplicate or identify fault at this time, go to TEST Z,
step 1).

70) For Continuous Memory Only DTC P0401: Run KOER Self-Test

DTC P0401 indicates EGR MONITOR failed due to PCM detecting EGR flow is less than desired
minimum while driving. Possible causes for this fault are:

z

Vacuum Supply

z

EGR Valve Stuck Closed

z

EGR Valve Leaks Vacuum

z

EGR Flow Path Restricted

z

EGRVR Circuit Shorted To PWR

z

VREF Circuit Open To DPFEGR Sensor

z

DPFEGR Sensor Downstream Or Upstream Hoses Disconnected, Reversed Or Restricted

z

VPWR Circuit Open To EGRVR Solenoid

z

Damaged EGR Orifice Tube

z

Faulty EGRVR Solenoid

z

Faulty PCM

If fault is currently present, KOER DTC P1408 should be present. Perform KOER ON-DEMAND
SELF-TEST. If DTC P1408 is present, go to next step. If DTC P1408 is not present, go to step 90).

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 61) to step 63). No test procedures have been omitted.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 63) to step 70). No test procedures have been omitted.

2003 Ford Pickup F150

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

71) For KOER Only DTC P1408: Retrieve Continuous Memory DTCS

DTC P1408 indicates KOER self-test failed due to measured EGR flow falling below or exceeding
required calibration. Possible causes are:

z

Vacuum Supply

z

EGR Valve Stuck Closed

z

EGR Valve Leaks Vacuum

z

EGR Flow Path Restricted

z

EGRVR Circuit Shorted To PWR

z

VREF Circuit Open To DPFEGR Sensor

z

DPFEGR Sensor Downstream Or Upstream Hoses Disconnected, Reversed Or Restricted

z

VPWR Circuit Open To EGRVR Solenoid

z

Damaged EGR Orifice Tube

z

Faulty EGRVR Solenoid

z

Faulty PCM

Retrieve all Continuous Memory DTCs. If DTC P1406 is present, go to step 60). If DTC P1406 is not
present, go to next step.

72) Run KOER Self-Test While Monitoring EGR Vacuum

Disconnect vacuum hose at EVR and T-in a vacuum gauge. Perform KOER ON-DEMAND SELF-
TEST. Approximately 30 seconds into test, EGR flow will be requested for a few seconds. The vacuum
at this time should show a brief deflection to near zero from a steady value of approximately 15 in. Hg,
indicating a request for the valve to open. If the vacuum decreases briefly to near zero from a steady value
during KOER Self-Test, the vacuum indicated is sufficient to open the EGR valve. Fault is unlikely to be
in EGR vacuum control system. Turn ignition switch to OFF position, go to next step. If the vacuum does
not decrease briefly to near zero from a steady value during KOER Self-Test, the vacuum indicated is
insufficient to open the EGR valve. Turn ignition switch to OFF position, go to step 80).

73) Inspect DPFEGR Sensor Pressure Hoses

Visually inspect both pressure hoses for proper connection at DPFEGR sensor and EGR valve assembly.
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 damage. If a fault
is detected, repair pressure hoses as necessary. If a fault is not detected, go to next step.

74) 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

NOTE:

If any DTC other than DTC P1406 is present, service those DTCs after
completing this test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS.

2003 Ford Pickup F150

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