Engine Controls Tests W/codes - Diesel Ford Econoline I

INTRODUCTION

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

If no diagnostic trouble codes or only pass codes (system functioning properly) are found during self-diagnostics, proceed to TROUBLE SHOOTING - NO CODES - DIESEL article for diagnosis by symptom.

DIAGNOSTIC FORMATS

QUICK TEST and SYSTEM TESTS are diagnostic formats used to test and service the diesel EEC-V system. QUICK TEST allows technician to identify problems and retrieve diagnostic trouble codes. System tests check circuits, sensors and actuators.

Before starting any system test, follow all steps under QUICK TEST to determine appropriate system test to perform. If vehicle passes QUICK TEST and no driveability symptoms or intermittent faults exist, EEC-V system is functioning properly at this time.

DIAGNOSTIC TROUBLE CODES

During QUICK TEST, 3 types of Diagnostic Trouble Codes (DTCs) are retrieved: KOEO, KOER and Continuous Memory DTCs. See QUICK TEST for self-test procedures. DTCs may be cleared from PCM memory after they have been recorded or repaired. See CLEARING CODES .

KOEO & KOER DTCs

KOEO and KOER DTCs indicate faults are present at time of testing. A hard fault may cause CHECK ENGINE or Malfunction Indicator Light (MIL) to go on and remain on until fault is repaired. The is located on instrument panel and may be labeled SERVICE ENGINE SOON or CHECK ENGINE. If KOEO or KOER codes are retrieved during KOEO ON-DEMAND SELF-TEST or KOER ON-DEMAND SELF-TEST, use DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART to find appropriate system test to perform.

Continuous Memory DTCs

Continuous Memory DTCs are retrieved after KOER ON-DEMAND SELF-TEST. Unlike KOEO or KOER self-test which can only be activated on-demand, Continuous Memory Self-Test is always active. A fault may or may not be present at time of checking for Continuous Memory DTCs. This self-test is helpful in diagnosing intermittent problems.

After noting and/or repairing fault, clear DTCs from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problem. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES - DIESEL article.

Note. Continuous Memory DTCs should be recorded when retrieved. These DTCs may be used to identify intermittent problems that exist after all KOEO and KOER DTCs have been repaired. Some Continuous Memory DTC faults may not be valid after KOEO and KOER DTCs are serviced.

RETRIEVING CODES

Fault codes are retrieved from powertrain control system through Data Link Connector (DLC). (Scheme 20) DLC is located under left side of instrument panel, right side of steering column. Self-diagnostic test procedures are for use with New Generation Star (NGS) scan tool. If a generic scan tool is used, ensure scan tool is certified OBD-II standard.

Scheme 20

KOEO & KOER On-Demand Self-Test DTCs

Record DTCs in order received. These DTCs indicate current faults in system and should be serviced in order of appearance. Use DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART to identify appropriate system test to perform.

Note. If self-test will not activate or TOOL COMMUNICATION ERROR is received, go to TEST QA under SYSTEM TESTS.

Pass Codes

SYSTEM PASS indicates no DTCs were recorded in that portion of test No codes present (system pass) indicates no diagnostic trouble codes were recorded in that portion of test. If system pass is not retrieved in KOEO ON-DEMAND SELF-TEST, DTCs retrieved during KOER ON-DEMAND SELF-TEST may not be valid.

These DTCs result from information stored by PCM during continuous self-test monitoring. Use these DTCs for diagnosis only when KOEO ON-DEMAND SELF-TEST and KOER ON-DEMAND SELF-TEST result in a SYSTEM PASS and all steps under QUICK TEST have been successfully completed. These codes indicate faults previously recorded. Fault may or may not be currently present. See DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART .

CLEARING CODES

Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select RETRIEVE/CLEAR CONTINUOUS DTCs.
7. Turn ignition on.
8. Select CLEAR ALL.

All DTCs should now be cleared from PCM memory. If problem has not been corrected or fault is still present, hard code will immediately be reset in PCM memory.

POWERTRAIN CONTROL MODULE LOCATION

POWERTRAIN CONTROL MODULE LOCATION

Diagnostic Aids

After each service or repair procedure has been completed, repeat QUICK TEST to ensure all electronic engine control systems are functioning properly and DTCs are no longer present.

Note. If performing repeated self-tests, disconnect glow plug relay to keep battery from going dead. Relay is located on top, right side of engine. Ignore any glow plug DTCs while glow plug relay is disconnected.

Description

Quick test is made up of 7 functional tests of EEC-V system. All self-tests are completely menu driven using the New Generation Star (NGS) scan tool. The following procedures must be followed in sequence to avoid misdiagnosis

1. «VISUAL CHECK»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__visual-check)
2. «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__vehicle-preparation-equipment-hookup)
3. «KOEO (KEY ON ENGINE OFF) ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)
4. «KOER (KEY ON ENGINE RUNNING) ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)
5. «CONTINUOUS MEMORY SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)
6. «KOEO (KEY ON ENGINE OFF) INJECTOR ELECTRICAL SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__koeo-injector-electrical-self-test)
7. «KOER (KEY ON ENGINE RUNNING) SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)
8. «KOER (KEY ON ENGINE RUNNING) CYLINDER CONTRIBUTION SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)
9. «KOEO GLOW PLUG MONITOR SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel)

VISUAL CHECK

Perform the following and make all necessary repairs before continuing with QUICK TEST

1. Inspect air cleaner and inlet ducts.
2. Inspect system wiring harness for proper connections, bent or broken pins, corrosion, loose wires and proper routing.
3. Check Powertrain Control Module (PCM), sensors and actuators for physical damage.
4. Check engine coolant for proper level and mixture.
5. Check transmission fluid level and quality.

VEHICLE PREPARATION & EQUIPMENT HOOKUP

Apply parking brake and place shift lever in Park (A/T) or Neutral (M/T) position. Block drive wheels. Turn off all electrical accessories. Ensure engine is at normal operating temperature. If vehicle is equipped with an auxiliary powertrain control system (RPM control), it must be turned off when performing any self-test procedure. Connect appropriate test equipment to vehicle as follows.

Generic Scan Tool

Ensure scan tool meets or exceeds OBD-II standard. Follow scan tool manufacturer's operating instructions to hookup equipment and record DTCs.

New Generation Star (NGS) Scan Tool

Turn ignition off. Ensure proper memory (EPROM) card is inserted into NGS scan tool. Connect service connectors of adapter cable to vehicle Data Link Connector (DLC) and NGS scan tool. (Scheme 21) Connect NGS scan tool power supply cable to power and go to KOEO ON-DEMAND SELF-TEST.

Scheme 21

KOEO on-demand self-test is a functional test of PCM performed with ignition key on, engine off. This test checks if PCM inputs and outputs are functioning electronically without any faults. A fault must be present at time of testing for KOEO ON-DEMAND SELF-TEST to detect a fault.

Performing Self-Test

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO ON-DEMAND SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. If any Injector Driver Module (IDM) module DTCs are present, note and clear DTCs. IDM stores both history and hard DTCs. To ensure IDM is hard code, repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
10. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

KOER on-demand self-test is a functional test of PCM performed with ignition key on, engine running. A check is made on Injection Control Pressure (ICP) and Exhaust Backpressure (EBP) systems. During this test, engine RPM will increase, PCM will command ICP high then low, then command EBP high and low. A fault must be present at time of testing for KOER on-demand self-test to detect a fault.

Note. When performing this self-test, engine may run rough.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER ON-DEMAND SELF-TEST.
7. Start engine and allow to idle.
8. Follow operating instructions from scan tool menu.
9. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

Continuous memory self-test is a functional test of PCM. DTCs can be retrieved or cleared with ignition on, engine off or with engine running. Unlike KOEO and KOER self-tests, which can only be activated on demand, continuous monitor is always active in monitoring the system. When a fault is detected, code will be stored in memory. This makes it possible to diagnose intermittent faults.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select RETRIEVE/CLEAR CONTINUOUS DTCs.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. If any Injector Driver Module (IDM) module DTCs are present, note and clear DTCs. IDM stores both history and hard DTCs. To ensure IDM is hard code, repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
10. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

KOEO INJECTOR ELECTRICAL SELF-TEST

Injector self-test is a functional test of PCM performed with ignition key on, engine off. This test determines if injector circuits and solenoids are electrically operating without fault. All injectors will buzz together for about 2 seconds, then each individual injector will buzz for about one second in numerical order.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO INJECTOR ELECTRICAL SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. If any Injector Driver Module (IDM) module DTCs are present, note and clear DTCs. IDM stores both history and hard DTCs. To ensure IDM is hard code, repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
10. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

Note. If no DTCs are present and injector self-test aborts while trying to perform test, go to TEST NA, step 29) under SYSTEM TESTS.

KOER switch self-test is a functional test of PCM performed with ignition key on, engine running. This test will set a code if test does not detect a transition on one or more switches. After pressing trigger to start self-test, wait 5 seconds before running through driver operated controls to eliminate chance of setting a false code. Accelerator pedal must first be depressed and released to begin test, then parking brake, speed control on, off, set, resume, coast, transmission control or clutch. Depress and release brake pedal last, which will test both the Brake Pressure Applied (BPA) switch and Brake On/Off (BOO) switch.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER SWITCH SELF-TEST.
7. Start engine and allow it to idle.
8. Follow operating instructions from scan tool menu.
9. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

Note. Speed control DTCs will be set during KOER SWITCH SELF-TEST if vehicle is not equipped with speed control. This is a normal condition. On vehicles without speed control, ignore DTCs P0565, P0566, P0567, P0568 and P0569.

This test determines if all engine cylinders are contributing equally to engine performance. PCM checks cylinders in numerical order. A fault must be present at time of testing to detect a fault.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER CYLINDER CONTRIBUTION SELF-TEST.
7. Start engine and allow it to idle.
8. Follow operating instructions from scan tool menu.
9. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) . After test has been completed, cycle ignition switch before performing other self-tests or driving vehicle.

This test activates glow plug relay and monitors glow plug relay circuits. A fault must be present at time of testing to detect a fault.

To perform self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Start engine and allow it to idle.
2. Select VEHICLE & ENGINE SELECTION menu.
3. Select NEW VEHICLE, YEAR & MODEL.
4. Select DIAGNOSTIC DATA LINK.
5. Select PCM - POWERTRAIN CONTROL MODULE.
6. Select DIAGNOSTIC TEST MODE.
7. Select KOER GLOW PLUG MONITOR SELF-TEST.
8. Follow operating instructions from scan tool menu.
9. Maintain system voltage until test is complete.
10. Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__diagnostic-trouble-code-dtc-reference-chart) .

ADDITIONAL SYSTEM FUNCTIONS

Note. Additional diagnostic system features are available to help diagnose driveability problems and service electronic engine control systems.

PARAMETER IDENTIFICATION (PID)

PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. To access PID mode, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select PID/DATA MONITOR & RECORD.
6. Turn ignition on or start engine and allow to idle.
7. Follow operating instructions from scan tool menu.
8. Select PIDs and press START to begin monitoring. If PID value is not as specified, perform appropriate system test.

DRIVER OPERATED CONTROLS CHECK

Using New Generation Star (NGS) scan tool, select appropriate PID to be checked. See PARAMETER IDENTIFICATION (PID) and PARAMETER IDENTIFICATION (PID) VALUES . If PID value is not as specified, perform appropriate system test.

PARAMETER IDENTIFICATION (PID) VALUES (1)

Output state self-test allows a technician to energize and de-energize output actuators on command. After accessing OUTPUT STATE TEST MODE, outputs can be turned on and off separately. After pressing trigger to start self-test, accelerator pedal must be depressed then released to cycle outputs high on solenoids, IDM relay, wait to start light, Fuel Delivery Control Signal (FDCS), Electronic Feedback (EF) and Transmission Control Indicator Light (TCIL). Depress and release accelerator again to cycle outputs low. This self-test does not set any DTCs.

To perform output state self-test, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO OUTPUT STATE SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.

This mode allows access to emission related data values from specific generic PIDs. These values are immediately stored in continuous memory when an emission related fault occurs. This provides a snapshot of the conditions that were present when the fault occurred. Freeze frame will be stored until PCM memory is erased.

To perform freeze frame data mode, turn ignition off. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Follow operating instructions from scan tool menu.
4. Select GENERIC OBD-II FUNCTIONS. Press CONT button if OBD-II monitors are not complete.
5. Turn ignition on.
6. Select FREEZE FRAME PID REQUEST.

Primary function of drive cycle procedure is to clear DTC P1000 and to satisfy specifications for SAE J1979. Each OBD-II monitor must run during drive cycle. If drive cycle has been completed and P1000 is not cleared, repeat entire drive cycle. If a particular step is interrupted, repeat drive mode. If drive cycle is interrupted with a key-off, only drive modes that were incomplete must be run. A scan tool can be used to observe a monitor system status, Parameter Identification (PID) values and DTC output.

Performing Drive Cycle

Note. Rough road conditions may prevent certain steady state conditions and steady accelerations from validating the transmission and load related monitors. On models with Power Take-Off (PTO), disengaged PTO system before performing drive cycle.

1. Turn ignition on, but do not crank engine until WAIT TO START light turns off, or 10 seconds has passed (whichever is greater).
2. Start engine. Allow engine to idle with transmission in Park or Neutral for 40 seconds.
3. The following conditions must be followed to run certain OBD-II monitors that require engine to be under a load. On A/T models, select OVERDRIVE CANCEL to perform test in 3rd gear. On all models, turn on accessories (headlights, A/C compressor, blower fan, etc.). DO NOT use hazards or PTO. Select an uphill or level road. DO NOT select a downhill road. Driving downhill will unload engine and defeat test.
4. Accelerate steadily to 3rd gear (A/T) or 4th gear (M/T) and keep engine speed at 1500 RPM for 3 seconds. Accelerate steadily from 35 MPH to 65 MPH in about 15 seconds. Repeat this procedure 3 times while maintaining conditions set in step 3) . Before proceeding, turn all accessories off and disengage OVERDRIVE CANCEL. On A/T models, go to next step. On M/T models, go to step 6 .
5. On A/T models, drive vehicle in 4th gear continuously for one minute. Accelerate steadily from a full stop to 4th gear and then return to a full stop. Repeat this procedure 10 times, then go to next step.
6. Before continuing, use scan tool and select EOT PID from PID/DATA monitor menu. Ensure EOT PID value is more than 140°F (60°C). Allow engine to idle for 20 seconds in Park or Neutral. Turn ignition off. State engine. Allow engine to idle for 40 seconds in Park or Neutral. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . Drive cycle is complete.
7. If P1000 is present after performing drive cycle, repeat step 4 maintaining a minimum MFDES PID value of 37 milligrams/stroke with engine speed at more than 1500 RPM for 11 seconds. Also, repeat step 6 . MFDES PID value must remain less than 12 milligrams/stroke for 11 seconds.

