2005 MY OBD System Operation Summary for Gasoline Engines

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1:$In the 2002.5 MY, Ford introduced a revised DPFE system. It functions in the same manner as the conventionalDPFE system, however, the various system components have been combined into a single component called theEGR System Module (ESM). This arrangement increases system reliability while reducing cost. By relocating theEGR orifice from the exhaust to the intake, the downstream pressure signal measures Manifold AbsolutePressure (MAP). The ESM will provide the PCM with a differential DPFE signal, identical to the conventionalDPFE system. The DPFE signal is obtained by electrically subtracting the MAP and P1 pressure signals andproviding this signal to the DPFE input on the PCM. 2003 MY and later implementations of the ESM system willadd a separate input to the PCM for the MAP sensor signal.PCMNew ESMDPFE EGR SYSTEMEGR System Module(ESM) ComponentsDPFEsignalEVRMAP SIGNALEGRVALVEFRESH AIR INLETVREFSig RtnEGR DCP1INTAKE(MAP)MAPDPFESENSORDELTA P = P1 - MAPEXHAUSTFORD MOTOR COMPANY REVISION DATE: APRIL 28, 2004 PAGE 52 OF 131
The ESM Delta Pressure Feedback EGR Monitor is a series of electrical tests and functional tests that monitorvarious aspects of EGR system operation.First, the Delta Pressure Feedback EGR (DPFE) sensor input circuit is checked for out of range values (P1400 orP0405, P1401 or P0406). The Electronic Vacuum Regulator (EVR) output circuit is checked for opens and shorts(P1409 or P0403).EGR Electrical Check Operation:DTCsMonitor executionMonitor SequenceSensors OKMonitoring DurationP1400 or P0405 - DPFE Circuit LowP1401 or P0406 - DPFE Circuit HighP1409 or P0403 - EVR circuit open or shortedContinuous, during EGR monitorNone4 seconds to register a malfunctionTypical EGR electrical check entry conditions:EGR system enabledTypical EGR electrical check malfunction thresholds:DPFE sensor outside voltage: > 4.96 volts, < 0.0489 voltsEVR solenoid smart driver status indicates open/shortDPFE Sensor Transfer FunctionESM DPFE volts = Vref [( 0.683 * Delta Pressure) + 10 ] / 100Volts A/D Counts in PCM Delta Pressure, Inches H 2 O0.0489 10 -13.20.26 53 -7.00.5 102 00.74 151 7.01.52 310 302.55 521 603.57 730 904.96 1015 130.7Note: EGR normally has large amounts of water vapor that are the result of the engine combustion process. Duringcold ambient temperatures, under some circumstances, water vapor can freeze in the DPFE sensor, hoses, aswell as other components in the EGR system. In order to prevent MIL illumination for temporary freezing, thefollowing logic is used:If an EGR system malfunction is detected above 32 o F, the EGR system and the EGR monitor is disabled for thecurrent driving cycle. A DTC is stored and the MIL is illuminated if the malfunction has been detected on twoconsecutive driving cycles.If an EGR system malfunction is detected below 32 o F, only the EGR system is disabled for the current drivingcycle. A DTC is not stored and the I/M readiness status for the EGR monitor will not change. The EGR monitor,however, will continue to operate. If the EGR monitor determined that the malfunction is no longer present (i.e., theice melts), the EGR system will be enabled and normal system operation will be restored.FORD MOTOR COMPANY REVISION DATE: APRIL 28, 2004 PAGE 53 OF 131
Page 1: Table of ContentsIntroduction - OBD
Page 4 and 5: !The Catalyst Efficiency Monitor us
Page 6 and 7: TYPICAL INDEX RATIO CATALYST MONITO
Page 8 and 9: There are three different misfire m
Page 10 and 11: 0#1The acceleration that a piston u
Page 12 and 13: J1979 Misfire Mode $06 DataTest ID
Page 14 and 15: 0$Secondary air systems typically u
Page 16 and 17: 201 34536/#/Vehicles that meet enha
Page 18 and 19: 0.040” EVAP Monitor Operation:DTC
Page 20 and 21: 201 3536/#/Some vehicles that meet
Page 22 and 23: slosh. If the monitor aborts, it wi
Page 24 and 25: 0.020” EVAP Monitor Operation:DTC
Page 26 and 27: Test ID Comp ID Description for J18
Page 28 and 29: Ford's EONV implementation for Cali
Page 30 and 31: 1#4;!In this phase, the EONV test i
Page 32 and 33: 0.020” EONV EVAP Monitor Operatio
Page 34 and 35: 201!!#/Additional malfunctions that
Page 36 and 37: Fuel Tank Pressures Sensor Offset C
Page 38 and 39: :As fuel system components age or o
Page 40 and 41: -:-The time between HO2S switches i
Page 42 and 43: $-A functional test of the rear HO2
Page 44 and 45: -- 3 amps, (NTK)< 0.400 amps or > 3
Page 46 and 47: 1:$The Delta Pressure Feedback EGR
Page 48 and 49: If an EGR system malfunction is det
Page 50 and 51: After the vehicle has warmed up and
Page 54 and 55: The ESM may provide the PCM with a
Page 56 and 57: Next, the differential pressure ind
Page 58 and 59: I/M Readiness IndicationIf the infe
Page 60 and 61: The Stepper Motor EGR Monitor consi
Page 62 and 63: Note: BARO is inferred at engine st
Page 64 and 65: $. 6The Electric Stepper Motor EGR
Page 66 and 67: The MAP sensor is also checked for
Page 68 and 69: When the entry conditions for the f
Page 70 and 71: 1!2Ford plans to comply with the PC
Page 72 and 73: ETC System Failure Mode and Effects
Page 74 and 75: ;#11!%;11!)The purpose of the TPPC
Page 76 and 77: Currently, vehicles use either an E
Page 78 and 79: Fuel Rail Pressure Sensor Check Ope
Page 80 and 81: Loss of Keep Alive Memory (KAM) pow
Page 82 and 83: CKP Ignition System Check Operation
Page 84 and 85: The Idle Air Control (IAC) solenoid
Page 86 and 87: There are several different styles
Page 88 and 89: The PCM continually calculates a ca
Page 90 and 91: Most vehicle applications no longer
Page 92 and 93: Intermediate Shaft Speed Sensor Fun
Page 94 and 95: Primary Pulley Speed Sensor Functio
Page 96 and 97: Secondary Pulley Pressure Sensor Ch
Page 98 and 99: Typical Shift Solenoid mechanical f
Page 100 and 101: Shift Completion Check Operation:DT
Page 102 and 103:
Pressure Control Solenoid Check Ope
Page 104 and 105:
Forward Clutch/Reverse Clutch Solen
Page 106 and 107:
4$=%$> );4R70E is the replacement f
Page 108 and 109:
! 4%:> );;The Analog Transmission R
Page 110 and 111:
$%$> );;The Digital Transmission Ra
Page 112 and 113:
Direct One Way ClutchThe Direct One
Page 114 and 115:
Direct One Way ClutchThe Direct One
Page 116 and 117:
$&&> %$> );;Transmission Range Sens
Page 118 and 119:
4:=%:.)%:> );;The Transmission Rang
Page 120 and 121:
CFT 30 Mechatronic Illustration;Tra
Page 122 and 123:
Internal TCM Power SupplyIf the pow
Page 124 and 125:
shift, rpm does not go up during a
Page 126 and 127:
The shift solenoids are monitored f
Page 128 and 129:
*> #606Exponentially Weighted Movin
Page 130 and 131:
@$!The readiness function is implem
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2005 MY OBD System Operation Summary for Gasoline Engines

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