Ford F150 Pickup. Instruction - 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