SUMMARY

If no diagnostic trouble code is present but driveability problem still exists, proceed to TROUBLE SHOOTING - NO CODES - DIESEL article for symptom diagnosis or intermittent diagnostic procedures.

DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART

DIAGNOSTIC TROUBLE CODE (DTC) DEFINITION

SYSTEM TESTS

Note. A breakout box, connected to vehicle harness at PCM, is necessary to perform most system tests. References to test pin No. found in system test steps refer to test terminals on manufacturer's breakout box.

HOW TO USE SYSTEM TESTS

1. Ensure all non-EEC related faults found while performing procedure in basic diagnostic procedures article have been corrected. DO NOT perform any system test unless specifically instructed by a QUICK TEST procedure or a diagnostic trouble code reference chart. Follow each test step in order until fault is found. DO NOT replace any part unless directed to do so. When more than one code is retrieved, service first code displayed.
2. System tests ensure electrical circuits are okay before sensors or other components are replaced. Always test circuits for continuity between sensor and PCM. Test all circuits for short to power, opens or short to ground. Voltage Reference (VREF) and Voltage Power (VPWR) circuits should be tested with ignition on or off as specified in system test.
3. DO NOT measure voltage or resistance at PCM. DO NOT connect any test light unless specified in testing procedure. All measurements are made by probing rear of connector (wiring harness side). Isolate both ends of a circuit and turn ignition off when checking for shorts or continuity, unless instructed otherwise.
4. Disconnect solenoids and switches from wiring harness before measuring continuity and resistance or applying voltage. After each repair, check all component connections and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
5. An open circuit is defined as a resistance reading of more than 5 ohms. This specification tolerance may be too high for some items in electronic engine control system. If resistance approaches 5 ohms, always clean suspect connector and coat it with protective dielectric silicone grease. A short is defined as a resistance reading of less than 10,000 ohms to ground, unless stated otherwise in system test.

TEST A: VEHICLE BATTERY

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Enter this test only if directed here from QUICK TEST or another test. This test is only intended to diagnose

1. Closed loop power relay.
2. Powertrain Control Module (PCM).
3. Battery positive voltage (B+).
4. Wiring harness circuits (SIG RTN, PWR GND, ignition switch, VREF, KAPWR and VPWR). (Scheme 22)or (Scheme 23).

To prevent replacement of good components, be aware the following non-EEC related areas and components may be cause of problem

1. Battery cables.
2. Ignition switch.
3. Voltage regulator.
4. Ground straps.
5. Generator.

Scheme 22

Scheme 23

1. 1) DTC P0560, P0562 Or P0563: Check Battery Voltage Turn ignition off. Measure voltage between battery terminals. If voltage is 10.5 volts or less, repair charging system as necessary. If voltage is more than 10.5 volts, go to next step (Pickup) or step 12) (Econoline).
2. 2) Check For Battery Voltage (Pickup) Measure voltage between negative battery terminal and input terminal (Black/Orange wire) of fuse No. 24 at power distribution box. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit between power distribution box and starter relay.
3. 3) Check Fuse Remove and inspect fuse No. 24 at power distribution box. If fuse is okay, go to next step. If fuse is blown, locate and repair short to ground and replace fuse.
4. 4) Check Circuit No. 554 Turn ignition off. Remove PCM relay from power distribution box. Measure resistance between non-powered side of No. 24 fuse holder and Yellow/Black wire at PCM relay connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Yellow/Black wire.
5. 5) Check Ignition Feed To Diode Remove diode from power distribution box. Turn ignition on. Measure voltage between negative battery terminal and ignition feed side of diode connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Red/Light Green wire or replace defective ignition switch.
6. 6) Check Diode Turn ignition off. Using an ohmmeter, check diode continuity. Ensure continuity exists in one direction only. Replace diode as necessary. If diode is okay, go to next step (Pickup) or step 13) (Econoline).
7. 7) Check Circuit No. 175 (Pickup) Measure resistance of White/Light Blue wire between PCM relay connector and non-powered side of diode connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in White/Light Blue wire.
8. 8) Check Ground Circuit Turn ignition off. Measure resistance between negative battery terminal and circuit No. 57 (Black wire) at PCM relay connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Black wire.
9. 9) Check Circuit No. 361 Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Red wire between PCM relay connector and test pins No. 71 and 97 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red wire between PCM relay and PCM connector.
10. 10) Check PWR GND Circuit Measure resistance between negative battery terminal and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If each reading is less than 5 ohms, go to step 14) (Econoline) or next step (Pickup).
11. 11) Check PCM Relay (Pickup) Install PCM relay. Turn ignition on. Measure resistance between non-powered side of fuse No. 24 (Yellow/Black wire) and test pins No. 71 and 97 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, replace PCM relay.
12. 12) Check Voltage At PCM Relay (Econoline) Turn ignition off. Remove PCM relay from power distribution box. Measure voltage between negative battery terminal and circuit No. 37 (Yellow wire) at PCM relay connector. If battery voltage is present, go to step 5) . If battery voltage is not present, locate and repair open circuit in Yellow wire between PCM relay and starter relay.
13. 13) Check Circuit No. 16 (Econoline) Turn ignition off. Measure resistance of Red/Light Green wire between non-powered side of diode connector and PCM relay connector. If resistance is less than 5 ohms, go to step 8) . If resistance is 5 ohms or more, repair open circuit in Red/Light Green wire between diode and relay.
14. 14) Check PCM Relay (Econoline) Install PCM relay. Turn ignition on. Measure voltage between negative battery terminal and test pins No. 71 and 97 at breakout box. If battery voltage is present, replace PCM. If battery voltage is not present, replace PCM relay.

TEST C: REFERENCE VOLTAGE

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

SIG RTN is a dedicated ground used by most electronic engine control system sensors. VREF is a 5-volt reference voltage that is continuously output by PCM. This consistent voltage signal is used on all 3-wire sensors. This test is only intended to diagnose the following components and circuits

1. 3-wire sensors.
2. Vehicle wiring harness circuits (SIG RTN and VREF). (Scheme 24)
3. Powertrain Control Module (PCM).

Scheme 24

1. 1) Check Vehicle Battery Power Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM to breakout box. Turn ignition on. Measure voltage between test pins No. 55, 71 and 97 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are more than 10.5 volts and within one volt of each other, go to next step. If any reading is 10.5 volts or less or not within one volt of each other, go to «TEST A»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-a-vehicle-battery).
2. 2) Check VREF Voltage Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is 4-6 volts, go to next step. If voltage is less than 4 volts, go to step 5). If voltage is more than 6 volts, go to step 4).
3. 3) Check VREF & SIG RTN Circuits Turn ignition off. Disconnect suspect sensor connector. Disconnect PCM from breakout box. Measure resistance between test pin No. 90 at breakout box and VREF circuit terminal at suspect sensor wiring harness connector. Also, measure resistance between test pin No. 91 at breakout box and SIG RTN circuit terminal at suspect sensor wiring harness connector. (Scheme 24) If both readings are less than 5 ohms, no problem is indicated at this time. Fault may be intermittent. If any reading is 5 ohms or more, locate and repair open in VREF or SIG RTN circuit.
4. 4) Check For Excess Voltage Disconnect PCM connector from breakout box. Disconnect scan tool. Turn ignition on. Measure voltage between negative battery terminal and test pin No. 90 at breakout box. If voltage is less than 5 volts, replace PCM. If voltage is 5 volts or more, locate and repair short to power.
5. 5) Check SIG RTN Circuit Turn ignition off. Measure resistance between test pin No. 91 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, replace PCM.
6. 6) Check For Shorted Accelerator Pedal (AP) Sensor Disconnect AP sensor connector. Sensor is located above accelerator pedal. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace AP sensor.
7. 7) Check For Shorted Camshaft Position (CMP) Sensor Turn ignition off. Disconnect CMP sensor connector. Sensor is located in front of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace CMP sensor.
8. 8) Check For Shorted Injection Control Pressure (ICP) Sensor Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top left side of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace ICP sensor.
9. 9) Check Exhaust Backpressure (EBP) Sensor Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top center of engine (Econoline) or top left of engine (Pickup). Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace EBP sensor.
10. 10) Check For Shorted Manifold Absolute Pressure (MAP) Sensor Turn ignition off. Disconnect MAP sensor connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace MAP sensor.
11. 11) Check For Shorted Barometric Pressure (BARO) Sensor Turn ignition off. Disconnect BARO sensor connector. Sensor is located below left side of instrument panel. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace BARO sensor.
12. 12) Check For Shorted VREF Circuit Disconnect PCM connector from breakout box. Ensure all 6 sensors are disconnected. Measure resistance between test pin No. 90 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to ground.

TEST DA: INTAKE AIR TEMPERATURE (IAT) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

This test is intended to diagnose the following components and circuits

1. Intake Air Temperature (IAT) sensor.
2. Wiring harness circuits (IAT and SIG RTN).
3. Powertrain Control Module (PCM).

Scheme 25

1. 1) DTC P0113 This DTC indicates sensor signal voltage is more than self-test maximum. Check for following possible causes: Faulty IAT sensor. Faulty harness connector. Faulty Powertrain Control Module (PCM). Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, select IAT V PID (voltage) from PID/DATA monitor menu. If voltage is 4.9 volts or more, go to next step. If voltage is less than 4.9 volts, go to step 8).
2. 2) Induce Opposite Failure Disconnect IAT sensor connector. Connect a jumper wire between ground and terminal No. 2 (Gray wire) at IAT sensor wiring harness connector. (Scheme 25) If voltage is more than zero volts, go to step 4). If voltage is zero volts, go to next step.
3. 3) Check SIG RTN Circuit Turn ignition off. Measure resistance between ground and terminal No. 1 (Gray/Red wire) at IAT sensor wiring harness connector. If resistance is less than 5 ohms, replace IAT sensor. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
4. 4) Check Sensor Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 2 (Gray wire) at IAT sensor wiring harness connector and test pin No. 39 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Gray wire.
5. 5) DTC P0112 This DTC indicates sensor signal is less than self-test minimum. Possible causes for this fault are: Circuit grounded in wiring harness. Faulty sensor. Faulty harness connector. Faulty Powertrain Control Module (PCM). Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, select IAT V PID (voltage) from PID/DATA monitor menu. If voltage is.13 volt or less, go to next step. If voltage is more than.13 volt, go to step 8).
6. 6) Induce Opposite Failure Observe scan tool and disconnect IAT sensor connector. If voltage is 4.59 volts or more, replace IAT sensor. If voltage is less than 4.59 volts, go to next step.
7. 7) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 39 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to ground in Gray/Yellow wire.
8. 8) Continuous Memory DTC P0112 Or P1113: Check Sensor These DTCs indicate possible intermittent fault. Possible causes for this fault are: Faulty sensor. Faulty sensor connector. Open or grounded circuit in harness. Faulty PCM. With scan tool connected, turn ignition on. Access IAT V PID (voltage) from PID/DATA monitor menu. While observing scan tool, tap on sensor to simulate road shock. Wiggle sensor connector. If no change in voltage occurs, go to next step. If any change in voltage occurs, replace IAT sensor.
9. 9) Check Wiring Harness While observing IAT V PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (voltage fluctuates), isolate fault and repair as necessary. If no fault is found, go to next step.
10. 10) Inspect PCM & Wiring Harness Connectors Turn ignition off. Disconnect PCM 104-pin connector and IAT connector. Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete.

TEST DB: ENGINE OIL TEMPERATURE (EOT) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

This test is intended to diagnose the following components and circuits

1. Engine Oil Temperature (EOT) sensor.
2. Wiring harness circuits (EOT and SIG RTN).
3. Powertrain Control Module (PCM).

Scheme 26

1. 1) DTC P0198 This DTC indicates sensor signal voltage is more than self-test maximum. Check for following possible causes: Faulty sensor. Faulty Harness Or Connector Faulty Powertrain Control Module (PCM). Disconnect EOT sensor connector. Sensor is located on top of engine near rear of generator. Measure resistance between ground and terminal No. 1 (Gray/Red wire) at EOT sensor wiring harness connector. (Scheme 26) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
2. 2) Induce Opposite Failure Turn ignition on. Connect a jumper wire between terminals at EOT sensor wiring harness connector. Check for DTCs. If DTC P0197 is not present, go to next step. If DTC P0197 is present, replace EOT sensor.
3. 3) Check Sensor Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 2 (Light Green/Red wire) at EOT sensor wiring harness connector and test pin No. 38 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Light Green/Red wire.
4. 4) DTC P0197 This DTC indicates sensor signal is less than self-test minimum. Possible causes for this fault are: Circuit grounded in wiring harness. Faulty sensor. Faulty harness connector. Faulty Powertrain Control Module (PCM). Disconnect EOT sensor connector. Sensor is located on top of engine near rear of generator. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). DTC If P0198 is not present, go to next step. If DTC P0198 is present, replace EOT sensor.
5. 5) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 38 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to ground in wiring harness.
6. 6) Continuous Memory DTC P0198 Or P0197 These DTCs indicate possible intermittent fault. Possible causes for this fault are: Faulty sensor. Faulty sensor connector. Open or grounded circuit in harness. Faulty PCM. With scan tool connected, turn ignition on. Access EOT PID from PID/DATA monitor menu. While observing scan tool, tap on sensor to simulate road shock. Wiggle sensor connector. If PID value does not change to 212°F (100°C), go to next step. If PID value changes to 212°F (100°C), go to step 9).
7. 7) Check Wiring Harness While observing EOT PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (PID value changes to 212°F (100°C), isolate fault and repair as necessary. If no fault is found, go to next step.
8. 8) Inspect PCM & Wiring Harness Connector Turn ignition off. Disconnect PCM 104-pin connector. Inspect connector for damaged pins, corrosion and loose wires. If connector and terminals are damaged, repair as necessary and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If connector and terminals are okay, fault cannot be duplicated at this time and testing is complete.
9. 9) Inspect EOT Sensor Connector Turn ignition off. Disconnect EOT sensor connector. Sensor is located on top of engine near rear of generator. Inspect connector for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If connector and terminals are okay, replace EOT sensor. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
10. 10) DTC P0196 Or P1184 These DTCs indicate engine oil temperature is not warm enough to perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Possible causes for this fault are: Engine not normal operating temperature. Low oil level. Faulty cooling system. Faulty EOT sensor. Faulty EOT sensor circuit. Verify no KOEO DTCs are present. Drive vehicle or operate engine until engine is at normal operating temperature. Perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P0196 or P1184 is present, go to next step. If DTC P0196 or P1184 is not present, repair other DTCs that are present. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
11. 11) Check EOT Sensor With scan tool connected, turn ignition on. Access EOT PID from PID/DATA monitor menu. While observing scan tool, tap on sensor to simulate road shock. Wiggle sensor connector. If PID value does not fluctuate or does not change to less than 165°F (74°C), go to next step. If PID value fluctuates or changes to less than 165°F (74°C), replace EOT sensor.
12. 12) Check Wiring Harness While observing EOT PID, wiggle and bend small sections of EOT sensor wiring harness working toward PCM. If fault is indicated (PID value fluctuates, isolate fault and repair as necessary. If no fault is found, go to next step.
13. 13) Inspect PCM & EOT Sensor Wiring Harness Connectors Turn ignition off. Disconnect PCM 104-pin connector and EOT sensor connector. EOT sensor is located on top of engine near rear of generator. Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete.

TEST DC: INJECTION CONTROL PRESSURE (ICP) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. ICP sensor's primary function is to provide a feedback signal to indicate fuel rail pressure. PCM uses this signal to correct injector timing and pulse width.

Scheme 27

1. 1) DTC P1280: Low ICP Circuit Input This DTC indicates injector control signal is out of self-test range (low). Possible causes for this fault are: Biased ICP sensor/PCM. Open ICP sensor circuit. Open VREF circuit. Shorted ICP sensor circuit. Faulty Powertrain Control Module (PCM). Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Turn ignition on. Measure voltage between ground and Brown/White wire (VREF circuit) at ICP sensor wiring harness connector. (Scheme 27) If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Brown/White wire.
2. 2) Check SIG RTN Circuit Measure voltage between Brown/White wire and Gray/Red wire at ICP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Gray/Red wire (SIG RTN circuit).
3. 3) Check ICP Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Dark Blue/Light Green wire between ICP wiring harness connector and test pin No. 87 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Dark Blue/Light Green wire.
4. 4) Check VREF Circuit Measure resistance of Brown/White wire between ICP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire.
5. 5) Check SIG RTN Circuit Measure resistance of Gray/Red wire between ICP sensor wiring harness connector and test pin No. 91 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
6. 6) Check For Short To Ground Measure resistance between test pin No. 87 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground in Dark Blue/Light Green wire.
7. 7) Check For Short Connect PCM connector to breakout box. Measure resistance between test pin No. 87 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace ICP sensor. If any reading is 10,000 ohms or less, replace PCM. Clear DTCs and repeat QUICK TEST.
8. 8) DTC P1281: High ICP Circuit Input This DTC indicates injector control signal is out of self-test range (high). Possible causes for this fault are: Biased ICP sensor/PCM. Shorted ICP sensor circuit. Faulty Powertrain Control Module (PCM). Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Turn ignition on. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1280 is present, replace ICP sensor. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1280 is not present, go to next step.
9. 9) Check For Short To Power Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground in Dark Blue/Light Green wire.
10. 10) Check For Short Connect PCM connector to breakout box. Measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10,000 ohms, replace ICP sensor. If any reading is 10,000 ohms or less, replace PCM.
11. 11) KOEO DTC P1210: These DTCs indicate injector control signal is greater than expected. Possible causes for this fault are: Biased ICP sensor. Shorted ICP sensor circuit. Open ICP SIG RTN circuit. Faulty Powertrain Control Module (PCM). Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Measure resistance between ground and Gray/Red wire at ICP sensor wiring harness connector. (Scheme 27) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair short to ground in Gray/Red wire.
12. 12) Check For Short To Power Turn ignition on. Measure voltage between ground and Dark Blue/Light Green wire at ICP sensor wiring harness connector. If voltage is less than.25 volt, go to next step. If voltage is.25 volt or more, locate and repair short to power in ICP signal circuit.
13. 13) Check ICP Sensor Turn ignition off. Reconnect ICP sensor connector. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, select ICP PID from PID/DATA monitor menu. If ICP PID reading indicates zero psi, replace PCM. If ICP PID reading does not indicate zero psi, replace ICP sensor.
14. 14) Continuous Memory DTC P1212 This DTC indicates that there was no ICP signal present during cranking. Possible causes for this fault are: Empty/low oil reservoir. Injection Pressure Regulator (IPR) circuit fault. Faulty IPR valve. Faulty ICP sensor. Faulty high pressure oil pump. If any KOEO DTCs are present, service DTCs as necessary before continuing with this test. If DTC P1212 is still present, go to next step. If no KOEO DTCs are present, go to next step.
15. 15) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If oil level is within 1" (25.4 mm), check fuel pressure. See FUEL PUMP PRESSURE TEST under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article. Repair as necessary. If fuel pressure is okay, check PID values while cranking engine. See CHECK PARAMETER IDENTIFICATION (PID) DURING CRANKING under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article. Repair as necessary. If PID values are okay, clear DTCs. Using scan tool, select ICP V PID from PID/DATA monitor menu. Crank engine for 5 seconds and observe scan tool. If ICP V PID voltage is.85 volt or more, fault is intermittent. Go to step 19). If ICP V PID voltage is less than.85 volt, go to next step.
16. 16) Check Injection Control Pressure (ICP) Sensor Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Attempt to start vehicle. If vehicle starts, replace ICP sensor and retest. If vehicle does not start, go to next step.
17. 17) Check Oil System Pressure Perform INJECTION CONTROL PRESSURE LEAK TEST and check for pressurized oil leaks. See HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article. Repair as necessary. If no leaks are found, go to next step.
18. 18) Check Injection Pressure Regulator (IPR) Valve Reconnect all hoses and ICP sensor connector. Replace IPR valve. Ensure oil reservoir level is full. Attempt to start vehicle. If vehicle starts, replacing IPR valve corrected fault. If vehicle does not start, replace high pressure oil pump.
19. 19) Check For Intermittent Faults Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, select ICP PID from PID/DATA monitor menu. While observing ICP PID, wiggle and bend small sections of wiring harness starting at ICP sensor and working toward PCM. If ICP PID reading fluctuates, isolate fault and repair as necessary. If ICP PID does not fluctuate, go to next step.
20. 20) Check Injection Pressure Regulator (IPR) Circuit Inspect wiring harness and connectors between IPR valve and PCM. Repair as necessary. If wiring harness and connectors are okay, no problem is indicated at this time.
21. 21) DTC P1284 This DTC indicates a ICP sensor circuit failure has occurred while performing KOER CYLINDER CONTRIBUTION SELF-TEST. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If a ICP circuit fault is indicated, go to appropriate system test and service DTC as necessary. If no ICP fault is indicated, replace PCM.
22. 22) Continuous Memory DTC P1210 This DTC indicates ICP signal voltage was too high during normal driving conditions. Possible causes for this fault are: Biased ICP sensor. Injection Control Pressure (ICP) circuit fault. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If any KOEO DTCs are present, service DTCs as necessary before continuing with this test. If DTC P1210 is still present, go to next step. If no DTCs are present, fault is intermittent. Go to next step.
23. 23) Check ICP Signal Ground Circuit Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Connect DVOM between test pin No. 91 at breakout box and Gray/Red wire at ICP sensor wiring harness connector. Set DVOM to ohms scale. While observing DVOM, wiggle and bend small sections of wiring harness starting at ICP sensor and working toward PCM. If resistance stays at less than 5 ohms, go to next step. If resistance changes to 5 ohms or more, isolate fault and repair as necessary.
24. 24) Check ICP Signal Circuit For Short To Power Measure voltage between ground and test pin No. 87 at breakout box. No voltage should be present. While observing DVOM, wiggle and bend small sections of wiring harness starting at ICP sensor and working toward PCM. If no voltage is present, go to next step. If any voltage is indicated, repair intermittent short to power and repair as necessary.
25. 25) Check ICP Sensor Circuit Turn ignition off. Reconnect ICP sensor connector. Remove breakout box and reconnect PCM 104-pin connector to PCM. Clear DTCs. Turn ignition on. Lightly tap on ICP sensor. Check for DTCs. If DTC P1210 is present, replace ICP sensor. If DTC P1210 is not present, fault cannot be duplicated at this time and testing is complete.

TEST DD: ACCELERATOR PEDAL (AP) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Note. AP sensor is not serviced separately. If AP sensor is defective, accelerator pedal assembly must be replaced.

Perform this test when directed by QUICK TEST. This test is intended to diagnose the following

1. AP sensor.
2. Wiring harness circuits (VREF, SIG RTN and AP).
3. Powertrain Control Module (PCM).

Scheme 28

Scheme 29

1. 1) DTC P0123 DTC P0123 indicates AP sensor circuit high input. Possible causes for this fault are: Damaged accelerator pedal assembly. AP sensor not installed properly. Faulty AP sensor. Short to power in wiring harness. Faulty Powertrain Control Module (PCM). With scan tool connected, turn ignition on. Access AP PID (voltage) from PID/DATA monitor menu. While observing scan tool, slowly depress accelerator pedal. If voltage reading changes to more than 4.5 volts, go to next step. If voltage reading does not change to more than 4.5 volts, fault cannot be duplicated at this time.
2. 2) Induce Opposite Failure Disconnect AP sensor connector. AP sensor is mounted above accelerator pedal. (Scheme 28) Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. If voltage reading changes from more than 4.5 volts to zero volts when connector is disconnected, circuit is okay. Replace accelerator pedal assembly. If voltage reading does not change from more than 4.5 volts to zero volts when connector is disconnected, go to next step.
3. 3) Check AP Sensor Signal Wire Turn ignition on. Measure voltage between ground and AP signal circuit terminal (Gray/White wire) at AP sensor wiring harness connector. (Scheme 29) If voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, replace PCM.
4. 4) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 89 at breakout box. If voltage is present, locate and repair short to power in Gray/White wire. If voltage is not present, replace PCM.
5. 5) DTC P0122 DTC P0122 indicates AP sensor circuit low input. Possible causes for this fault are: Damaged accelerator pedal assembly. AP sensor not installed properly. Faulty AP sensor. Grounded wiring harness. Faulty Powertrain Control Module (PCM). With scan tool connected, turn ignition on. Access AP PID (voltage) from PID/DATA monitor menu on scan tool. While observing scan tool, slowly depress accelerator pedal. If voltage reading changes to less than.37 volt, go to next step. If voltage reading does not change to less than.37 volt, fault cannot be duplicated at this time.
6. 6) Induce Opposite Failure Disconnect AP sensor connector. AP sensor is mounted above accelerator pedal. Connect a jumper wire between VREF circuit terminal (Brown/White wire) and AP sensor signal circuit terminal (Gray/White wire) at AP sensor wiring harness connector. If voltage reading changes from less than.37 volt to more than 4.5 volts with jumper connected, circuit is okay. Replace accelerator pedal assembly. If voltage reading does not change from less than.37 volt to more than 4.5 volts with jumper connected, go to next step.
7. 7) Check VREF Circuit Voltage Turn ignition on. Measure voltage between ground and VREF circuit terminal (Brown/White wire) at AP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open in VREF circuit.
8. 8) Check AP GND Circuit Turn ignition off. Measure resistance between ground and AP GND circuit terminal (Yellow/Black wire on Econoline or Yellow/White wire on Pickup) at AP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in AP GND circuit.
9. 9) Check AP Sensor Circuit Continuity Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between AP sensor signal circuit terminal (Gray/White wire) and test pin No. 89 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in AP signal circuit.
10. 100 Check For Short To Ground Turn ignition off. Ensure AP sensor is disconnected. Measure resistance between test pin No. 89 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If each reading is more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground in AP sensor signal circuit (Gray/White wire).
11. 11) Check VREF Circuit Continuity Measure resistance between VREF circuit terminal (Brown/White wire) at AP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in VREF circuit.
12. 12) Check AP GND Circuit Continuity Measure resistance between AP GND circuit terminal (Yellow/Black wire on Econoline or Yellow/White wire on Pickup) at AP sensor wiring harness connector and test pin No. 24 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open in AP GND circuit.

TEST DE: EXHAUST BACKPRESSURE (EBP) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Exhaust Backpressure (EBP) sensor.
2. Wiring harness circuits (SIG RTN, VREF and EBP Signal).
3. Powertrain Control Module (PCM).

Scheme 30

Scheme 31

Scheme 32

1. 1) DTC P0470 This DTC indicates PCM detected EBP sensor malfunction during KOEO ON-DEMAND SELF-TEST. Possible causes for this DTC are: Faulty EBP sensor. Open or shorted circuit. Faulty PCM. Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, select EBP PID from PID/DATA monitor menu. If EBP reading is less than 18.5 psi, clear DTCs. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC is still present, replace PCM. If EBP reading is 18.5 psi or more, go to next step.
2. 2) Check Signal Ground Circuit Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. Inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and Gray/Red wire at EBP sensor wiring harness connector. (Scheme 30) If resistance is less than 5 ohms, replace EBP sensor. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
3. 3) Continuous DTC P0470 This DTC indicates PCM detected a EBP sensor malfunction during normal driving conditions. Possible causes for this DTC are: Faulty EBP sensor. Faulty connection. Faulty PCM. Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, select EBP PID from PID/DATA monitor menu. While observing EBP PID, wiggle and bend small sections of wiring harness starting at EBP sensor connector and working toward PCM. If EBP reading fluctuates, isolate fault and repair as necessary. If reading does not fluctuate, go to next step.
4. 4) Check Connector Disconnect EBP sensor connector. Sensor is located on top front of engine. Disconnect PCM 104-pin connector. Inspect connectors for damaged pins, corrosion and loose wires. Repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If both connectors are okay, no problem is indicted at this time.
5. 5) DTC P0471 This DTC indicates PCM detected an EBP sensor malfunction during normal driving conditions and with EBP sensor enabled. Possible causes for this DTC are: Faulty EBP sensor. Plugged or restricted sensor supply tube. Damaged Exhaust Pressure Regulator (EPR) linkage or butterfly damage. Faulty PCM. Perform «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If any DTCs are present, repair fault(s) before continuing with this test. Using scan tool, select EBP PID from PID/DATA monitor menu. Road test vehicle performing hard accelerations while monitoring EBP PID. If EBP reading increases to more than 25 psi with EBP sensor on, no problem is indicated at this time. If EBP reading does not increase to more than 25 psi, go to next step.
6. 6) Check For Exhaust Leaks Inspect turbo pipe, crossover pipes and exhaust manifolds for leaks. Repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If no exhaust leaks are present, go to next step.
7. 7) Check Sensor Supply Tube Inspect EBP sensor supply tube from exhaust manifold to sensor bracket. Ensure tube is not restricted or plugged. Replace tube as necessary. If tube is okay, go to next step.
8. 8) Check EBP Sensor Disconnect EBP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between EBP sensor and sensor wiring harness connector. Start engine. Measure voltage between signal circuit and signal ground at ICP/EBP adapter cable. Briefly accelerate engine to Wide Open Throttle (WOT) several times. If voltage reading during acceleration is more than 1.35 volts, clear DTCs and retest. If DTC is still present, replace PCM. If voltage reading during acceleration is not more than 1.35 volts, replace EBP sensor.
9. 9) DTC P0472: EBP Circuit Low Input This DTC indicates EBP sensor circuit low input was detected during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. Possible causes for this DTC are: Biased sensor/PCM. Open or shorted EBP sensor circuit. EBP sensor circuit shorted. Faulty PCM. Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. Turn ignition on. Measure voltage between ground and Brown/White wire at EBP sensor wiring harness connector. (Scheme 30) If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Brown/White wire (VREF circuit).
10. 10) Check SIG RTN Circuit Measure resistance between ground and Gray/Red wire at EBP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
11. 11) Check EBP Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Purple/Light Blue wire at EBP sensor wiring harness connector and test pin No. 30 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Purple/Light Blue wire.
12. 12) Check VREF Circuit Measure resistance between Brown/White wire at EBP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire.
13. 13) Check For Grounded EBP Signal Circuit Measure resistance between test pin No. 30 and test pins No. 29, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is less than 10,000 ohms, locate and repair short to ground in EBP signal circuit (Purple/Light Blue wire).
14. 14) Check For Internal PCM Short Connect PCM connector to breakout box. Measure resistance between test pin No. 30 and test pins No. 29, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace EBP sensor. If any reading is 10,000 ohms or less, replace PCM.
15. 15) DTC P0473 This DTC indicates EBP sensor circuit high input was detected during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. Possible causes for this DTC are: Biased sensor/PCM. EBP sensor shorted to VREF circuit. Faulty PCM. Turn ignition on. Disconnect EBP sensor connector. Sensor is located on top of engine. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P0472 is present, replace EBP sensor. If DTC P0472 is not present, go to next step.
16. 16) Check For Short To Power Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 30 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to power in Purple/Light Blue wire.
17. 17) DTC P0478 This DTC indicates excessive backpressure existed during normal driving. Possible causes for this DTC are: Stuck butterfly. Plugged EBP sensor tube. Restricted exhaust. Misadjusted Exhaust Pressure Regulator (EPR) linkage. Faulty PCM. Visually inspect exhaust backpressure control valve (note tang position). (Scheme 31) If valve is in open position, go to next step. If valve is not in open position, repair damaged linkage or butterfly as necessary.
18. 18) Check For Exhaust Restriction Using scan tool, select EBP PID from PID/DATA monitor menu. Start engine. Briefly accelerate engine speed to Wide Open Throttle (WOT) while monitoring EBP PID. If EBP PID reading is less than 28 psi, go to next step. If EBP PID reading is 28 psi or more, repair restricted exhaust system.
19. 19) Check EBP System Ensure engine is cold and Engine Oil Temperature (EOT) is less than 70°F (21°C). Road test vehicle while monitoring EBP PID reading on scan tool. With EBP sensor on, if EBP reading stays at less than 50 psi, replace PCM. With EBP sensor on, if EBP reading does not stay at less than 50 psi, check and adjust turbocharger control rod as necessary. Spring scale reading should be 10 lbs. (4.5 kg). (Scheme 32)

TEST DF: CAMSHAFT POSITION (CMP) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Camshaft Position (CMP) sensor.
2. Wiring harness circuits (CMP GND, VREF and CMP Signal).
3. Powertrain Control Module (PCM).

Scheme 33

1. 1) DTC P0340, P0341 & P0344: Clear & Attempt To Regenerate DTC Ensure scan tool is connected to Data Link Connector (DLC). Clear continuous DTCs. Using scan tool, select RPM PID from PID/DATA monitor menu. Crank engine while monitoring RPM PID. If PID indicates cranking RPM, go to next step. If PID does not indicate cranking RPM, go to step 3).
2. 2) Check For DTC P0344 Or P0341 Start and run engine until coolant is at normal operating temperature. Raise engine speed to 3300 RPM for 2 minutes. Turn ignition off. Check for DTCs. If DTC P0344 or P0341 is present, go to next step. If DTC P0344 or P0341 is not present, fault is intermittent. Go to step 12).
3. 3) Check CMP Signal Turn ignition off. Disconnect CMP sensor connector. Measure resistance between ground and terminal "A" (Light Blue wire) at CMP sensor wiring harness connector. (Scheme 33) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, go to step 9).
4. 4) Check CMP Circuit No. 351 Turn ignition on. Measure voltage between ground and terminal "B" (Brown/White wire) at CMP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, VREF circuit is defective. Go to «TEST C»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-c-reference-voltage).
5. 5) Check CMP Circuit No. 795 Measure voltage between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, go to step 7).
6. 6) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If battery voltage is present, locate and repair short to power in Dark Green wire. Confirm repair by repeating steps 1) and 2). If battery voltage is not present, replace CMP sensor.
7. 7) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Dark Green wire. Confirm repair by repeating steps 1) and 2). If resistance is 5 ohms or more, go to next step.
8. 8) Check For Open Circuit Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Dark Green wire between CMP sensor wiring harness connector and test pin No. 21 at breakout box. If resistance is less than 5 ohms, an open circuit exists at PCM terminal No. 21. Inspect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all components and go to step 11). If resistance is 5 ohms or more, locate and repair open circuit in Dark Green wire. Confirm repair by repeating steps 1) and 2).
9. 9) Check For Open In CMP Sensor Ground Circuit Turn ignition off. Ensure CMP sensor is disconnected. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Light Blue wire between CMP sensor wiring harness connector and test pin No. 65 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue wire. Confirm repair by repeating steps 1) and 2).
10. 10) Check For CMP Sensor Ground Through PCM Connect PCM to breakout box. Measure resistance between ground and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are less than 5 ohms, PCM internal ground is not supplied to terminal No. 65. Reconnect all components and go to next step. If any reading is 5 ohms or more, locate and repair open in ground circuit. Confirm repair by repeating steps 1) and 2).
11. 11) Confirm PCM Fault Repeat steps 1) and 2). If fault is still present, replace PCM. If fault is not present, no problem is indicated at this time. Testing is complete.
12. 12) Check For Intermittent Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM. To prevent vehicle from starting, disconnect Injector Driver Module (IDM) relay. Relay is located in power distribution box in engine compartment. Connect DVOM between test pin No. 65 and test pin No. 21 at breakout box. Rotate crankshaft (by hand) until voltage toggles from battery voltage to.3-2.7 volts. If lower voltage reading is.3-2.7 volts, go to next step. If lower voltage reading is not.3-2.7 volts, go to step 3).
13. 13) Check Wiring Harness With DVOM still connected between test pins No. 21 and 65, rotate crankshaft (by hand) until voltage stays at.3-2.7 volts. While observing DVOM, wiggle wiring harness. If a fault occurs, voltage reading will jump to battery voltage or zero volts. If fault occurs, locate and repair intermittent in wiring harness. Confirm repair by repeating steps 1) and 2). If no fault occurs, no problem is indicated at this time.

TEST DG: BAROMETRIC PRESSURE (BARO) SENSOR (1999 MODELS)

Note. On 1999 models, BARO sensor is located behind left side of instrument panel (Econoline) or below instrument panel, at base of steering column (Pickup). On 1999 1/2 models. BARO sensor is part of Powertrain Control Module (PCM). For testing procedures on 1999 1/2 models, go to TEST DG: BAROMETRIC PRESSURE (BARO) SENSOR (1999 1/2 MODELS) .

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. A BARO sensor that is detected out of range (high or low) by PCM will cause the PCM to ignore BARO sensor signal and use Manifold Absolute Pressure (MAP) sensor signal as an indication of barometric pressure. BARO sensor is located behind left side of instrument panel (Econoline) or below instrument panel, at base of steering column (Pickup).

1. 1) DTC P0107: BARO Circuit Low Input This DTC indicates BARO sensor circuit low input was detected during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. Possible causes for this DTC are: Biased BARO sensor/PCM. Open BARO or VREF sensor circuit. Shorted SIG RTN or PWR GND circuit. Faulty PCM. Turn ignition off. Disconnect BARO sensor connector. Sensor is located behind left side of instrument panel (Econoline) or below instrument panel, at base of steering column (Pickup). Turn ignition on. Measure voltage between ground and Brown/White wire at BARO sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Brown/White wire.
2. 2) Check SIG RTN Circuit Measure voltage between Gray/Red wire and Brown/White wire at BARO sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Gray/Red wire.
3. 3) Check BARO Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Dark Blue/Light Green wire between BARO sensor wiring harness connector and test pin No. 63 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Dark Blue/Light Green wire.
4. 4) Check VREF Circuit Measure resistance of Brown/White wire between BARO sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire.
5. 5) Check SIG RTN Circuit Measure resistance of Gray/Red wire between BARO sensor wiring harness connector and test pin No. 91 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
6. 6) Check For Grounded Signal Circuit Measure resistance between test pin No. 63 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground in Dark Blue/Light Green wire (BARO signal circuit).
7. 7) Check For Grounded Signal Circuit Connect PCM connector to breakout box. Measure resistance between test pin No. 63 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace BARO sensor. If any reading is 10,000 ohms or less, replace PCM.
8. 8) DTC P0108 This DTC indicates BARO sensor circuit high input was detected during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. Possible causes for this fault are: Biased BARO sensor/PCM. BARO sensor circuit shorted to VREF circuit. Faulty PCM. Turn ignition on. Disconnect BARO sensor connector. Sensor is located behind left side of instrument panel (Econoline) or below instrument panel, at base of steering column (Pickup). Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0107 is present, replace BARO sensor. If DTC P0107 is not present, go to next step.
9. 9) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 63 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to power in Dark Blue/Light Green wire.

TEST DG: BAROMETRIC PRESSURE (BARO) SENSOR (1999 1/2 MODELS)

Note. On 1999 1/2 models, BARO sensor is part of Powertrain Control Module (PCM). On 1999 models, BARO sensor is located behind left side of instrument panel (Econoline) or below instrument panel, at base of steering column (Pickup). For testing procedures on 1999 models, go to TEST DG: BAROMETRIC PRESSURE (BARO) SENSOR (1999 MODELS) .

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. A BARO sensor that is detected out of range (high or low) by PCM will cause the PCM to ignore BARO sensor signal and use Manifold Absolute Pressure (MAP) sensor signal as an indication of barometric pressure. BARO sensor is part of PCM and is not serviced separately. If BARO sensor is faulty, PCM must be replaced.

1. 1) KOEO DTC P0107: BARO Circuit Low Input This DTC indicates BARO sensor circuit low input was detected during KOEO ON-DEMAND SELF-TEST. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0107 is present, BARO sensor is defective. Replace PCM. If DTC P0107 is not present, fault is intermittent. If DTC P0107 reappears, replace PCM.
2. 2) KOEO DTC P0108 This DTC indicates BARO sensor circuit high input was detected during KOEO ON-DEMAND SELF-TEST. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0108 is present, BARO sensor is defective. Replace PCM. If DTC P0108 is not present, fault is intermittent. If DTC P0108 reappears, replace PCM.
3. 3) Continuous Memory DTC P0107: BARO Circuit Low Input This DTC indicates BARO sensor circuit low input was detected during normal operation. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0107 is present, BARO sensor is defective. Replace PCM. If DTC P0107 is not present, fault is intermittent. If DTC P0107 reappears, replace PCM.
4. 4) Continuous Memory DTC P0108 This DTC indicates BARO sensor circuit high input was detected during normal operation. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0108 is present, BARO sensor is defective. Replace PCM. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0108 is not present, fault is intermittent. If DTC P0108 resets, replace PCM.

TEST DH: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose the following

1. MAP sensor.
2. Wiring harness circuits (VREF, SIG RTN and MAP SIG). (Scheme 34)
3. Powertrain Control Module (PCM).

Scheme 34

1. 1) DTC P0236, P1247 Or P1248 DTC P0236 indicates faulty turbo boost sensor circuit performance. DTCs P1247 and P1248 indicate turbo boost pressure is low or not detected. Possible causes for these faults are: Damaged MAP sensor hose. Faulty MAP sensor. Low turbo boost. Intake manifold or crossover leaks. Faulty PCM. Inspect MAP sensor hose and manifolds for damage, misrouting or restriction. Replace hose and manifolds as necessary. If hose and manifolds are okay, go to next step. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 1) to step 3). No test procedures have been omitted.
2. 3) Sensor Voltage Check Disconnect MAP sensor connector. MAP sensor is mounted on firewall. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect DVOM to MAP sensor. Set DVOM to voltage scale. Disconnect vacuum hose from MAP sensor. Turn ignition on. Using Pressure Adapter (014-00761), apply 10 psi to MAP sensor. If voltage is 2.5-3.1 volts, go to next step. If voltage is not 2.5-3.1 volts, replace MAP sensor.
3. 4) MAP Sensor Performance Test Reconnect vacuum hose to MAP sensor. Disconnect MAP sensor vacuum hose from intake manifold. Install a pressure (boost) gauge to intake manifold. Road test vehicle and accelerate vehicle to achieve full boost. If boost is 12 psi or more, clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC resets, replace PCM. If boost is less than 12 psi, inspect intake manifolds and crossover tubes for leaks. Check turbo condition. Repair as necessary.
4. 5) KOEO DTC P0237 DTC P0237 indicates low input to turbo boost sensor. Possible causes for this fault are: Faulty MAP sensor. Open or shorted wiring harness circuits. Faulty PCM. Turn ignition off. Disconnect MAP sensor connector. Turn ignition on. Measure voltage between ground and Brown/White wire at MAP sensor wiring harness connector. (Scheme 34) If voltage is about 5 volts, go to next step. If voltage is not about 5 volts, repair Brown/White wire.
5. 6) Check SIG RTN Circuit Turn ignition off. Measure resistance between ground and Gray/Red wire at MAP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Gray/Red wire.
6. 7) Check MAP Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 79 at breakout box and Light Green/Black wire at MAP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Light Green/Black wire.
7. 8) Check For Short To Ground Measure resistance between test pin No. 79 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is less than 10,000 ohms, locate and repair short to ground in Light Green/Black wire.
8. 9) Check For Short To Power Measure resistance between test pins No. 79 and 90 at breakout box. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, repair short to power in Light Green/Black wire.
9. 10) Check PCM Connect PCM to breakout box. Turn ignition on. Measure voltage between ground and Light Green/Black wire at MAP sensor wiring harness connector. If voltage is 4.5-5.5 volts, replace MAP sensor. If voltage is not 4.5-5.5 volts, replace PCM.
10. 11) KOEO DTC P0238 DTC P0238 indicates high input in turbo boost sensor circuit. Possible causes for this fault are: Faulty MAP sensor. Short to power in MAP signal circuit. Faulty PCM. Disconnect MAP sensor connector. Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P0238 is present, go to next step. If DTC P0238 is not present, replace MAP sensor.
11. 12) Check MAP Sensor Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 79 and test pins No. 55, 71, 91 and 97 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is less than 10,000 ohms, locate and repair short to power in Light Green/Black wire.
12. 13) Continuous DTC P0237 Continuous DTC P0237 indicates low input to turbo boost sensor. Possible causes for this fault are: Faulty MAP sensor. Open or shorted wiring harness circuits. Faulty PCM. Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P0237 is present, go to step 5). If DTC P0237 is not present, go to next step.
13. 14) Check For Intermittent Fault Clear DTCs. Wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. Retrieve DTCs. If Continuous DTC P0237 is present, locate and repair intermittent circuit fault in wiring harness. If Continuous DTC P0237 is not present, fault cannot be duplicated at this time and testing is complete.
14. 15) Continuous DTC P0238 Continuous DTC P0238 indicates high input to turbo boost sensor during normal driving conditions. Possible cause for this fault is: Open or shorted wiring harness circuits. Clear DTCs. Wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. Retrieve DTCs. If Continuous DTC P0238 is present, locate and repair intermittent circuit fault in wiring harness. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If Continuous DTC P0238 is not present, fault cannot be duplicated at this time and testing is complete.

TEST DI: MANIFOLD AIR TEMPERATURE (MAT) SENSOR (PICKUP)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose the following

1. MAT sensor.
2. Wiring harness circuits (VREF, SIG RTN and MAT SIG). (Scheme 34)
3. Powertrain Control Module (PCM).

1. 1) DTC P1119 DTC P1119 indicates that MAT sensor signal voltage is more than self-test maximum. Possible causes for these faults are: Open circuit in wiring harness. Faulty MAT sensor. Faulty PCM. Disconnect MAT sensor connector. MAT sensor is located at center front of engine. Measure resistance between ground and Gray/Red wire at MAT sensor wiring harness connector. If resistance is less than 5 ohms, go to step 2) . If resistance is 5 ohms or more, repair open circuit in Gray/Red wire. If hose and manifolds are okay, go to next step.
2. 2) Induce Opposite Failure Turn ignition on. Connect a jumper wire between MAT sensor wiring harness connector terminals. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P1118 is not present, go to next step. If DTC P1118 is present, replace MAT sensor.
3. 3) Check MAT Signal Circuit Continuity Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 62 at breakout box and Red/Yellow wire at MAT sensor wiring harness connector. If resistance is less than 5 ohms, go to step 6) . If resistance is 5 ohms or more, repair open circuit in Red/Yellow wire.
4. 4) DTC P1118: Induce Opposite Failure DTC P1118 indicates that MAT sensor signal voltage is less than self-test maximum. Possible causes for these faults are: Grounded circuit in wiring harness. Faulty MAT sensor. Faulty PCM. Disconnect MAT sensor connector. MAT sensor is located at center front of engine. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P1119 is not present, go to next step. If DTC P1119 is present, replace MAT sensor.
5. 5) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 62 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10,000 ohms, replace PCM. If any reading is 10,000 ohms or less, locate and repair short to ground.
6. 6) Check For Open SIG RTN Circuit Measure resistance of Gray/Red wire between MAT sensor wiring harness connector and test pin No. 91 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Red/Gray wire.

TEST DJ: WATER IN FUEL (WIF) SENSOR

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Note. WIF sensor may also be referred to as fuel line heater

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. WIF sensor output to PCM.
2. WIF sensor wiring harness circuits.
3. Powertrain Control Module (PCM).

1. 1) Continuous DTC P1140 DTC P1140 indicates PCM detected water in the fuel filter housing or a short to ground in the monitoring circuit. Possible causes for this DTC are: Water in fuel filter housing. Short to ground in wiring harness circuit. Faulty WIF sensor. Faulty PCM. Using a spare piece of hose, connect one end of hose to water drain tube at bottom of fuel filter. Place remaining end of hose into a suitable one quart container. Start engine. Open drain valve at bottom of fuel filter housing. Fill container with fuel and close drain valve. Check fuel in container. If water or other contaminants are not present, go to next step. If water or other contaminants are present, clear DTCs. Start engine and recheck for DTCs. If WIF indicator light turns on and DTC P1140 resets, repeat this test step. If water or other contaminants are still present, flush and clean fuel tank and fuel system.
2. 2) Check For Short To Ground In WIF Signal Circuit Turn ignition on. Disconnect WIF sensor connector. WIF sensor is located on top left center of engine. Clear DTCs. Cycle ignition switch. Retrieve DTCs. If DTC P1140 is present, go to next step. If P1140 is not present, go to step 4) .
3. 3) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and Gray/Red wire at WIF sensor wiring harness connector. If resistance is more than 10,000 ohms, replace PCM. If resistance is 10,000 ohms or less, repair short to ground in Gray/Red wire.
4. 4) Check WIF Sensor Remove fuel filter. Visually inspect inside of filter housing for debris. If any debris is present, clean filter housing. Remove WIF sensor. Clean and reinstall sensor. Clear DTCs and retest. If no debris is present, replace WIF sensor. Clear DTCs and retest.

TEST DK: WATER IN FUEL INDICATOR LIGHT

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. WIFIL circuit to PCM.
2. Power circuit to water in fuel indicator light.
3. Powertrain Control Module (PCM).

Scheme 35

Scheme 36

1. 1) DTC P1139 DTC P1139 indicates PCM detected a WIF indicator light circuit failure. Possible causes for this DTC are: Open or shorted wiring harness circuits. Faulty PCM. Turn ignition on and observe water in fuel indicator light. If water in fuel indicator light turns on for about 2 seconds then turns off, clear DTCs and retest. If P1139 resets, check for an intermittent open or short circuit in Red wire between PCM and water in fuel indicator light. Repair as necessary. If water in fuel indicator light does not turn on for about 2 seconds then turn off, go to next step.
2. 2) State Of Indicator Light Turn ignition off. If water in fuel indicator light stayed on in step 1), go to next step. If water in fuel indicator light did not stay on in step 1), go to step 4).
3. 3) Check For Short To Ground Disconnect PCM 104-pin connector. Turn ignition on. If water in fuel indicator light is on, repair short to ground in WIFIL circuit (Red wire) between PCM and water in fuel indicator light. If water in fuel indicator light is off, replace PCM.
4. 4) Check Fuse On Econoline, check fuse No. 2 (15-amp) at instrument panel fuse block. On Pickup, check fuse No. 19 (10-amp) at instrument panel fuse block. On all models, if fuse is okay, go to next step. If fuse is blown, check for cause of blown fuse. Repair as necessary. Replace fuse.
5. 5) Check Power To Instrument Cluster Turn ignition off. Disconnect instrument cluster connectors. Turn ignition on. Measure voltage between ground and terminal No. 12 (Red/Yellow wire) at instrument cluster White 12-pin connector. (Scheme 35)or (Scheme 36). If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open circuit in Red/Yellow wire between instrument cluster and fuse block.
6. 6) Check For Open Circuit Install Breakout Box (014-00950), leaving PCM disconnected. On Econoline, measure resistance between terminal No. 12 (Red/Yellow wire) at instrument cluster White 12-pin connector and test pin No. 28 at breakout box. On Pickup, measure resistance between terminal No. 11 at instrument cluster 12-pin connector. On all models, if resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Red wire between instrument cluster connector and PCM connector.

TEST DL: VEHICLE SPEED SENSOR (ECONOLINE)

Note. Speed signal for Pickups is provided by the ABS Control Module.

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose the following.

1. Vehicle Speed Sensor (VSS)
2. VSS (+) and VSS (-) Wiring Harness Circuits
3. Powertrain Control Module (PCM)

1. 1) DTC P0500 DTC P0500 indicates PCM detected a VSS circuit failure. The following are possible causes for this fault. Open Or Shorted Wiring Harness Circuits Faulty VSS Faulty PCM Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect VSS connector located on left side of transmission. Measure resistance between Gray/Black wire at VSS harness connector and test pin No. 58 at breakout box. Measure resistance between Pink/Orange wire at VSS harness connector and test pin No. 33 at breakout box. If both readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, repair open in Gray/Black wire or Pink/Orange wire between VSS and PCM.
2. 2) Check Short To Ground, SIG RTN & Power Measure resistance between test pin No. 58 and test pins No. 33, 51, 71, 76, 77, 91 and 103 at breakout box. Also measure resistance between test pins No. 33 and 71 at breakout box. If all readings are more than 500 ohms, go to next step. If any reading is 500 ohms or less, repair short to ground in SIG RTN or VPWR circuit as necessary. See WIRING DIAGRAMS article.
3. 3) Check VSS Resistance Measure resistance between VSS terminals. If resistance is not 190-250 ohms, replace VSS. If resistance is 190-270 ohms, replace PCM. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 3) to step 10). No test procedures have been omitted.
4. 10) KOER DTC P1501: Check PCM VSS PID For Input Signal This DTC indicates VSS input signal is out of self-test range. A DTC P1501 will be set and self-test will abort whenever PCM detects VSS input signal during KOER ON-DEMAND SELF-TEST. A noisy VSS input signal from Radio Frequency Interference (RFI) Or Electromagnetic Interference (EMI) external source (ignition wires, charging circuits, etc.) are possible causes for this fault. Connect scan tool to Data Link Connector (DLC). Start engine and allow to idle. Using scan tool, select VSS PID from PID/DATA MONITOR & RECORD menu and observe vehicle speed input to PCM. While observing VSS PID, increase engine speed to 2000 RPM and return to idle several times. If VSS PID measurement is 3 MPH or more, go to step 13) . If VSS PID value is less than 3 MPH, fault cannot be duplicated at this time. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
5. 11) Continuous Memory DTC P0503: Check For Intermittent Fault This DTC indicates poor or noisy VSS performance. Possible causes for this fault are as follows. Noisy Vehicle Speed Sensor (VSS) Input Signal From RFI Or EMI External Source (Ignition Wires, Charging Circuits Etc.) Faulty VSS Or Driven Gears Faulty Wiring Harness Or Connectors Turn ignition switch to OFF position. Disconnect VSS connector located on left side of transmission. Visually inspect VSS and VSS circuits for potential faults as follows. Loose VSS Circuit Connectors Loose VSS Circuit Connector Terminals Damaged VSS Wiring Harness Insulation Incorrect VSS Circuit Routing Incorrect VSS Installation If no faults are found, go to next step. If any faults are found, repair as necessary.
6. 12) Check PCM VSS PID For Input Signal Using scan tool, select VSS PID. Test drive vehicle at several steady speeds at more and less than 30 MPH. NOTE: On scan tools with Data Record feature, record data for playback to help identify variations. During each steady speed, check for VSS PID variations of plus (+) or minus (-) 5 MPH for 10 seconds or more. If any variations occur, go to next step. If variations do not occur, fault cannot be duplicated at this time. Testing is complete.
7. 13) Check VSS Wiring Harness Routing Visually inspect VSS wiring harness. Ensure wiring is not routed near ignition wires or alternator wires. Verify VSS wiring harness is shielded and grounded (if applicable). Repeat step 1) to check VSS circuits. If faults are found, repair wiring as necessary. If no faults are found, fault cannot be duplicated at this time.

TEST FA: AIR CONDITIONING

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. A/C wiring harness circuits. (Scheme 37)or (Scheme 38).
2. A/C clutch.
3. Powertrain Control Module (PCM).

Scheme 37

Scheme 38

1. 1) DTC P1464 DTC P1464 indicates A/C was on during KOER CYLINDER CONTRIBUTION SELF-TEST. Clear DTCs. Turn A/C heater control switch off. Perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Retrieve DTCs. If DTC P1464 is present, go to next step. If P1464 is not present, fault may be intermittent. Go to step 4).
2. 2) Check For Short To Power Turn ignition on. Turn A/C heater control switch off. Disconnect A/C clutch connector. Measure voltage between ground and Black/Yellow wire (Econoline) or Tan/Light Green wire (Pickup) at A/C clutch wiring harness connector. (Scheme 37)or (Scheme 38). If battery voltage is present, repair short to power in Black/Yellow wire (Econoline) or Tan/Light Green wire (Pickup). If battery voltage is not present, go to next step.
3. 3) Check For Short To Power Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 41 at breakout box. If battery voltage is present, locate and repair short to power in Black/Yellow wire (Econoline) or Tan/Light Green wire (Pickup). If battery voltage is not present, no problem is indicted at this time. Testing is complete.
4. 4) Check For Intermittent Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 41 at breakout box. Wiggle and bend small sections of wiring harness starting at A/C low pressure switch and working toward PCM. If fault is indicated (voltage present), isolate fault and repair as necessary. If no fault is found, no problem is indicated at this time. Testing is complete.

TEST FB: BRAKE PRESSURE APPLIED (BPA) SWITCH

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. Brake Pressure Applied (BPA) switch is a pressure switch that senses brake pressure and is redundant with the Brake On/Off (BOO) switch to provide a back-up to deactivate cruise control.

