Solenoid Wiring Diagram Ford 03 Escape
Hello,
It's been a little while. Good news, I fixed my problem. It turns out that it was just a loose wire on the connector to the EGR solenoid. Initially, as my previous post indicated, I was unable to detect the lose wire in the connector when doing a continuity test. Most likely I was forcing contact while I was probing. In either case, I'll detail how this was diagnosed, resolved and how FORSCAN was an excellent tool to have handy.
1) I purchased an ELM327 off of amazon ($12.99-Foseal Car OBD2 OBD 2 OBDII Bluetooth Diagnostic Scan Tool Check Engine Light for Android & Windows System Torque Pro:http://www.amazon.com/gp/product/B00T5G53ZM?psc=1&redirect=true&ref_=oh_aui_detailpage_o01_s00)
2) I downloaded FORSCAN on to my laptop Windows 7 64 bit with bluetooth capability (free).
Using FORSCAN, I read the P0403 DTC error code which indicated that FORSCAN was communicating with the ELM327 and the ELM327 with the car. I monitored the following PCM readouts:
EGRVR% - EGR voltage percentage
EGRVR_F - EGR voltage Fault detection
EGR_F - EGR fault detection
EGR_EVAL - Yes = good,
Now I don't quite know the difference between how the two faults are detect but I'm glad I monitored both.
After connecting my FORSCAN to the ELM327 with the car running, I found that the EGRVR_F said "open circuit". The rest of the monitors also indicated a fault. I was then on the hunt for a loose wire.
At this point, I setup my wife in my escape with my laptop with FORSCAN displaying the four readouts in oscilloscope mode. I told her to tell me if anything changes (fault detection etc.) While she was monitoring FORSCAN I wiggled the wires at the PCM and at the EGR solenoid. Low and behold when the wires on the EGR solenoid were wiggled a certain way contact was made and the EGR fault went away. Problem Diagnosed!
This would have been difficult to find in real time with a multimeter. Having the time trace in FORSCAN's oscilliscope mode made it easy to find and didn't require probing anything. This is especially useful like in my case, where probing forced continuity that's not there without the probe.
To fix the problem, I purchased a replacement connector from Amazon ($30 - Dorman - TECHoice 645-210 Exhaust Gas Recirculation Modulator Connector). Although this connector did not have an image on amazon it was the correct part number. It came with the connector w/attached wires and two crimp connectors. I had to strip off some of the outer casing holding the wires together that came from the PCM, but I was able to cut the wires and attach the new connector. One thing to note is that the wire gauges between the connector and the wires there are not the same. The control wire from the PCM was much thinner. So you just need to be extra careful crimping that wire. It worked fine for me and then I covered it all with electrical tape. There's probably a more appropriate way to interface two different gauge wires.
After installing the part, I retested it with FORSCAN and I no longer had the fault codes. 
I took my escape for a drive and collected the raw data and showed the EGR functioning perfectly. In addition, with the car parked, I tested the FORSCAN's control function of the EGR voltage from the PCM to the solenoid. It worked perfectly. I was able to manually adjust the voltage leading to the EGR solenoid and made the car come close to stalling for a second. My escape has been running fine for the past week now.
So that's it. If someone else encounters P0403, I hope this forum discussion helps. Thank you all for your input.
Regards,
2003EscapeNY
Source: https://www.escape-city.com/threads/2003-ford-escape-p0403-diagnosis-help.29236/
Posted by: juliocomfort.blogspot.com