Engine Controls - MIL ON/DTC P0403 Set
TSB 12-7-807/19/12
MALFUNCTION INDICATOR LAMP (MIL) ON,
DIAGNOSTIC TROUBLE CODE (DTC) P0403, EGR
CONTROL CIRCUIT FAILURE - BUILT ON OR
BEFORE 4/29/2012
FORD:
2010-2012 Transit Connect
This article supersedes TSB 12-4-9 to add a production fix date and update the Service Procedure.
ISSUE
Some 2010-2012 Transit Connect vehicles built on or before 4/29/2012 may exhibit MIL on with DTC P0403 Exhaust Gas Recirculation (EGR) control circuit failure.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Locate and disconnect the Electric Exhaust Gas Recirculation (EEGR) Assembly connector. (Figure 1)
2. Check the resistance of the EEGR coils across the following pins:
a. Pin 1 = circuit CE101 (WH-VT) and pin 2 = circuit CBKO2 (GN).
b. Pin 3 = circuit CE102 (YE-BU) and pin 2 = circuit CBKO2 (GN).
c. Pin 4 = circuit CE103 (BU-BN) and pin 5 = circuit CBKO2 (GN).
d. Pin 6 = circuit CE104 (GN) and pin 5 = circuit CBKO2 (GN).
3. Are each of the resistance readings within 12-24 Ohms?
a. No - Replace EEGR Assembly and proceed to Step 4.
b. Yes - EEGR assembly is okay. Proceed to Step 4.
4. Carefully remove the tape and convolute from the EEGR connector harness. Save the convolute for later.
5. Replace the EEGR connector using pigtail connector kit and the following steps:
a. Disconnect the battery.
b. Obtain the EEGR pigtail connector kit and cut to size.
(1) Overall take out length should not be longer than 160 mm (6 1/8"). This measurement should be from the back side of the EERG connector to the middle of the harness node. (Figure 2A)
c. On the engine harness, cut each circuit individually. Place a heat shrink sleeve over the wire. Solder the pigtail circuit to the wire harness per the instruction sheet procedure.
d. Slide the heat shrink sleeve over the soldered splice and apply heat to the shrink sleeve to seal the splice.
e. Remove approximately 60 mm (2-3/8") of the saved convolute and reinstall over the new EEGR valve connector harness. The convolute should butt up against the engine harness. (Figure 3A)
f. Tape under the convolute first and leave 10 mm (13/32") of tape beyond the convolute, then tape over the convolute starting at the end nearest to the connector back to the harness.
(1) 50 to 60 mm (2" to 2-3/8") of insulated wires should be seen from the back of the connector. (Figure 3B)
g. Using standard 20 mm (13/16") electrical tape, cut a strip in half lengthwise to 10 mm (13/32") width.
h. Fold back the EEGR connector harness so that 20 mm (13/16") of wire is bent from the back of the connector (Figure 4A)
i. Use the half-width electrical tape and tape the harness to the connector. (Figure 4A)
(1) Do not tape over the locking tab of the connector.
6. Reconnect EEGR connector.
a. Harness take-out will now fit under the coolant hose due to shortened length.
7. Reconnect the battery.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATION DESCRIPTION TIME
120708A 2011-2012 Transit 1.2 Hr.
Connect: Diagnose And
Replace The EEGR
Electrical Connector (Do
Not Use With Any Other
Labor Operations)
120708B 2011-2012 Transit 1.6 Hrs.
Connect: Diagnose And
Replace The EEGR
Assembly And Electrical
Connector (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
12A581 30
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