Scheme 39

1. 1) DTC P0571: Check BPA Parameter Identification (PID) Using scan tool, select BPA PID from PID/DATA monitor menu. Note PBA PID reading. While observing BPA PID reading, firmly depress then release brake pedal. If BPA PID reading indicates ON only, go to next step. If BPA PID reading does not indicate ON only, go to step 5).
2. 2) Check BPA Switch Turn ignition off. Disconnect BPA switch. If BPA PID switches to OFF, replace BPA switch. Reconnect all connectors and recheck BPA PID. If BPA PID does not switch to OFF, go to next step (Pickup) or step 4) (Econoline).
3. 3) Check For Short To Power (Pickup) Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Black/Yellow wire at BPA switch wiring harness connector. (Scheme 39) If battery voltage is present, locate and repair short to power in Black/Yellow wire. If battery voltage is not present, inspect PCM terminal No. 31 for damaged pin, corrosion and loose wire. Repair as necessary. Reconnect all connectors and go to step 11).
4. 4) Check For Short To Power (Econoline) Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Red/Light Green wire at BPA switch wiring harness connector. If battery voltage is present, locate and repair short to power in Red/Light Green wire. Reconnect all connectors and recheck BPA PID. If battery voltage is not present, replace PCM.
5. 5) Check BPA PID Using scan tool observe BPA PID reading. Depress and release brake pedal. If BPA PID reading indicates OFF only, go to next step (Pickup) or step 7) (Econoline). If BPA PID reading does not indicate OFF only, fault may be intermittent. Go to step 14).
6. 6) Check Fuse (Pickup) Remove and inspect fuse No. 5 (15-amp) from instrument panel fuse block. If fuse is blown, replace fuse. If fuse blows again, go to step 8). If fuse is okay, go to step 10).
7. 7) Check Fuse (Econoline) Remove and inspect fuse No. 1 (15-amp) from instrument panel fuse block. If fuse is blown, replace fuse. If fuse blows again, go to step 19). If fuse is okay, go to step 16).
8. 8) Check For Short To Ground (Pickup) Ensure BPA switch is disconnected. Measure resistance between ground and Purple/Orange wire at BPA switch wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Purple/Orange wire.
9. 9) Check For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Black/Yellow wire at BPA switch wiring harness connector. If resistance is more than 10,000 ohms, go to step 21). If resistance is 10,000 ohms or less, locate and repair short to ground in Black/Yellow wire.
10. 10) Check BPA Switch (Pickup) Turn ignition on. Ensure BPA switch is disconnected. Connect a jumper wire between Black/Yellow wire and Purple/Orange wire at BPA switch wiring harness connector. Using scan tool, check BPA PID reading. If BPA PID reading indicates ON, replace BPA switch. If BPA PID reading does not indicate ON, go to next step.
11. 11) Check For Open In Circuit No. 298 Turn ignition off. Measure resistance of Purple/Orange wire between BPA switch wiring harness connector and No. 5 fuse holder. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Purple/Orange wire.
12. 12) Check For Open In Circuit No. 307 Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Black/Yellow wire at BPA switch wiring harness connector and test pin No. 31 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black/Yellow wire.
13. 13) Confirm PCM Fault Turn ignition on. Using scan tool, select BPA PID from PID/DATA monitor menu. While observing BPA PID reading, depress and release brake pedal. If BPA PID switches from ON to OFF, no problem is indicated at this time. If BPA PID does not switch from ON to OFF, replace PCM. Reconnect all connectors and recheck BPA PID.
14. 14) Check For Intermittent Open Or Short Ensure BPA switch is disconnected. Turn ignition on. On Econoline, connect a jumper wire between Red/Light Green wire and Light Green/Red wire at BPA switch wiring harness connector. On Pickup, connect a jumper wire between Black/Yellow wire and Purple/Orange wire at BPA switch wiring harness connector. On all models, using scan tool, select BPA PID from PID/DATA monitor menu. BPA PID reading should indicate ON. While observing BPA PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (BPA PID switches to OFF), isolate fault and repair as necessary. If no fault is indicated, go to next step.
15. 15) Check For Intermittent Short To Power Ensure jumper wire is still connected. Remove fuse No. 1 (Econoline) or fuse No. 5 (Pickup) at instrument panel fuse block. Turn ignition on. Using scan tool, select BPA PID from PID/DATA monitor menu. BPA PID should indicate OFF. While observing BPA PID reading, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (BPA PID switches to ON), isolate fault and repair as necessary. If no fault is indicated, no problem is indicated at this time.
16. 16) Check For Open In Circuit No. 10 (Econoline) Turn ignition off. Measure resistance of Light Green/Red wire between BPA switch wiring harness connector and No. 1 fuse holder. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Green/Red wire.
17. 17) Check For Open BPA Switch Reinstall fuse No. 1. Ensure BPA switch is disconnected. Turn ignition on. Connect a jumper wire between Red/Light Green wire and Light Green/Red wire at BPA switch wiring harness connector. Using scan tool, select BPA PID from PID/DATA monitor menu. If BPA PID reading indicates ON, replace BPA switch and retest. If BPA PID reading does not indicate ON, go to next step.
18. 18) Check For Open In Circuit No. 810 Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Red/Light Green wire between BPA switch wiring harness connector and test pin No. 31 at breakout box. If resistance is less than 5 ohms, replace PCM and retest. If resistance is 5 ohms or more, locate and repair open circuit in Red/Light Green wire and retest.
19. 19) Check Circuit No. 10 For Short To Ground Remove fuse No. 1 at instrument panel fuse block. Measure resistance between ground and Light Green/Red wire at BPA switch wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Light Green/Red wire. Replace fuse and retest.
20. 20) Check Circuit No. 810 For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Red/Light Green wire at BPA switch wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Red/Light Green wire. Replace fuse and retest.
21. 21) Check PCM For Internal Short Connect PCM connector to breakout box. Measure resistance between test pin No. 31 and test pins No. 25, 76, 77 and 103 at breakout box. If all readings are more than 10,000 ohms, no problem is indicated at this time. If any reading is 10,000 ohms or less, replace PCM. Reinstall fuse and retest.

TEST FC: CLUTCH PEDAL POSITION (CPP) SWITCH (PICKUP)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Clutch Pedal Position (CPP) switch.
2. Wiring harness circuits (CPP and SIG RTN).
3. Powertrain Control Module (PCM).

Scheme 40

1. 1) DTC P0704: Check CPP Parameter Identification (PID) Using scan tool, select CPP PID from PID/DATA monitor menu. With clutch pedal released, observe CPP PID reading. If CPP PID reading indicates ON only, go to next step. If CPP PID reading does not indicate ON only, go to step 4).
2. 2) Check CPP Switch Turn ignition on. Disconnect CPP switch. If CPP PID reading switches to OFF, replace CPP switch. Reconnect all connectors, clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If CPP PID reading does not switch to OFF, go to next step.
3. 3) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Tan/Light Blue wire at CPP switch wiring harness connector. (Scheme 40) If battery voltage is present, locate and repair short to power in Tan/Light Blue wire. If battery voltage is not present, inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 11).
4. 4) Check CPP PID Depress clutch pedal to floor. Check CPP PID reading. If CPP PID reading indicates OFF only, go to next step. If CPP PID reading does not indicate OFF only, fault may be intermittent. Go to step 12).
5. 5) Check Fuse No. 19 Remove and inspect fuse No. 19 from instrument panel fuse block. If fuse is blown, go to next step. If fuse is okay, go to step 8).
6. 6) Check For Short To Ground Disconnect CPP switch connected. Measure resistance between ground and Red/Yellow wire at CPP switch wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Red/Yellow wire. If resistance is 5 ohms or more, go to next step.
7. 7) Check For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Tan/Light Blue wire at CPP switch wiring harness connector. If resistance is less than 10,000 ohms, locate and repair short to ground in Tan/Light Blue wire. If resistance is 10,000 ohms or more, inspect terminal No. 29 at PCM connector for damaged pins, corrosion and loose wires. Repair as necessary and go to step 11).
8. 8) Check For Open Circuit Ensure ignition is off and CPP switch is disconnected. Measure resistance of Red/Yellow wire between output side of No. 19 fuse holder and CPP switch wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red/Yellow wire.
9. 9) Check CPP Switch Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and Red/Yellow wire at CPP switch wiring harness connector. Check CPP PID reading. If CPP PID reading indicates ON, replace CPP switch. If CPP PID reading indicates OFF, go to next step.
10. 10) Check Circuit No. 306 Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Tan/Light Blue wire at CPP switch wiring harness connector and test pin No. 29 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Tan/Light Blue wire.
11. 11) Confirm PCM Fault Turn ignition on. Using scan tool, select CPP PID from PID/DATA monitor menu. While observing CPP PID reading, depress and release clutch pedal. If CPP PID switches from ON to OFF, no problem is indicated at this time. If CPP PID does not switch from ON to OFF, replace PCM. Recheck CPP PID.
12. 12) Check For Intermittent Ensure CPP switch is disconnected. Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and Red/Yellow wire at CPP switch wiring harness connector. Using scan tool, select CPP PID from PID/DATA monitor menu. CPP PID should indicate ON. While observing CPP PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (CPP PID switches to OFF), isolate fault and repair as necessary. If no fault is indicated, go to next step.
13. 13) Check For Intermittent Short To Power Ensure CPP switch is disconnected. Remove fuse No. 19 from instrument panel fuse block. Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and Red/Yellow wire at CPP switch wiring harness connector. Using scan tool, select CPP PID from PID/DATA monitor menu. CPP PID reading should indicate OFF. While observing CPP PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (CPP PID switches to ON), isolate fault and repair as necessary. If no fault is indicated, no problem is indicated at this time.

TEST FD: BRAKE PEDAL POSITION (BPP) SWITCH

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Note. BPP switch may also be referred to as Brake On/Off (BOO) switch.

Perform this test when directed by QUICK TEST. This test is intended to diagnose a faulty BPP switch circuit or PCM. To prevent replacement of good components, be aware following non-EEC related areas may be at fault

1. Wiring harness circuit (BPP).
2. Powertrain Control Module (PCM).

Scheme 41

Scheme 42

1. 1) DTC P0703: Check BPP PID Using scan tool, select BPP PID from PID/DATA monitor menu. Turn ignition on. While observing PID, firmly depress and release brake pedal. If PID reading indicates ON only, go to next step. If PID reading does not indicate ON only, go to step 4).
2. 2) Check BPP Switch Turn ignition on. Disconnect BPP switch connector. Switch is located at top of brake pedal. If BPP PID reading switched to OFF, replace BPP switch. If BPP PID reading did not switch to OFF, go to next step.
3. 3) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Light Green wire (Econoline) or Red/Light Green wire (Pickup) at BPP switch wiring harness connector. (Scheme 41)or (Scheme 42). If battery voltage is present, locate and repair short to power in Light Green wire (Econoline) or Red/Light Green wire (Pickup). If battery voltage is not present, inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 12).
4. 4) Check BPP PID If BPP PID reading indicates OFF only, go to next step (Pickup) or step 6) (Econoline). If BPP PID reading does not indicate OFF only, fault is intermittent. Go to step 13).
5. 5) Check Fuse No. 15 (Pickup) Remove and inspect fuse No. 15 (5-amp) from instrument panel fuse block. If fuse is okay, go to step 9). If fuse is blown, go to step 7).
6. 6) Check Fuse No. 11 (Econoline) Remove and inspect fuse No. 1 (15-amp) from instrument panel fuse block. If fuse is okay, go to step 9). If fuse is blown, go to next step.
7. 7) Check For Short to Ground Measure resistance between ground and Light Green/Red wire (Econoline) or Light Blue/Black wire (Pickup) at BPP switch wiring harness connector. If resistance is less than 10,000 ohms, locate and repair short to ground in wiring harness between fuse block and BPP switch. Clear DTCs and repeat If resistance is 10,000 ohms or more, go to next step.
8. 8) Check Circuit No. 511 For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Light Green wire (Econoline) or Red/Light Green wire (Pickup) at BPP switch wiring harness connector. If resistance is less than 10,000 ohms, locate and repair short to ground in Light Green wire (Econoline) or Red/Light Green wire (Pickup). If resistance is 10,000 ohms or more, inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 12).
9. 9) Check For Open Circuit Turn ignition off. On Econoline, measure resistance of Light Green/Red wire between BPP switch wiring harness connector and output side of No. 11 fuse holder. On Pickup, measure resistance of between Light Blue/Black wire at BPP switch wiring harness connector and output side of No. 15 fuse holder. On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in wiring harness between fuse block and BPP switch connector.
10. 10) Check For Open BPP Switch Turn ignition on. Connect a jumper wire between BPP switch wiring harness connector terminals. Using scan tool, select BPP PID from PID/DATA monitor menu. If PID reading indicates ON, replace BPP switch. If PID reading indicates OFF, remove jumper wire and go to next step.
11. 11) Check For Open In Circuit No. 511 Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure resistance between Light Green wire (Econoline) or Red/Light Green wire (Pickup) at BPP switch wiring harness connector and test pin No. 92 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Green wire (Econoline) or Red/Light Green wire (Pickup).
12. 12) Confirm PCM Fault Turn ignition on. Using scan tool, select BPP PID from PID/DATA monitor menu. While observing PID, firmly depress and release brake pedal. If PID reading switches from ON to OFF, no problem is indicated at this time. If PID reading does not switch from ON to OFF, replace PCM.
13. 13) Check For Intermittent Open Or Short Circuit Ensure BPP switch is disconnected. Turn ignition on. Connect a jumper wire between BPP switch wiring harness connector terminals. Confirm BPP PID reading on scan tool indicates ON and brakelights are also on. While observing BPP PID, wiggle and bend small sections of wiring harness starting at BPP switch connector and working toward PCM. If fault is indicated (PID changes to OFF), isolate fault in wiring harness and repair as necessary. If no fault is indicated, go to next step.
14. 14) Check For Intermittent Short To Power Remove fuse No. 11 (Econoline) or fuse No. 15 (Pickup). Confirm BPP PID reading on scan tool indicates OFF and brakelights are also off. While observing BPP PID, wiggle and bend small sections of wiring harness starting at BPP switch connector and working toward PCM. If fault is indicated (PID changes to ON), isolate fault in wiring harness and repair as necessary. If no fault is indicated, fault cannot be duplicated at this time.

TEST FE: IDLE VALIDATION SWITCH (IVS)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Note. IVS is not serviced separately. If IVS is defective, accelerator pedal assembly must be replaced.

Perform this test when directed by QUICK TEST. IVS provides PCM with a signal to verify when accelerator pedal is in idle position.

1. 1) DTC P0220 Or P0221 This DTC indicates a malfunction has occurred in Idle Validation Switch (IVS) circuit. Possible causes for this fault are: Faulty accelerator pedal assembly. Open circuit. Short to power in IVS circuit. Faulty Powertrain Control Module (PCM). Turn ignition off. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access AP and IVS PIDs from PID/DATA monitor menu. With accelerator pedal in the up position, if IVS PID reading indicates ON, go to step 7). If IVS PID reading does not indicate ON, go to next step.
2. 2) Check IVS Transition Voltage Observe AP (voltage) and IVS (state) PID reading and slowly depress accelerator pedal. If IVS PID reading switches to ON at.4-1.6 volts, clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC resets, replace PCM. If IVS PID does not switch to ON at.4-1.6 volts, go to next step.
3. 3) Check IVS Observe IVS PID reading and fully depress accelerator pedal. If IVS PID reading switches to ON at any time, replace accelerator pedal assembly. If IVS PID does not switch to ON at any time, go to next step.
4. 4) Check IVS Resistance Turn ignition off. Disconnect IVS. (Scheme 28) Inspect IVS connector for damaged pins, corrosion and loose wires. Repair as necessary. With accelerator pedal depressed, measure resistance between IVS terminals. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace accelerator assembly.
5. 5) Check Power Circuit Turn ignition on. Measure voltage between ground and Red/Light Green wire (Econoline) or Red/Yellow wire (Pickup) at IVS wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, replace fuse or locate and repair open circuit between fuse block and IVS.
6. 6) Check SIG RTN Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Red/Orange wire (Econoline) or Red/Light Green wire (Pickup) at IVS wiring harness and test pin No. 10 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Red/Orange wire (Econoline) or Red/Light Green wire (Pickup).
7. 7) Check For Short To Power Disconnect IVS connector. If IVS PID reading indicates OFF, replace accelerator pedal assembly. If IVS PID indicates ON, locate and repair short to power in Red/Orange wire (Econoline) or Red/Light Green wire (Pickup) between PCM and IVS wiring harness connector.

TEST FF: PARKING BRAKE APPLIED (PBA) SWITCH

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. Parking Brake Applied (PBA) switch detects when parking brake is applied to enable Power Take-Off (PTO) raised-idle mode.

