Engine Controls - Basic Diagnostic Procedures - Except Diesel Ford Econoline I

INTRODUCTION

Note. References to Econoline include Cutaway and RV Cutaway. References to Pickup include Cab & Chassis.

The following diagnostic steps will help prevent overlooking a simple problem. This is also where to begin diagnosis for a no-start condition.

The first step in diagnosing any driveability problem is verifying the symptom(s) with a test drive under the conditions the problem reportedly occurred.

Before entering self-diagnostics, perform a careful and complete visual inspection. Most engine control problems result from mechanical breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test listed in this article.

VISUAL INSPECTION

Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not pinched or cut. Inspect air induction system for possible vacuum leaks.

Compression

Check engine compression with engine at normal operating temperature, all spark plugs removed (on dual plugs, remove exhaust side only), and throttle wide open. Ensure crankcase is full and oil is of correct viscosity. With compression gauge installed, use remote starter switch to crank engine. Crank engine at least 5 revolutions, and record highest reading. Repeat procedure for all cylinders, using approximately same number of revolutions. Lowest compression reading should not be less than 75 percent of highest compression reading. No cylinder compression reading should be less than 100 psi (7 kg/cm 2 ).

Exhaust System Backpressure

Using a vacuum or pressure gauge, check exhaust system. Remove Heated Oxygen Sensor (HO2S) or air injection check valve (if equipped). Connect a 0-5 psi pressure gauge, and run engine at 2500 RPM. If exhaust system backpressure is greater than 2 psi, exhaust system or catalytic converter is plugged.

If using a vacuum gauge, connect vacuum gauge hose to intake manifold vacuum port, and start engine. Observe vacuum gauge. Open throttle part way and hold steady. If vacuum gauge reading slowly drops after stabilizing, check exhaust system for restrictions.

PRELIMINARY CHECKS

Note. For fuel system checks on natural gas vehicles, see TEST HA and TEST HB in SELF-DIAGNOSTICS - EEC-V article.

Ensure following systems and components are in good condition and operating properly before diagnosing problems in fuel injection system

1. Check battery and charging system condition.
2. Check all wiring and vacuum connections.
3. Check air cleaner and ducting.
4. Check state of tune.
5. Check fuel delivery system.
6. Check cooling system.
7. Check inertia fuel shutoff switch.
8. Check for blown head gasket (liquid in cylinder).
9. Check fuel tank contents and fuel gauge accuracy.
10. Check for dirt, water or other contamination in fuel.
11. Check fuel lines and fittings for leaks.
12. Check fuel delivery system for proper pressure and volume.
13. Check for inoperative fuel injectors.
14. Check for improperly installed electronic equipment such as anti-theft system, CB radio, cellular telephone or stereo.

Engine Does Not Crank

Check for enabled anti-theft system. Check starting and charging system for correct operation. Check for hydrostatic lock (liquid in cylinder). Repair as necessary.

Engine Cranks But Will Not Start

1. Check fuel tank contents and fuel gauge accuracy. Check for dirt, water or contamination in fuel.
2. Check fuel lines and fittings for leaks. If no leaks are found, check fuel delivery system for proper pressure and volumes. Reset Inertia Fuel Shutoff (IFS) switch (if necessary).
3. Check for damaged or contaminated fuel injector wiring harness and connector. Ensure fuel injectors pulse when engine is cranked.
4. Check ignition system for strong spark at spark plugs. If no spark exists or if spark is weak, proceed as follows: On all EEC-V models, go to step 1) of TEST JE in SELF-DIAGNOSTICS - EEC-V article. On Villager, go to step 1) of TEST JA in SELF DIAGNOSTICS - VILLAGER article.

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel tank cap. Using Fuel Pressure Gauge (T80L-9974-B), release pressure from system at pressure relief valve (Schrader valve) located on fuel injection manifold rail. Place fuel pressure gauge in a suitable container. Using gauge, release pressure from system.
2. If fuel pressure gauge is not available, disconnect Inertia Fuel Shutoff (IFS) switch. See «INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-except-diesel) table. Remove fuel cap to release fuel tank pressure. Crank engine for 15 seconds to release system pressure.

INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION

FUEL PRESSURE

Note. For fuel pressure procedure for diesel engines, see SYSTEM & COMPONENT SYSTEM TESTING-DIESEL article.

Note. EEC-V PCM has 104-pin connector.

1. Release fuel pressure. Install fuel pressure gauge. Turn ignition on and read fuel pressure. Compare fuel pressure reading on fuel pressure gauge with specifications in «FUEL PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/specifications/#fuel-system-pressure-specifications) .
2. If fuel pressure is not within specifications, check fuel pressure regulator. With engine running, connect hand vacuum pump and apply vacuum to regulator.
3. Ensure fuel pressure changes as vacuum at regulator is increased and decreased. If no pressure change occurs, replace regulator and recheck system. For additional testing information, go to TEST HC in SELF-DIAGNOSTICS - EEC-V or SELF-DIAGNOSTICS - VILLAGER article.

Fuel Injector Resistance

Disconnect injector harness connectors. Using digital ohmmeter, measure resistance between injector terminals. See INDIVIDUAL INJECTOR RESISTANCE table. Replace any injector not within specification.

