Emissions - MIL ON/DTC's P0402/P0403/Runs Rough

Article No.
03-15-2

08/04/03

^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES
(DTC) P0402 AND/OR P0403 OR RUNS ROUGH IN
WET WEATHER CONDITIONS

^ ELECTRICAL - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DIAGNOSTIC TROUBLE
CODES (DTC) P0402 AND/OR P0403 STORED

FORD:
2000-2003 FOCUS

ISSUE
Some vehicles may exhibit a runs rough and/or Malfunction Indicator Lamp (MIL) on condition with Diagnostic Trouble Codes (DTC) P0402 and/or P0403, in wet weather conditions or in a car wash.

ACTION
If the vehicle exhibits a runs rough and/or MIL Light on with DTC P0402 and/or P0403, in wet weather or a car wash, and there is evidence of water ingestion into the EVR, follow the repair procedure below.

SERVICE PROCEDURE SEALING COWL AREA

Vehicles built before January 4, 2003 - (These vehicles have seals molded into the grilles, that cannot be removed).

Start from the bottom edge of the cowl grill center joint, and fill the vertical gap with RTV (Overlap both sides of the gap by about 3/16"), continue filling the gap up to the cowl seals. Continue to "SEALING THE EVR/DPFE" section in the article.

Vehicles built after January 4, 2003





NOTE
ON VEHICLES BUILT JANUARY 4, 2003 TO FEBRUARY 25, 2003, RELOCATE THE COWL SEAL GAP. REMOVE COWL SEALS, SWAP THE SEALS FROM SIDE TO SIDE, SUCH THAT THE SEAL GAP IS AWAY FROM THE COWL GAP AND APPLY BLACK RTV SILICONE SEALANT TO THE COWL GRILL CENTER JOINT GAP (REFER TO FIGURE 1). SOME VEHICLES MAY ALREADY HAVE THIS DONE. CONTINUE WITH PROCEDURE.

1. Remove cowl seal enough to expose the cowl grill center joint gap on the driver's side (for about 12").

2. Start from the bottom edge of the cowl grill center joint and fill the vertical gap with RTV (Overlap both sides of the gap by about 3/16"), continue over the rim & into the channel, up the wall of the channel, and continue over the top surface approximately 1/2" (up to where the first row of holes start in the driver's side grille).

3. Reinstall cowl seal. Continue to "SEALING THE EVR/DPFE" section in the article.

SEALING THE EVR/DPFE

Form an EVR umbrella using the Bulkhead insulation.

1. Vehicles with Bulkhead Mounted DPFE Sensors.

a. Remove the DPFE.

b. Fold the insulation on the partition wall 90° downward so it lays over the top of the EVR.





c. Reinstall the DPFE such that the insulation is trapped in place between the bottom of the DPFE & the top of the EVR. Tighten to 36 +/- 6 lb-in. (4.1 +/- 0.7 N.m) (Refer to Figure 2).

d. Verify the DPFE & EVR hoses are fully seated.

2. Vehicles with tube-mounted DPFE.

a. Remove the EVR solenoid.

b. Trace out a 2.5" wide x 3" tall rectangle in the insulation, starting from the bottom, and just outside of the EVR mounting lugs.

c. Cut vertically upward from the bottom along each of the two vertical lines, stopping at the line drawn horizontally.

d. Fold the section of insulation 90° upward.





e. With the insulation held up, reinstall the EVR solenoid. Tighten to 36 +/- 6 lb-in. (4.1 +/- 0.7 N.m) (Refer to Figure 3).

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage

OPERATION DESCRIPTION TIME

031502A Form EVR Umbrella Using 0.5 Hr.
The Bulkhead Insulation
(Includes Time To Check
For Codes And Seal Cowl)

DEALER CODING
CONDITION
BASIC PART NO. CODE
9J459 49





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