Scheme 43

Scheme 44

1. 1) DTC P1536 This DTC indicates that PCM does not detect a PBA state change during KOEO ON-DEMAND SELF-TEST. Possible causes for this fault are: Low brake fluid. Short to ground or power. Open circuit. Faulty Powertrain Control Module (PCM). Start engine and observe BRAKE warning and ABS warning lights (bulb check). If both lights are on, go to next step. If one or both lights are off, repair wiring in bulb circuit(s) as necessary. After repair is completed, perform bulb check again.
2. 2) Check For Brake System Problem Turn ignition on. Ensure parking brake is fully off. Check BRAKE warning and ABS warning lights. If both lights are on, a fault exists in brake system. Check and repair brake system as necessary. If one or both lights are off, go to next step.
3. 3) Check PBA Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, select PBA PID from PID/DATA monitor menu. Observe PBA PID reading and cycle parking brake. If PBA PID reading indicates ON only, go to next step. If PBA PID reading does not indicate ON only, go to step 6).
4. 4) Check PBA Switch Turn ignition on. Disconnect PBA switch. Switch is located on top of parking brake pedal. If PBA PID switches to OFF, replace PBA switch. If PBA PID does not switch to OFF, go to next step.
5. 5) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector. Measure resistance between ground and Purple/White wire (Econoline) or Light Green/Red wire (Pickup) at PBA switch wiring harness connector. (Scheme 43)or (Scheme 44). If resistance is less than 10,000 ohms, locate and repair short to ground in Purple/White wire (Econoline) or Light Green/Red wire (Pickup). If resistance is 10,000 ohms or more, inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 9).
6. 6) Check PBA PID Using scan tool, observe PBA PID reading. Cycle parking brake. If PBA PID reading indicates OFF only, go to next step. If PBA PID reading does not indicate OFF only, fault may be intermittent. Go to step 10).
7. 7) Check PBA Switch Turn ignition on. Ensure PBA switch is disconnected. Connect a jumper wire between ground and Purple/White wire (Econoline) or Light Green/Red wire (Pickup) at PBA switch wiring harness connector. Using scan tool, check PBA PID reading. If PBA PID reading indicates ON, replace PBA switch. If PBA PID reading does not indicate ON, go to next step.
8. 8) Check For Open Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 5 at breakout box. If battery voltage is present, PBA circuits are okay. Reconnect all connectors and go to next step. If battery voltage is not present, locate and repair open circuit.
9. 9) Confirm PCM Fault Turn ignition on. Using scan tool, select PBA PID from PID/DATA monitor menu. While observing PBA PID reading, cycle parking brake. If PBA PID switches from ON to OFF, no problem is indicated at this time. If PBA PID does not switch from ON to OFF, replace PCM.
10. 10) Check For Intermittent Short To Ground Ensure PBA switch is disconnected. Turn ignition on. Using scan tool, select PBA PID from PID/DATA monitor menu. PBA PID reading should indicate OFF. While observing PBA PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (PBA PID switches to ON), isolate fault and repair as necessary. If no fault is indicated, go to next step.
11. 11) Check For Intermittent Open Engage parking brake. Using scan tool, select PBA PID from PID/DATA monitor menu. PBA PID should indicate ON. While observing PBA PID reading, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (PBA PID switches to OFF), isolate fault and repair as necessary. If no fault is indicated, no problem is indicated at this time.

TEST FG: SPEED CONTROL COMMAND SWITCH (SCCS)

Perform this test when directed by QUICK TEST or by another system test. This test is intended to diagnose the following

1. Speed control switches.
2. Wiring harness circuits (SCCS).
3. Powertrain Control Module (PCM).

When performing KOER SWITCH SELF-TEST, wait 5 seconds after pressing trigger to the test before running through driver operated controls. Test may take up to 5 minutes to complete.

1. 1) DTC P0565, P0566, P0567, P0568 Or P0569: Speed Control DTC P0565, P0566, P0567, P0568 Or P0569 will set if PCM does not detect when a switch has been pressed during KOER SWITCH SELF-TEST. Possible causes for these faults are: Switch not depressed during test. Faulty speed control switch. Faulty SCCS circuit. Open or short in SC GND circuit. Open in power supply circuit. Turn ignition on. Using scan tool, access SCCS PID from PID/DATA monitor menu. Do not depress any switches. If SCCS PID voltage is 10 volts, go to step 5) . If SCCS PID voltage is zero volts, go to step 8) . If SCCS PID voltage is 6.58-6.78 volts, go to next step.
2. 2) Switch On Function Check Depress speed control On switch. If SCCS PID voltage is 10 volts, go to next step. If SCCS PID voltage is not 10 volts, go to step 11) .
3. 3) Switch Off Function Check Depress speed control Off switch. If SCCS PID voltage is zero volts, go to next step. If SCCS PID voltage is not zero volts, check clockspring and clockspring circuits. See appropriate article in AIR BAG RESTRAINT SYSTEMS. Repair as necessary.
4. 4) Command Switches Function Depress speed control Resume, Coast and Set/Accel switches. Observe voltage reading on scan tool as each switch is depressed. If SCCS PID voltage reading agrees with voltage specification, repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC is still present, replace PCM. See «SPEED CONTROL COMMAND SWITCH PID SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table. If any SCCS PID voltage reading does not agree with voltage specification, replace speed control switch assembly. Clear DTCs and repeat KOER SWITCH SELF-TEST. SPEED CONTROL COMMAND SWITCH PID SPECIFICATIONS Switch Volts Coast .48-.88 Set/Accel 2.54-2.94 Resume 4.46-4.86
5. 5) Check For Shorted Command Switch Remove driver-side air bag module. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch 3-pin connector. Recheck SCCS PID value. If SCCS PID voltage reading is 6.58-6.78 volts, switch assembly is shorted. Replace speed control switch assembly. If SCCS PID voltage reading is not 6.58-6.78 volts, go to next step.
6. 6) Check Sliding Contact (Clockspring) Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. If SCCS PID voltage reading is 6.58-6.78 volts, clockspring is shorted to power. Replace clockspring. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If SCCS PID voltage reading is not 6.58-6.78 volts, go to next step.
7. 7) Signal Circuit Check Turn ignition off. Ensure steering column connector and speed control switch 3-pin connector are disconnected. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 61 at breakout box. If SCCS PID voltage reading is zero volts, replace PCM. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If SCCS PID voltage reading is not zero volts, locate and repair short to power in Light Blue/Black wire.
8. 8) Check For Shorted Command Switch Remove driver-side air bag module. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch 3-pin connector. If SCCS PID voltage is 6.58-6.78 volts, replace speed control switch assembly. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If SCCS PID voltage is not 6.58-6.78 volts, go to next step.
9. 9) Check Sliding Contact (Clockspring) Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. If SCCS PID voltage is 6.58-6.78 volts, clockspring and wiring harness in steering column are shorted to ground. Replace clockspring. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If SCCS PID voltage is not 6.58-6.78 volts, go to next step.
10. 10) Signal Circuit Check Turn ignition off. Ensure clockspring-to-steering column connector is disconnected. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 61 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If each reading is more than 10,000 ohms, replace PCM. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If any reading is 10,000 ohms or less, locate and repair short to ground in Light Blue/Black wire. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
11. 11) Check Power Circuit Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. Turn ignition on. Measure voltage between ground and Dark Blue wire at 6-pin connector (steering column side of connector). If battery voltage is present, go to next step. If battery voltage is not present, repair open circuit. See appropriate wiring diagram in appropriate CRUISE CONTROL SYSTEMS article in ACCESSORIES & EQUIPMENT.
12. 12) Check Speed Control Switch Turn ignition off. Remove driver-side air bag module. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch 3-pin connector. Depress speed control On switch. Check for continuity between Dark Blue wire and Light Blue/Black wire at speed control switch 3-pin connector. If continuity exists, go to next step. If continuity does not exist, replace speed control switch assembly. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
13. 13) Check Circuit No. 151 Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 61 at breakout box and Light Blue/Black wire) at 6-pin wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Light Blue/Black wire. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
14. 14) Check Clockspring Check for defective clockspring. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Repair as necessary. If clockspring is okay, replace PCM. Clear DTCs and repeat «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .

TEST FH: 4x4 LOW (PICKUP)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. 4x4 low switch.
2. Wiring harness circuits for 4x4 low switch.
3. Powertrain Control Module (PCM).

Scheme 45

1. 1) DTC P1729 Or P1781: Perform Switch Functional Check Turn ignition on. Observe 4x4L indicator and switch to and from 4x4L. If indicator light agrees with lever position, go to next step. If indicator light does not agree with lever position, go to step 4).
2. 2) Check 4x4L Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, select 4x4L PID from PID/DATA monitor menu. Observe 4x4L PID reading and switch to and from 4x4L. If 4x4L PID reading agrees with lever position, go to next step. If 4x4L PID reading does not agree with lever position, go to step 11).
3. 3) Check For Intermittent While observing 4x4L PID, wiggle and bend all wiring harness circuits for 4x4L. If 4x4L PID switched states (on/off) at any time, isolate fault and repair as necessary. If 4x4L PID did not switch states, no problem is indicated at this time.
4. 4) Check Voltage At Switch Disconnect 4x4L switch 2-pin connector. Switch is located on front of transfer case. Measure voltage between ground and Light Blue/Black wire at 4x4L switch wiring harness connector. (Scheme 45) If voltage is more than 10.5 volts, replace 4x4L switch. If voltage is 10.5 volts or less, go to next step.
5. 5) Check Indicator Light Observe 4x4L indicator light and shift to and from 4x4L. If indicator light always stays on, locate and repair short to ground between indicator light and switch connector. If indicator light does not always stay on, go to next step.
6. 6) Check Voltage At Fuse Measure voltage between ground and both sides of fuse No. 19 at instrument panel fuse block. If battery voltage is present at both readings, go to step 9). If battery voltage is not present at both readings, go to next step.
7. 7) Check Power Feed To Fuse Measure voltage between ground and power side of No. 19 fuse holder (Red/Light Green wire). If battery voltage is present, go to next step. If battery voltage is not present, repair open circuit in Red/Light Green wire.
8. 8) Check For Short To Ground Ensure 4x4 lever is not in LOW position. Turn ignition off. Measure resistance between ground and non-powered side of No. 19 fuse holder (Red/Yellow wire). If resistance is more than 10,000 ohms, replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If resistance is 10,000 ohms or less, locate and repair short to ground in Red/Yellow wire.
9. 9) Check 4x4L Bulb Turn ignition off. Remove and inspect 4x4L indicator bulb. Replace bulb as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If bulb is okay, go to next step.
10. 10) Check Voltage At Indicator Bulb Turn ignition on. Shift out of 4x4 Low. Measure voltage between ground and Red/Yellow wire at indicator bulb socket. If battery voltage is present, locate and repair open circuit in Light Blue/Black wire between indicator bulb and 4x4L switch. If battery voltage is not present, locate and repair open circuit in Red/Yellow wire between fuse and indicator bulb.
11. 11) Check Circuit No. 784 Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect 4x4L switch connector. Measure resistance between Light Blue/Black wire at 4x4L switch wiring harness connector and test pin No. 14 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue/Black wire.
12. 12) Check For Short To Ground Measure resistance between ground and Light Blue/Black wire at 4x4L switch wiring harness connector. If resistance is less than 10,000 ohms, locate and repair short to ground in Light Blue/Black wire. If resistance is 10,000 ohms or more, replace PCM. Clear DTCs and repeat QUICK TEST.

TEST FJ: INJECTOR DRIVER MODULE (IDM) FEEDBACK

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Injector Driver Module (IDM).
2. Wiring harness circuit (EF).
3. Powertrain Control Module (PCM).

1. 1) DTC P1668 This DTC indicates a PCM/IDM communication error. Possible causes for this fault are: Faulty Injector Driver Module (IDM). Open or grounded circuit. Faulty Powertrain Control Module (PCM). Perform again. If DTC P1668 is present, go to next step. If DTCs P1663 and P1667 are present together with or without DTC P1668, go to step 6) . If DTCs P1668 and P1298 are present, replace IDM. If DTCs P1668 and P1667 are present, go to «TEST KA»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-ka-cylinder-identification-cid) . If DTCs P1668 and P1663 are present, go to «TEST KF»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-kf-fuel-delivery-command-signal) . If DTCs P1668 and P1662 are present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) . If DTC P1670 is present without any other DTCs, go to step 10) .
2. 2) Check Circuit No. 818 Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between terminal No. 4 (Gray/White wire) at IDM connector and test pin No. 48 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/White wire.
3. 3) Check For Short To Ground Turn ignition off. Measure resistance between negative battery terminal and test pin No. 48 at breakout box. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Gray/White wire.
4. 4) Check For Short To Power Turn ignition on. Measure voltage between negative battery terminal and test pin No. 48 at breakout box. If any voltage is indicated, locate and repair short to power in Gray/White wire. If no voltage is indicated, go to next step.
5. 5) Check SIG RTN Circuit Turn ignition off. Measure resistance of Gray/Red wire between test pin No. 91 at breakout box and terminal No. 2 at IDM connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire.
6. 6) Check IDM Power Connect PCM to breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Turn ignition on. Measure voltage between ground and terminal No. 14 (Dark Green/Light Green wire) at IDM wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) .
7. 7) Check IDM Ground Turn ignition off. Measure resistance between ground and terminal No. 26 (Black/Pink wire) at IDM connector. If resistance is less than 5 ohms, replace IDM. If resistance is 5 ohms or more, locate and repair open circuit in Black/Pink wire.
8. 8) Measure EF Circuit Frequency Reconnect IDM connector. Start engine and allow it to idle. Using New Generation Star (NGS) scan tool, select frequency meter. Use 4V DC scale. using scan tool test probe, connect test pin No. 48 of breakout box to SIG INPUT on scan tool. Using a second test probe, connect test pin No. 77 (ground) of breakout box to COMMON on scan tool. Measure frequency at specified engine RPM. See «IDM FREQUENCY SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table. If frequency is not as specified, replace IDM. If frequency is as specified, replace PCM. Clear DTCs and repeat QUICK TEST. IDM FREQUENCY SPECIFICATIONS Engine RPM Frequency (Hz) 1000 66 2000 133 3000 200
9. 9) DTC P1316 This DTC indicates IDM DTCs are stored in the IDM. Injector faults are stored in the IDM and reported to PCM during KOEO ON-DEMAND SELF-TEST and KOEO INJECTOR ELECTRICAL SELF-TEST. An intermittent fault will store a DTC in the IDM. IDM DTCs are cleared by using CLEAR ALL command from the RETRIEVE/CLEAR CONTINUOUS DTCs menu on scan tool. Possible causes for this fault are: Faulty Injector Driver Module (IDM). Open or grounded circuit. Faulty Powertrain Control Module (PCM). Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) again. If any DTCs are present, perform appropriate test and repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If no DTCs are present, go to next step
10. 10) DTC P1316 Or P1670: Check For Intermittent Open Turn ignition off. Disconnect IDM connector. IDM is located in left side of engine compartment. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Gray/White wire between terminal No. 4 at IDM connector and test pin No. 48 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. Also measure resistance of Brown/Orange wire between terminal No. 17 at IDM connector and test pin No. 95 at breakout box while performing wiggle test. If both resistance readings stay at 5 ohms or less, go to next step. If any resistance reading changes to more than 5 ohms, locate and repair open circuit in Gray/White wire or Brown/Orange wire between PCM and IDM.
11. 11) Check For Intermittent Short To Ground Measure resistance between negative battery terminal and test pin No. 48 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM connector and work toward PCM. Also measure resistance between negative battery terminal and terminal No. 95 at breakout box while performing wiggle test. If both resistance readings stay at more than 10,000 ohms, go to next step. If any resistance reading changes to 10,000 ohms or less, locate and repair short to ground in Gray/White wire or Brown/Orange wire.
12. 12) Check For Intermittent Short To Power Turn ignition on. Measure voltage between negative battery terminal and test pin No. 48 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM connector and work toward PCM. Also measure voltage between negative battery terminal and terminal No. 95 at breakout box while performing wiggle test. If no voltage is indicated, go to next step. If any voltage is indicated, locate and repair short to power in Gray/White wire or Brown/Orange wire.
13. 13) Verify DTC P1316 &/Or DTC P1670 Clear DTCs. Turn ignition key off and on, then start engine. Road test vehicle. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . Retrieve DTCs. If DTC P1316 and/or DTC P1670 is present in continuous memory with any KOEO DTCs, perform appropriate system test and repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P1316 and/or DTC P1670 is present in continuous memory without any KOEO DTCs, go to next step.
14. 14) Attempt To Generate IDM DTCs Disconnect one fuel injector connector. Start engine to generate IDM DTCs. Perform «KOEO INJECTOR ELECTRICAL SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__koeo-injector-electrical-self-test) . Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If any IDM DTCs are present, replace PCM. If no IDM DTCs are present, replace IDM.