Fuel Injector Check (Gasoline)

Start engine and allow to idle. If engine will not start, crank engine for 10 seconds. Using a stethoscope, listen for clicking sound at each injector. If clicking sound is heard, fuel injector is operating. If clicking sound is not heard, proceed as follows

1. For all EEC-V models, go to step 8) of TEST HD in SELF-DIAGNOSTICS-EEC-V article.
2. For Villager, go to step 4) of TEST HD in SELF-DIAGNOSTICS-VILLAGER article.

Note. For additional testing and information, see SYSTEM & COMPONENT TESTING - EEC-V article.

INDIVIDUAL INJECTOR RESISTANCE

INERTIA FUEL SHUTOFF (IFS) SWITCH

1. In event of a collision, electrical contacts in inertia switch open, automatically shutting off fuel pump. Fuel pump shuts off even if engine does not stop running. Engine will stop due to lack of fuel.
2. Engine cannot be restarted until inertia switch is manually reset. To reset inertia switch, depress button on switch. See «INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-except-diesel) table under FUEL SYSTEM PRESSURE RELEASE.

NO-START DIAGNOSIS

Note. For diesel information, see SYSTEM & COMPONENT TESTING - DIESEL article.

DEFINITION

No-start is defined as engine cranks okay, but does not start. Engine may fire a few times.

Before diagnosing problems in ignition system, ensure following systems and components are in good condition and operating properly

1. Battery.
2. Timing belt or chain.
3. Fuel delivery and injection system.
4. All wiring and vacuum connections.
5. Air cleaner and ducts.
6. Cooling system.

DISTRIBUTORLESS IGNITION SYSTEM

Note. For additional testing, see TEST JF in SELF DIAGNOSTICS - EEC-V article.

Spark Check

1. Perform self diagnostic QUICK TEST to check for ignition-related fault codes, and repair as necessary. See QUICK TEST in SELF DIAGNOSTICS - EEC-V article. If no fault codes are retrieved, check ignition system wiring harness connectors for corrosion and tight fit. See WIRING DIAGRAMS article. Clean or repair connectors as necessary.
2. If wiring and connectors are okay, use Neon Bulb Spark Tester (D8IP-6666-A) to check for spark at each spark plug wire while cranking engine. If spark is strong and consistent at each spark plug (one spark per crankshaft revolution), ignition system is okay. If spark is not present, go to TEST JD in SELF DIAGNOSTICS - EEC-V article.

Spark Output Check

1. Check for trouble codes stored in PCM and repair if necessary. See QUICK TEST in SELF DIAGNOSTICS - EEC-V article. If no trouble codes are retrieved, check ignition system wiring harness connectors for damage, corrosion and tight fit.
2. If no fault codes are retrieved and vehicle will start, go to TROUBLE SHOOTING - NO CODES - EEC-V article. If no fault codes are retrieved and vehicle is a no-start, connect a high-output spark tester between ignition coil wire and engine ground. Check for spark at coil wire while cranking engine. A consistent Blue spark should be present.
3. If spark is present, go to step 4 . If no spark is present, remove distributor cap and crank engine to ensure distributor rotor rotates. If okay, check resistance of coil secondary wire. On Villager, resistance should be less than 9100 ohms per foot. On all models except Villager, resistance should be less than 7000 ohms per foot. Service coil wire if necessary and retest. If spark is not present, go to TEST A in SELF DIAGNOSTICS - EEC-V article.
4. If a consistent Blue spark is present at coil wire during cranking, inspect distributor cap and rotor for cracks or carbon tracking. Service as necessary and test spark output at spark plugs. If spark is present at spark plugs and engine will not start, go to TROUBLE SHOOTING - NO CODES - EEC-V article.

IGNITION COIL RESISTANCE

IGNITION COIL RESISTANCE

Villager

1. Ensure engine is at operating temperature, all accessories are off, and transmission is in Park or Neutral. Set parking brake. Ensure idle speed is correct.
2. Connect timing light to No. 1 spark plug wire. Disconnect Idle Air Control (IAC) wiring harness connector. Start engine. Check base ignition timing. See «IGNITION TIMING»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-except-diesel) table.
3. If timing is not to specification, loosen distributor hold-down bolt. Adjust timing as necessary. Turn engine off. Reconnect IAC harness connector. Start engine. Ensure advance mechanism functions when engine speed is increased.

All Other Models (EEC-V)

Manufacturer does not recommend checking timing as false readings are common and timing is not adjustable. Timing specification is for reference purposes only. See IGNITION TIMING table.

IGNITION TIMING

IDLE SPEED

Idle speed is controlled by Powertrain Control Module (PCM) and is not adjustable. If idle concerns exist, see appropriate SELF-DIAGNOSTICS article. If no DTCs exist, go to appropriate TROUBLE SHOOTING - NO CODES article.

IDLE MIXTURE ADJUSTMENT

Note. Idle mixture is not adjustable. If idle mixture is incorrect, see TEST G in SELF-DIAGNOSTICS - EEC-V article.

THROTTLE POSITION (TP) SENSOR ADJUSTMENT

Note. Throttle Position (TP) sensor is not serviceable. If TP sensor service is required, see TEST DH in SELF-DIAGNOSTICS - EEC-V article.

SUMMARY

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to SELF-DIAGNOSTICS in SELF DIAGNOSTICS - EEC-V article. If no trouble codes are found in self-diagnostics, proceed to TROUBLE SHOOTING - NO CODES - EEC-V article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.

See also:
• FUEL PRESSURE SPECIFICATIONS
• INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION