Hi, My husband wanted me to post here to see if anyone could help with our 03 Exp EB 5.4L. Ok guys, he has been chasing an EGR issue for well over a year. What he has done is: replaced the EGR, DPFE, the hoses, the solenoid (and after all this a Ford tech told him that he knew what the problem was that he needed to replace the EGR tube because the orifice rusts out) so he recently bought a new one of those and installed it and still no change. So, after going nuts and doing more researching, he found threads on the EGR ports being clogged, he is thinking that this could be a high possibility because he looked inside the throttle body and it was absolutely black and awful. Here's where his main question come in, every picture that he has seen on the internet showing the clogged ports shows one main port coming from the EGR then 2 small ports making a 90 degree turn off the main port into the intake. Mine only has one larger port instead of 2 smaller ports. He found a guy locally that was parting an 03 Exp EB 5.4L and he grabbed the throttle body and the elbow so he could clean one and just do a swap. That one matches mine with only a single port. Why is everything he see on the internet showing 2 ports? The code it is kicking out is 403.

 

The P0403 is in reference to the electrical circuit of the EGRVR (EGR Vacuum Regulator solenoid. When the PCM enables the EGRVR solenoid, it checks to see that the EGRVR circuit voltage is within spec. If not, the PCM sets the P0403.


The red/yellow striped wire at the EGRVR solenoid harness side connector should have 12 volts with key on.

And the internal resistance of the EGRVR at its connector (with the connector unplugged) should have 20-40 ohms resistance.

 

Husband tested and we have 12 volts at the solenoid and 35 ohms on the EGRVR. So, what next?

 

Then check out the integrity of the brown/pink striped wire.


Check for an open in the brown/pink circuit:
With the EGRVR plugged in, disconnect the center(?) plug at the PCM. Check the Brown/pink pin (#22?) for any green crud (trademark) or looseness. With key ON you should have open circuit voltage at the pin. Lightly tap the EGRVR and/or wiggle its connector and wiring harness to see if voltage at pin goes intermittent.


Check for a short to vehicle power in the brown/pink circuit:
Unplug the EGRVR connector. With the PCM unplugged and with the key ON, you should have no voltage at pin 22. If you do, the brown/pink circuit is shorted to vehicle power some place.


Check for a short to ground in the brown/pink circuit:
With the EGRVR unplugged and with the PCM unplugged, the brown/pink wire should not ring to ground. And the brown/pink wire should have less than a few ohms resistance between the EGRVR connector and the PCM connector.

 

That wasn't the problem either

 

So what voltage(s) did you get as a result of this test?