Module Communications Network: Diagnosis Ford Econoline E350

INSPECTION & VERIFICATION

Note. Following inspection and verification should be followed for diagnosing module communications network.

1. Verify customer's original problem. Inspect vehicle for any obvious electrical component wiring or connector damage.
2. Inspect pins in 16-pin Data Link Connector (DLC) for damage. see scheme 2 The DLC is located below driver's side of instrument panel, to the right of steering column. If pins are okay, perform DATA LINK DIAGNOSTICS. If pins are damaged, repair as necessary and perform DATA LINK DIAGNOSTICS.

DATA LINK DIAGNOSTICS

1. Connect New Generation Star (NGS) scan tester on Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000) .
2. Turn ignition switch to ON position. Rotate dial on scan tester to menu item DIAGNOSTIC DATA LINK and press trigger. A test will be performed on the BUS (circuits No. 914 and 915) for the module communications network and the ISO 9141 communication link circuit No. 70. This is the Light Blue/White wire that goes between terminal No. 7 on DLC and 4-Wheel Anti-lock Brake (4WABS) module and air bag diagnostic monitor (also referred to as Electronic Crash Sensor (ECS) module).
3. If scan tester displays CKT 914 (+) = SYSTEM PASSED and CKT 915 (-) = SYSTEM PASSED, module communications network is okay. If scan tester displays CKT 70 = SYSTEM PASSED, ISO 9141 communication link is operating properly.
4. If scan tester displays ABS NO RESPONSE/NOT EQUIPPED, go to TEST A: 4-WHEEL ANTI-LOCK CONTROL SYSTEM DOES NOT RESPOND TO NGS under «TESTING»(ref-29217-S20588311422001101500000) .
5. If scan tester displays AIR BAG NO RESPONSE/NOT EQUIPPED, go to TEST B: AIR BAG DIAGNOSTIC MONITOR/ELECTRONIC CRASH SENSOR (ECS) DOES NOT RESPOND TO NGS under «TESTING»(ref-29217-S20588311422001101500000) .
6. If scan tester displays CKT 914 (+) = 00000001 and CKT 915(-) = 00000001, go to TEST C: POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO NGS under «TESTING»(ref-29217-S20588311422001101500000) .
7. If scan tester displays CKT 70 = 0000000F, go to TEST D: NO MODULE/NETWORK COMMUNICATION.

RETRIEVING DIAGNOSTIC TROUBLE CODES

Note. Procedure may be used for retrieving continuous Diagnostic Trouble Codes (DTCs).

1. Connect New Generation Star (NGS) scan tester to Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000) . NOTE: If instructed to retrieve Diagnostic Trouble Codes (DTCs) from a specified test procedure, ensure ignition is in proper position as listed in test procedure or the test will fail.
2. Turn ignition switch to RUN position unless otherwise instructed by specified test procedure. Rotate dial on scan tester to DIAGNOSTIC DATA LINK menu and press trigger.
3. Rotate dial on scan tester to highlight the desired module you wish to access. Ensure DIAGNOSTIC TEST MODES is highlighted and press trigger.
4. Rotate dial on scan tester to highlight RETRIEVE/CLEAR CONTINUOUS DTC and press trigger. Press button No. 3 to start.
5. Record all Diagnostic Trouble Codes (DTCS) that are displayed for specified module. Proceed to DIAGNOSTIC TROUBLE CODE (DTC) DEFINITIONS for DTC identification and reference for proper DTC testing procedure. DIAGNOSTIC TROUBLE CODE (DTC) DEFINITIONS are listed after «TESTING»(ref-29217-S20588311422001101500000) in this article.

CLEARING DIAGNOSTIC TROUBLE CODES

1. Connect New Generation Star (NGS) scan tester on Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000) . NOTE: If instructed to clear Diagnostic Trouble Codes (DTCs) from a specified test procedure, ensure ignition is in proper position as listed in test procedure or the test will fail.
2. Turn ignition switch to RUN position unless otherwise instructed by specified test procedure. Rotate dial on scan tester to DIAGNOSTIC DATA LINK menu and press trigger.
3. Rotate dial on scan tester to highlight the desired module you wish to access. Ensure DIAGNOSTIC TEST MODES is highlighted and press trigger.
4. Rotate dial on scan tester to highlight RETRIEVE/CLEAR CONTINUOUS DTC and press trigger. Press button No. 3 to start.
5. To clear an individual DTC from a selected module, rotate dial on scan tool to highlight the DTC to be cleared. Press button No. 8. This will clear only that DTC from that module.
6. To clear all DTCs from a selected module, press button No. 7. This clears all DTCs from that module.

ON-DEMAND SELF-TEST

Note. On-Demand Self-Test may be used to verify operation of a selected module.

1. Connect New Generation Star (NGS) scan tester on Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000) . NOTE: If instructed to perform On-Demand Self-Test from a specified test procedure, ensure ignition is in proper position as listed in test procedure or the test will fail.
2. Turn ignition switch to RUN position unless otherwise instructed by specified test procedure. Rotate dial on scan tester to DIAGNOSTIC DATA LINK menu and press trigger.
3. Rotate dial on scan tester to highlight the desired module to be tested and press trigger. Ensure DIAGNOSTIC TEST MODES is highlighted and press trigger.
4. Rotate dial on scan tester to highlight ON-DEMAND SELF-TEST and press trigger. Press button No. 3 to start the test. Prepare vehicle for entry condition as specified for each module. Press trigger. Record any Diagnostic Trouble Codes (DTCs) that are displayed.

DIAGNOSTIC COMMAND

Note. This procedure may be used to verify operation of output circuitry for selected module being tested.

1. Connect New Generation Star (NGS) scan tester on Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000) . NOTE: If instructed to retrieve PID from a specified test procedure, ensure ignition is in proper position as listed in test procedure or the test will fail.
2. Turn ignition switch to RUN position unless otherwise instructed by specified test procedure. Rotate dial on scan tester to DIAGNOSTIC DATA LINK menu and press trigger.
3. Rotate dial on scan tester to highlight the desired module you wish to access and press trigger. Rotate dial on scan tester to highlight ACTIVE/COMMAND MODES and press trigger.
4. Rotate dial on scan tester to selected command and press trigger.

TEST A: 4-WHEEL ANTI-LOCK CONTROL SYSTEM DOES NOT RESPOND TO NGS

1. Turn ignition off. Disconnect 4-wheel ABS control module 24-pin connector C144 (located on left front frame rail). Inspect anti-lock brake module connector C144 for damage. If anti-lock brake module connector is okay, go to next step. If anti-lock brake module connector is damaged, repair as necessary. Retest system for normal operation.
2. Measure resistance between 4-wheel ABS control module 24-pin connector C144 pin No. 5 and DLC pin No. 7 (Light Blue/White wire). see scheme 2and (Scheme 1). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, replace ABS module. Retest system for normal operation.
3. Ensure ignition is off. Disconnect Natural 76-pin harness connector C234 (on driver's side of engine compartment on safety wall). Inspect harness connector C234 for damage. If harness connector C234 is okay, go to next step. If harness connector C234 is damaged, repair as necessary. Retest system for normal operation.
4. Measure resistance between DLC pin No. 7 and male side of 76-pin harness connector C234 pin No. 43 (Light Blue/White wire). see scheme 2and (Scheme 2). If resistance is less than 5 ohms, repair Light Blue/White wire between 4-wheel ABS control module 24-pin connector C144 and 76-pin harness connector C234. If resistance is 5 ohms or more, repair Light Blue/White wire between DLC and 76-pin harness connector C234. Retest system for normal operation.

Scheme 1

Scheme 2

TEST B: AIR BAG DIAGNOSTIC MONITOR/ELECTRONIC CRASH SENSOR (ECS) DOES NOT RESPOND TO NGS

Note. Air bag diagnostic monitor is also referred to as Electronic Crash Sensor (ECS) module.

1. Turn ignition off. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article. Disconnect Gray 28-pin air bag diagnostic monitor connector C200 (located behind right kick panel). Inspect Gray 28-pin air bag diagnostic monitor connector C200 and DLC (located below instrument panel to right of steering column) for damage. If Gray 28-pin air bag diagnostic monitor connector C200 and DLC are okay, go to next step. If Gray 28-pin air bag diagnostic monitor connector C200 and DLC is damaged, repair as necessary. Retest system for normal operation.
2. Measure resistance in Light Blue/White wire between Gray 28-pin air bag diagnostic monitor connector C200 pin No. 19 and DLC pin No. 7. see scheme 2 If resistance is less than 5 ohms, replace air bag diagnostic monitor. If resistance is 5 ohms or more, repair Light Blue/White wire between Gray 28-pin air bag diagnostic monitor connector C200 and DLC. Retest system for normal operation.

TEST C: POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO NGS

1. Connect New Generation Star (NGS) scan tester to Data Link Connector (DLC) and perform proper hook-up procedure. See «EQUIPMENT HOOK-UP»(ref-29217-S12762081092001101500000). Retrieve continuous DTCs. See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-29217-S21818545792001101500000). If DTC 00000001 is retrieved for circuit No. 914 (Tan/Orange wire), go to next step. If DTC 00000001 is not retrieved for circuit No. 914 (Tan/Orange wire), go to step 8).
2. Turn ignition off. Disconnect PCM 104-pin connector C154 (located on left rear of engine compartment near brake master cylinder). Inspect PCM 104-pin connector C154 for damage. Inspect DLC for damage. If necessary, repair damaged connectors. Retest system for normal operation. Measure resistance between PCM 104-pin connector C154 pin No. 16 and DLC pin No. 2 (Tan/Orange wire). see scheme 2and (Scheme 3). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, go to step 5).
3. Ensure ignition is off. Disconnect Natural 76-pin harness connector C234 (on driver's side of engine compartment on safety wall). Inspect harness connector C234 for damage. If harness connector C234 is okay, go to next step. If harness connector C234 is damaged, repair as necessary. Retest system for normal operation.
4. Measure resistance between PCM 104-pin connector C154 pin No. 16 and male side of Natural 76-pin harness connector C234 pin No. 61 (Tan/Orange wire). (Scheme 2)and (Scheme 3). If resistance is less than 5 ohms, repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and DLC. If resistance is 5 ohms or more, repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and PCM. Retest system for normal operation.
5. Ensure ignition is in run. Measure voltage between DLC pins No. 2 and 4. If no voltage is present (zero volts), go to next step. If voltage is present, go to step 7).
6. Turn ignition off. Disconnect Natural 76-pin harness connector C234. Measure voltage between DLC pins No. 2 and 4. If voltage is present, repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and PCM. If no voltage is present (zero volts), repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and DLC. Retest system for normal operation.
7. Turn ignition off. Disconnect Natural 76-pin harness connector C234. Turn ignition on. Measure voltage between DLC pins No. 2 and 16. If voltage is present, repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and PCM. If no voltage is present (zero volts), repair circuit No. 914 (Tan/Orange wire) between Natural 76-pin harness connector C234 and DLC. Retest system for normal operation.
8. Ensure ignition is off. Disconnect PCM 104-pin connector C154 (located on left rear of engine compartment near brake master cylinder). Inspect PCM 104-pin connector C154 for damage. Inspect DLC for damage. If necessary, repair damaged connectors. Measure resistance between PCM 104-pin connector C154 pin No. 15 and DLC pin No. 10 (Pink/Light Blue wire). see scheme 2and (Scheme 3). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, goto step 10).
9. Ensure ignition is off. Disconnect Natural 76-pin harness connector C234. Inspect Natural 76-pin harness connector C234 for damage. If necessary, repair damaged connector. Measure resistance between PCM 104-pin connector C154 pin No. 15 and male side of 76-pin harness connector C234 pin No. 59 (Pink/Light Blue wire). (Scheme 2)and (Scheme 3). If resistance is less than 5 ohms, repair circuit No. 915 (Pink/Light Blue wire) between 76-pin harness connector C234 and DLC. If resistance is 5 ohms or more, repair circuit No. 915 (Pink/Light Blue wire) between 76-pin harness connector C234 and PCM. Retest system for normal operation.
10. Turn ignition to run. Measure voltage between DLC pins No. 4 and 10. If voltage is not present (zero volts), go to next step. If voltage is present, go to step 12).
11. Turn ignition off. Disconnect Natural 76-pin harness connector C234. Turn ignition to run. Measure voltage between DLC pins No. 4 and 10. If voltage is present, repair circuit No. 915 (Pink/Light Blue wire) between Natural 76-pin harness connector C234 and PCM. If voltage is not present (zero volts), repair circuit No. 915 (Pink/Light Blue wire) between Natural 76-pin harness connector C234 and DLC. Retest system for normal operation.
12. Measure voltage between DLC pins No. 10 and 16. If voltage is not present (zero volts), go to next step. If voltage is present, replace PCM. Retest system for normal operation.
13. Turn ignition off. Disconnect Natural 76-pin harness connector C234. Turn ignition to run. Measure voltage between DLC pins No. 4 and 10. If voltage is present, repair circuit No. 915 (Pink/Light Blue wire) between Natural 76-pin harness connector C234 and PCM. If voltage is not present (zero volts), repair circuit No. 915 (Pink/Light Blue wire) between Natural 76-pin harness connector C234 and DLC. Retest system for normal operation.

Scheme 3

TEST D: NO MODULE/NETWORK COMMUNICATION

Note. Air bag diagnostic monitor is also referred to as Electronic Crash Sensor (ECS) module.

1. Turn ignition off. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article. Disconnect Gray 28-pin air bag diagnostic monitor connector C200 (located behind right kick panel). Inspect Gray 28-pin air bag diagnostic monitor connector C200 and DLC (located below instrument panel to right of steering column) for damage. If Gray 28-pin air bag diagnostic monitor connector C200 and DLC are okay, go to next step. If Gray 28-pin air bag diagnostic monitor connector C200 or DLC is damaged, repair as necessary. Retest system for normal operation.
2. Measure resistance in Light Blue/White wire between Gray 28-pin air bag diagnostic monitor connector C200 pin No. 19 and DLC pin No. 7. see scheme 2 If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair Light Blue/White wire between Gray 28-pin air bag diagnostic monitor connector C200 and DLC. Retest system for normal operation.
3. If vehicle is equipped with 4-wheel ABS, go to step 5). Turn ignition to run. Measure voltage between DLC pins No. 7 and 16. If voltage is present, go to next step. If no voltage is present (zero volts), repair Light Blue/White wire. Reconnect all connectors. Reactivate air bag system. Retest system for normal operation.
4. Measure voltage between DLC pins No. 4 and 7. see scheme 2 If voltage is present, replace air bag diagnostic monitor. If no voltage is present (zero volts), repair Light Blue/White wire. Reconnect all connectors. Reactivate air bag system. Retest system for normal operation.
5. Turn ignition to run. Perform «DATA LINK DIAGNOSTIC»(ref-29217-S11448997402001101500000) under COMMUNICATION NETWORK DIAGNOSTICS. If DTC 00000003 is retrieved, go to next step. If DTC 00000003 is not retrieved, replace air bag diagnostic monitor. Retest system for normal operation.
6. Turn ignition off. Disconnect 4-wheel ABS control module 24-pin connector C144 (located on left front frame rail). Inspect anti-lock brake module connector C144 for damage. If anti-lock brake module connector is okay, go to next step. If anti-lock brake module connector is damaged, repair as necessary. Retest system for normal operation.
7. Reconnect 4-wheel ABS control module 24-pin connector C144. Perform «DATA LINK DIAGNOSTIC»(ref-29217-S11448997402001101500000) under COMMUNICATION NETWORK DIAGNOSTICS. If DTC 00000003 is retrieved, go to next step. If DTC 00000003 is not retrieved, replace 4-wheel ABS module. Retest system for normal operation.
8. Measure voltage between DLC pins No. 4 and 7. see scheme 2 If voltage is present, go to next step. If voltage is not present (zero volts), go to step 10).
9. Turn ignition off. Measure voltage between DLC pins No. 7 and 16. If voltage is not present (zero volts), go to next step. If voltage is present, verify NGS tester is functioning properly.
10. Ensure ignition is off. Disconnect Black 14-pin harness connector C201 (behind right kick panel). Turn ignition to run. Perform «DATA LINK DIAGNOSTIC»(ref-29217-S11448997402001101500000) under COMMUNICATION NETWORK DIAGNOSTICS. If DTC 00000003 is retrieved, repair Light Blue/White wire between DLC and Black 14-pin harness connector C201. If DTC 00000003 is not retrieved, repair Light Blue/White wire between 4-wheel ABS control module 24-pin connector C144 and Black 14-pin harness connector C201. Reconnect all connectors. Reactivate air bag system. Retest system for normal operation.

DIAGNOSTIC TROUBLE CODE (DTC) DEFINITIONS

AIR BAG DIAGNOSTIC MONITOR DTC DEFINITIONS (1)

4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) CONTROL MODULE DTC DEFINITIONS

POWERTRAIN CONTROL MODULE (PCM) DTC DEFINITIONS

Data Link Connectors Wiring Diagram (Diesel). Scheme 4

Data Link Connectors Wiring Diagram (Gasoline). Scheme 5

Ground Distribution Wiring Diagram (1 Of 4). Scheme 6

Ground Distribution Wiring Diagram (2 Of 4). Scheme 7

Ground Distribution Wiring Diagram (3 Of 4). Scheme 8

Ground Distribution Wiring Diagram (4 Of 4). Scheme 9

Power Distribution Wiring Diagram (1 Of 4). Scheme 10

Power Distribution Wiring Diagram (2 Of 4). Scheme 11

Power Distribution Wiring Diagram (3 Of 4). Scheme 12

Power Distribution Wiring Diagram (4 Of 4). Scheme 13