DTC P1408 [AJ (3.0L Duratec)]

DTC P1408	EGR flow out of self test range
DETECTION CONDITION	• The PCM monitors EGR flow using the D.P.F. EGR sensor during KOER self test (the EGR system is commanded on at a fixed engine speed). If the PCM detects that the measure EGR flow falls above or below the required calibration, the PCM determines that EGR flow out of self test range.
POSSIBLE CAUSE	• Vacuum hose malfunction (damaged, insufficient connected) • EGR valve stuck close • Vacuum leakage at EGR valve • EGR flow pass restricted • Short to power supply circuit in wiring EGR solenoid valve terminal 2 and PCM terminal 47 (R.H.D.) /E-27 (L.H.D.) • Open circuit in wiring between EGR solenoid valve terminal 2 and PCM terminal 47 (R.H.D.) /E-27 (L.H.D.) • Open circuit in wiring between EGR solenoid valve terminal 1 and main relay terminal 87 • Open circuit in wiring between D.P.F. EGR sensor terminal 1 and PCM terminal 90 (R.H.D.) /E-40 (L.H.D.) • D.P.F. EGR sensor downstream hose off or plugged • D.P.F. EGR sensor hoses both off • D.P.F. EGR sensor hoses connected reverse • EGR orifice tube damaged • Damaged EGR solenoid valve • Damaged PCM


STEP	INSPECTION		ACTION
1	VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded?	Yes	Go to the next step.
1		No	Record the FREEZE FRAME DATA on the repair order, then go to next step.
2	VERIFY REPAIR INFORMATION AVAILABILITY • Verify related service repair information availability. • Is any related repair information available?	Yes	Perform repair or diagnosis according to the available repair information. • If the vehicle is not repaired, go to next step.
2		No	Go to the next step.
3	INDETIFY TRIGGER DTC FOR FEEZE FRAME DATA • Is DTC P1408 on FREEZE FRAME DATA?	Yes	Go to the next step.
3		No	Go to FREEZE FRAME DATA DTC inspection. (See DTC TABLE [AJ (3.0L Duratec)].)
4	RETRIEVE CONTINUOUS MEMORY DTCS Note • If any DTC other than DTC P1406 is output, record DTC and refer to DTC table. • Retrieve continuous memory DTCs. • Is DTC P1406 displayed?	Yes	Go to Step 15.
4		No	Go to the next step.
5	RUN KOER SELF TEST WHILE MONITORING EGR VACUUM • Disconnect vacuum hose at EGR valve and connect hose to a vacuum gauge. Note • Since the EGR vacuum hose is disconnected, ignore DTCs during this KOER self test. • Run KOER self test while monitoring gauge. • Approximately 30 seconds into test, EGR flow will be requested for a few seconds. • The vacuum at this time should increase above 5.4 kPa {1.6 inHg} to open the valve. • Does the vacuum increase to 10 kPa {3.0 inHg} or greater at any time during KOER self test?	Yes	Go to the next step.
5		No	Go to Step 9.
6	INSPECT D.P.F.EGR SENSOR PRESSURE HOSES • Visually inspect both pressure hoses for reserved connection at D.P.F.EGR sensor or at orifice tube assembly. • Inspect both hoses for improper routing. Hoses should not be pinched or have dips where water could settle or freeze. • Inspect D.P.F.EGR sensor and orifice tube assembly for blockage or damage at the pickup tubes. • Is fault detected?	Yes	Repair pressure hose, then go to Step 24.
6		No	Go to the next step.
7	CHECK D.P.F.EGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP • Connect the WDS or equivalent to DLC. • Disconnect pressure hoses at D.P.F.EGR sensor. • Connect a hand vacuum pump to the downstream connection at sensor (intake manifold side of sensor or smaller diameter pickup tube.) • Turn the ignition switch to ON. • Access DPFEGR PID and note PID value. • Apply 27-30 kPa {8-9 inHg} vacuum to the D.P.F.EGR sensor and hold for a few seconds. • Quickly release vacuum. - The DPFEGR PID voltage must be between 0.2 and 1.3 V with the ignition switch ON and no vacuum applied. - The DPFEGR PID voltage must increase to greater than 4.0 V with the vacuum applied. - The DPFEGR PID must drop to less than 1.5 V in less than 3 seconds when vacuum is released. • Does DPFEGR PID voltage indicate a fault in the D.P.F.EGR sensor?	Yes	Replace D.P.F.EGR sensor.
7		No	Go to the next step.
8	CHECK EGR VALVE FUNCTION BY APPLYING VACUUM WITH HAND PUMP • Disconnect vacuum hose at EGR valve and plug hose. • Connect a hand vacuum pump to EGR valve. • Start the engine and bring to idle. • Access D.P.F.EGR and RPM PIDs. • Slowly apply 27-34 kPa {8-10 inHg} vacuum to the D.P.F.EGR sensor and hold for 10 seconds. If engine want to stall increase engine speed with throttle to maintain a minimum of 1,000 rpm. • Look for the following: - EGR valve starts opening at about 5.4 kPa {1.6 inHg} vacuum indicated by increasing D.P.F.EGR voltage. - DPFEGR PID voltage increasing until EGR valve is fully open. DPFEGR PID must read 2.5 V 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 can be leaking. • Does the DPFEGR PID voltage indicate that the EGR valve is opening as described in this test?	Yes	Go to Step 14.
8		No	Remove and inspect the EGR valve for signs of contamination, unusual wear, carbon deposits, binding and other damage. If the EGR valve is okay, look for an obstruct EGR valve port in the intake manifold or plugged orifice tube assembly. Repair or replace malfunctioning part. Then go to Step 24.
9	CHECK VACUUM SOURCE AND VACUUM HOSES TO AND FROM EGR SOLENOID VALVE • Inspect vacuum lines between vacuum source and EGR solenoid valve and between EGR solenoid valve and EGR valve for leaks, kinks, disconnects, blockage, routing or any damage. • Disconnect vacuum hoses at EGR solenoid valve. • Connect EGR solenoid valve vacuum source hose to a vacuum gauge. • With engine warm and at idle, take vacuum gauge reading. • Is the vacuum gauge reading a minimum of 51 kPa {15 inHg} at idle and vacuum lines okay?	Yes	Go to the next step.
9		No	Isolate fault and repair or replace malfunctioning part, according to inspection result. Then go to Step 24.
10	CHECK PWR VOLTAGE TO EGR SOLENOID VALVE • Disconnect EGR solenoid valve. • Turn the ignition switch to ON. • Measure voltage at EGR solenoid valve terminal 1 and harness connector. • Is the voltage greater than 10.5 V?	Yes	Go to the next step.
10		No	Repair or replace open circuit, then go to Step 24.
11	CHECK EGR SOLENOID VALVE RESISTANCE • Measure EGR solenoid valve resistance. • Is the resistance 26-40 ohms?	Yes	Go to the next step.
11		No	Replace EGR solenoid valve, then go to Step 24.
12	CHECK EGR SOLENOID VALVE CONTROL CIRCUIT SHORT TO POWER IN HARNESS • Disconnect PCM. • Turn the ignition switch to ON. • Measure voltage between PCM harness side connector terminal 47 (R.H.D.) /E-27 (L.H.D.) and battery negative post. • Is voltage greater than 1.0 V?	Yes	Repair short circuit, then go to Step 24.
12		No	Go to the next step.
13	CHECK EGR SOLENOID VALVE CIRCUIT FOR OPEN IN HARNESS • Measure resistance of between EGR solenoid valve terminal 2 and PCM terminal 47 (R.H.D.) /E-27 (L.H.D.) at harness side connector. • Is the resistance less than 5.0 ohms?	Yes	Go to the next step.
13		No	Repair open circuit, then go to Step 24.
14	CHECK EGR SOLENOID VALVE VACUUM OUTPUT CAPABILITY BY GRIUNDUNG EGR SOLENOID VALVE CONTROL CIRCUIT • Disconnect vacuum hose at the EGR valve and connect to a vacuum gauge. • Start the engine and run it at idle. • Turn the ignition switch to ON. • With engine at idle, jumper PCM terminal 47 (R.H.D.) /E-27 (L.H.D.) to chassis ground. • Is vacuum gauge reading 13.5 kPa {4.0 inHg}.	Yes	Replace PCM, then go to Step 24.
14		No	Replace EGR solenoid valve, then go to Step 24.
15	INPECT DOWNSTREAM PRESSURE HOSE CONNECTIONS Note • If the fault is currently present, DTC P1408 will be output in Key On Engine Running (KOER) self test. • Inspect downstream hose at D.P.F.EGR sensor and orifice tube assembly for disconnect or poor connection. • Is hose OFF or poorly connection?	Yes	Repair connections, then go to Step 24.
15		No	Go to next step.
16	INSPECT DOWNSTREAM PRESSURE HOSE FOR PLUGGING Note • It is essential that the D.P.F.EGR sensor pressure hose is the correct repair part and not a substitute. • 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. • Is there a fault detected the hose?	Yes	Repair or replace malfunctioning part, then go to Step 24.
16		No	Go to the next step.
17	CHECK ORIFICE TUBE ASSEMBLY AND D.P.F.EGR SENSOR • Inspect the connections at the D.P.F.EGR sensor for plugging or damage. • Inspect the intake manifold side pressure pickup tube and orifice tube assembly for plugging, loose connection or damage. • Is the D.P.F.EGR sensor or orifice tube assembly plugged, loose or damaged?	Yes	Repair or replace malfunctioning part, then go to the Step 24.
17		No	Go to the next step.
18	CHECK EGR SENSOR OUTPUT BY APPLYING VACUUM WITH HAND PUMP • Disconnect pressure hoses at D.P.F.EGR sensor. • Connect a hand vacuum to the downstream connection at sensor (intake manifold side of sensor or the smaller diameter pickup tube). • Turn the ignition switch to ON. • Access D.P.F.EGR sensor PID and note PID value. • Apply 27-30 kPa {8-9 inHg} vacuum to the D.P.F.EGR sensor and hold for a few seconds. • Quickly release the vacuum. - The DPFEGR PID voltage must be 0.2-1.3 V with the ignition switch ON and no vacuum applied. - The DPFEGR PID voltage must increase to greater than 4.0 V with the vacuum applied. - The DPFEGR PID must drop to less than 1.5 V in less than 3 seconds when vacuum is released. • Does the D.P.F. EGR PID voltage indicate a fault in the D.P.F.EGR sensor?	Yes	Replace D.P.F.EGR sensor, then go to the Step 24.
18		No	Intermittent concern exists, go to Intermittent Troubleshooting Procedure. (See INTERMITTENT CONCERN TROUBLESHOOTING [AJ (3.0L Duratec)].)
19	INSPECT EGR SYTEM FOR AN INTERMITTENT FAILURE • Visually Inspect the EGR system for signs of intermittent failure. • Is a fault found?	Yes	Repair or replace malfunctioning part, then go to Step 24.
19		No	Go to the next step.
20	INSPECT D.P.F.EGR SENSOR PRESSURE HOSE • Visually inspect both pressure hoses for reversed connection at D.P.F.EGR sensor or at orifice tube 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 D.P.F.EGR sensor and orifice tube assembly for blockage or damage at the pickup tubes. • Is a fault detected?	Yes	Repair or replace pressure hose, then go to Step 24.
20		No	Go to the next step.
21	CHECK D.P.F.EGR SENSOR OUTPUT BY APPLYING VACUUM WITH HJAND PUMP • Disconnect pressure hoses at D.P.F.EGR sensor. • Connect a hand vacuum pump to the downstream connection at sensor (intake manifold side of sensor or the smaller diameter pickup tube.) • Turn the ignition switch to ON. • Access DPFEGR PID and note PID value. • Apply 27-30 kPa {8-9 inHg} vacuum to the D.P.F.EGR sensor and hold a few seconds. • Quickly release the vacuum. - The DPFEGR PID voltage must be between 0.2 and 1.3 V with the ignition switch ON and no vacuum applied. - The DPFEGR PID voltage must increase to greater than 4.0 V with the vacuum applied. - The DPFEGR PID voltage must drop to less than 1.5 V in less than 3 seconds when vacuum is released. • Does the DPFEGR PID voltage indicate a fault in the D.P.F.EGR sensor?	Yes	Replace D.P.F.EGR sensor, then go to Step 24.
21		No	Go to the next step.
22	CHECK EGR VALVE FUNCTION BY APPLYING VACUUM WITH HAND PUMP • Disconnect vacuum hose at EGR valve and plug hose. • Connect a hand vacuum pump to EGR valve. • Start the engine and bring to idle. • Access PDFEGR and RPM PIDs. • Slowly apply 17-34 kPa {5-10 inHg} of vacuum to the EGR valve 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: - EGR valve starts opening at about 5.4 kPa {1.6 inHg} vacuum indicated by increase DPFEGR PID voltage. - DPFEGR PID voltage increasing until EGR valve fully open. DPFEGR PID should read 2.5 V 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. • Does the DPFEGR PID voltage indicate that the EGR valve is opening as described in this seat?	Yes	Go to the next step.
22		No	Remove and inspect the EGR valve for signs of contamination, unusual wear, carbon deposits, binding, leaking diaphragm and other damage. If EGR valve is okay, look for an obstructed EGR port in the intake manifold. If malfunctioning detected, repair or replace malfunctioning part. Then go to Step 24.
23	INSPECT VACUUM SIGNAL SUPPLY FOR INTERMITTENT FAILURE • Disconnect plugged hose at EGR valve and connect to a vacuum gauge. • Start the engine and run it at idle. • Connect a jumper wire between EGR valve solenoid valve terminal 2 and ground to activate the solenoid valve to full on. At idle, the vacuum gauge should read above 13.5 kPa {4.0 inHg}. • Observe vacuum gauge for an indication of a fault while performing the following: - Lightly tap on the EGR vacuum regulator solenoid and wiggle the EGR vacuum regulator solenoid connector, vacuum lines and vehicle harness between EGR solenoid valve terminal 2 and PCM terminal 47 (R.H.D.) /E-27 (L.H.D.). A fault us indicated by sudden drop in vacuum reading. • Is a fault indicated?	Yes	Isolate fault and repair or replace malfunctioning part, then go to the next step.
23		No	Intermittent concern exists, go to Intermittent Troubleshooting Procedure. (See INTERMITTENT CONCERN TROUBLESHOOTING [AJ (3.0L Duratec)].)
24	VERIFY TROUBLESHOOTING OF DTC P1408 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the WDS or equivalent. • Perform KOER self test. (See KOEO/KOER SELF-TEST [AJ (3.0L Duratec)].) • Is the PENDING CODE same DTC present?	Yes	Replace PCM, then go to next step. (See PCM REMOVAL/INSTALLATION [AJ (3.0L Duratec)].)
24		No	Go to the next step.
25	VERIFY AFTER SERVICE PRECAUTION • Perform "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [AJ (3.0L Duratec)].) • Is there any DTC present?	Yes	Go to applicable DTC inspection. (See DTC TABLE [AJ (3.0L Duratec)].)
25		No	Troubleshooting completed.