TEST FK: FUEL PUMP MONITOR/CONTROL

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. The Fuel Pump Control (FPC) circuit from the PCM is used to energize the fuel pump relay. With ignition on, fuel pump relay is energized for 20 seconds and all the time when engine RPM is detected. The Fuel Pump Monitor (FPM) circuit is downstream of the inertia switch and is used by the PCM to monitor voltage going to the fuel pump. This test is intended to diagnose

1. Fuel pump relay.
2. Inertia switch.
3. Warning light.
4. Wiring harness circuits (FPC and FPM).
5. Powertrain Control Module (PCM).

1. 1) KOEO DTC P0230 This DTC indicates that PCM has detected a fuel pump relay control circuit malfunction. Possible causes for this fault are: Blown fuse. Faulty fuel pump relay. Open circuit. Faulty Powertrain Control Module (PCM). On Econoline, check fuse No. 8 (30-amp) in instrument panel fuse block. On Pickup, check fuse No. 24 (30-amp) in engine compartment power distribution box. On all models, if fuse is okay, go to next step. If fuse is blown, replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
2. 2) Check Power To Fuel Pump Relay Remove fuel pump relay from power distribution box, located on left side of engine compartment. Turn ignition on. Measure voltage between ground and Red/Light Green wire (Econoline) or Red wire (Pickup) at fuel pump relay wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, repair open circuit in Red/Light Green wire (Econoline) or Red wire (Pickup).
3. 3) Check Fuel Pump Relay Ground Circuit Measure resistance between ground and Light Blue/Orange wire at fuel pump relay wiring harness connector. Turn ignition on. If resistance is less than 100 ohms within 20 seconds of turning ignition on, replace fuel pump relay. If resistance is not less than 100 ohms within 20 seconds or turning ignition on, go to next step.
4. 4) Check For Open Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Light Blue/Orange wire between fuel pump relay wiring harness connector and test pin No. 94 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open circuit in Light Blue/Orange wire.
5. 5) KOEO DTC P0231 This DTC indicates that PCM has detected voltage was not present at Fuel Pump Monitor (FPM) circuit when ignition was turned on. Possible causes for this fault are: Blown fuse. Faulty fuel pump relay. Open circuit. Faulty inertia switch. If DTC P0230 is also present, go to step 1) . If DTC P0230 is not also present, disconnect inertia switch connector. Inertia switch is located behind right kick panel. Turn ignition on. Measure voltage between ground and Dark Green/Yellow wire at fuel pump relay wiring harness connector within 20 seconds of turning ignition on. If battery voltage is present, go to next step. If battery voltage is not present, go to step 8) .
6. 6) Check Inertia Switch Reconnect inertia switch connector. Measure voltage between ground and Pink/Black wire at inertia switch wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, reset or replace inertia switch.
7. 7) Check Fuel Pump Monitor Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect inertia switch connector. Measure resistance between Pink/Black wire at inertia switch wiring harness connector and test pin No. 40 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Pink/Black wire.
8. 8) Check Fuel Pump Fuse Turn ignition off. On Econoline, check fuse No. 17 (30-amp) in engine compartment power distribution box. On Pickup, check fuse No. 19 (30-amp) in engine compartment power distribution box. On all models, if fuse is okay, go to next step. If fuse is blown, replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
9. 9) Check For Power To Fuel Pump Relay Remove fuel pump relay from engine power distribution box. Turn ignition on. Measure voltage between ground and Yellow wire (Econoline) or Light Blue/Orange wire (Pickup) at fuel pump relay wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Yellow wire (Econoline) or Light Blue/Orange wire (Pickup).
10. 10) Check Inertia Switch Power Circuit Turn ignition off. Disconnect inertia switch connector. Measure resistance of Dark Green/Yellow wire between fuel pump relay wiring harness connector and inertia switch wiring harness connector. If resistance is less than 5 ohms, replace fuel pump relay. If resistance is 5 ohms or more, locate and repair open circuit in Dark Green/Yellow wire.
11. 11) KOEO DTC P0232 This DTC indicates that PCM has detected that voltage was present at Fuel Pump Monitor (FPM) circuit when fuel pump was commanded off. Possible causes for this fault are: Short to power. Faulty fuel pump relay. Open circuit. On Econoline, check fuse No. 8 (30-amp) in instrument panel fuse block. On Pickup, check fuse No. 24 (30-amp) in engine compartment power distribution box. On all models, turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0232 is present, go to next step. If DTC P0232 is not present, go to step 15) .
12. 12) Check For Fuel Pump Relay Short Reinstall fuse. Remove fuel pump relay from engine compartment distribution center. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0232 is present, go to next step. If DTC P0232 is not present, replace fuel pump relay.
13. 13) Check For Short To Inertia Switch Disconnect inertia switch connector. Inertia switch is located behind right kick panel. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0232 is present, go to next step. If DTC P0232 is not present, repair short to power in Dark Green/Yellow wire between inertia switch and fuel pump relay.
14. 14) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 40 at breakout box. If battery voltage is present, repair short to power in fuel pump control or fuel pump monitor circuit. If battery voltage is not present, replace PCM.
15. 15) Check For Short To Ground Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between ground and test pin No. 94 at breakout box. If resistance is less than 5 ohms, repair short to ground in Light Blue/Orange wire between PCM and fuel pump relay. If resistance is 5 ohms or more, replace PCM.
16. 16) Continuous DTC P0230 This DTC indicates that PCM has detected a fuel pump relay control circuit fault. Possible causes for this fault are: Blown fuse. Faulty fuel pump relay. Open or intermittent circuit fault. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0230 is present, go to step 1) . If DTC P0230 is not present, go to next step.
17. 17) Check For Intermittent Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. Retrieve DTCs. If Continuous Memory DTC P0230 is present, locate and repair fault in wiring harness. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If Continuous Memory DTC P0230 is not present, no fault is indicated at this time. Testing is complete.
18. 18) Continuous DTC P0231 This DTC indicates that PCM detected voltage was not present on fuel pump monitor circuit when fuel pump was commanded on. Possible causes for this fault are: Blown fuse. Faulty fuel pump relay. Open circuit. Faulty inertia switch. If Continuous Memory DTC P0230 is also present, go to step 16) . Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If KOEO DTC P0231 is present, go to step 5) . If KOEO P0231 is not present, go to next step.
19. 19) Check For Intermittent Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. Retrieve DTCs. If Continuous Memory DTC P0231 is present, locate and repair fault in wiring harness. If Continuous Memory DTC P0231 is not present, no fault is indicated at this time. Testing is complete.
20. 20) Continuous Memory DTC P0232 This DTC indicates that PCM has detected that voltage was present at Fuel Pump Monitor (FPM) circuit when fuel pump was commanded off. Possible causes for this fault are: Short to power. Faulty fuel pump relay. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If KOEO DTC P0232 is present, go to step 11) . If KOEO DTC P0232 is not present, go to next step.
21. 21) Check For Intermittent Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. Retrieve DTCs. If Continuous Memory DTC P0232 is present, locate and repair fault in wiring harness. If Continuous Memory DTC P0232 is not present, no fault is indicated at this time. Testing is complete.

TEST H: AUXILIARY POWERTRAIN CONTROL SYSTEM

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test only when directed by QUICK TEST or if no DTCs are present and Auxiliary Powertrain Control Module (APCM) does not control engine RPM. Auxiliary powertrain control system provides an operator interface to the drive-by-wire powertrain control system to effect charge protection, RPM control and manual throttle control between 1300-2500 RPM. This test is intended to diagnose

1. Wiring harness circuits (KEY PWR, GND, BUS (+), BUS (-) and hi-mount brakelight).
2. Auxiliary Powertrain Control Module (APCM).

Enabling Conditions

1. Parking brake set, transmission in Park (A/T) or Neutral (M/T) and clutch pedal released. Service brake, accelerator pedal and brakelights must be functional. To operate system with hazard flashers, hi-mount brakelight circuit must be complete and operational.

Error DTCs are displayed from APCM only. (Scheme 46) Identify DTC and perform appropriate procedure or test step

1. If APCM is inoperative at all times, go to step 1) .
2. If APCM is inoperative with hazard flashers, go to step 7) .
3. If APCM DTC CErr or CrSD is displayed, go to step 5) .
4. If APCM DTC EErr or AErr is displayed, replace APCM.

Scheme 46

Scheme 47

1. 1) Verify Operation Procedure Refer to auxiliary powertrain control manual provided with system to verify correct operating procedures and entry conditions. If entry conditions are met, go to next step. If entry conditions are not met, correct operating procedure. Retest system. If system still does not operate, go to next step.
2. 2) Check For DTCs Ensure auxiliary powertrain control system is off. Using NGS scan tool, perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel), «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) and «KOER SWITCH SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Retrieve DTCs. If any DTCs are present, service DTCs as necessary. If no DTCs are present, go to next step.
3. 3) Check KEY PWR Voltage Disconnect APCM connector. Connector is located behind left side of instrument panel (Econoline) or lower right side of instrument panel (Pickup). Turn ignition on. Measure voltage between ground and terminal No. 2 (Red/Light Green wire on Econoline or Red/Yellow wire on Pickup) at APCM wiring harness connector. (Scheme 47) If battery voltage is present, go to next step. On Econoline, if battery voltage is not present, locate and repair open in Red/Light Green wire between ignition switch and APCM. On Pickup, if battery voltage is not present, remove and inspect fuse No. 19 from instrument panel fuse block. If fuse is blown, replace fuse and check for short to ground in Red/Yellow wire. If fuse is okay, locate and repair open circuit in Red/Light Green wire between fuse block and APCM.
4. 4) Check Ground Circuit Turn ignition off. Measure resistance between ground and terminal No. 1 (Black wire) at APCM wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black wire.
5. 5) Check For Open In BUS (-) Circuit Measure resistance of Pink/Light Blue wire between terminal No. 3 at APCM wiring harness connector and Data Link Connector (DLC). (Scheme 47) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in BUS (-) circuit.
6. 6) Check For Open In BUS (+) Circuit Measure resistance of Tan/Orange wire between terminal No. 4 at APCM wiring harness connector and Data Link Connector (DLC). (Scheme 47) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in BUS (+) circuit.
7. 7) APCM Inoperative With Hazard Flashers Turn ignition off. Depress brake pedal. If hi-mount brakelight is on, go to «TEST FD»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-fd-brake-pedal-position-bpp). If hi-mount brakelight is off, go to next step.
8. 8) Check Hi-Mount Brakelight Remove and inspect hi-mount brakelight bulb. Replace bulb as necessary and retest system operation. If bulb is okay, go to next step.
9. 9) Check Ground Circuit Measure resistance of Black wire between ground and hi-mount brakelight bulb socket. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in ground circuit.
10. 10) Check For Power To Bulb Turn ignition off. Depress brake pedal. Measure voltage between ground and Light Green wire (Econoline) or Dark Green wire (Pickup) at hi-mount brakelight bulb socket. If battery voltage is present, check for loose connection in bulb socket. Repair as necessary. If battery voltage is not present, repair open circuit.

TEST KA: CYLINDER IDENTIFICATION (CID)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Injector Driver Module (IDM).
2. Wiring harness circuit (CID).
3. Powertrain Control Module (PCM).

1. 1) DTCs P1298, P1667 & P1668 These DTCs indicate that PCM has detected a Cylinder Identification (CID) malfunction. Possible causes for this fault are: Faulty Injector Driver Module (IDM). Open or grounded circuit. Faulty Powertrain Control Module (PCM). Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . Proceed as follows: If only DTC P1667 is present, go to next step. If DTCs P1667 and P1298 are present, or if only DTC P1298 is present, replace Injector Driver Module (IDM). If DTCs P1663 and P1667 are present with or without DTC P1668, go to TEST FJ, step 6) . If DTCs P1662 and P1667 are present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) .
2. 2) Check CID Signal Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950). Connect PCM connector to breakout box. Turn ignition on. Measure voltage between ground and test pin No. 96 at breakout box. If voltage is .5-.7 volt, go to next step. If voltage is less than .5 volt, go to step 4) . If voltage is more than .7 volt, go to step 5) .
3. 3) Perform Output State Check Attach New Generation Star (NGS) scan tool. Turn ignition on. Using NGS scan tool, perform «OUTPUT STATE SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . See «ADDITIONAL SYSTEM FUNCTIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__additional-system-functions) . Measure voltage between No. 96 and pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If voltage does not toggle between .5-.7 volt and battery voltage, replace PCM. If voltage toggles between .5-.7 volt and battery voltage, fault is intermittent. Go to step 8) .
4. 4) Check Circuit No. 817 Turn ignition off. Disconnect PCM from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between terminal No. 16 (Yellow/Light Blue wire) at IDM connector and test pin No. 96 at breakout box. If resistance is less than 5 ohms, go to step 6) . If resistance is 5 ohms or more, locate and repair open circuit in Yellow/Light Blue wire.
5. 5) Check For Short To Power Turn ignition on. Measure voltage between ground and test pin No. 96 at breakout box. If battery voltage is present, locate and repair short to power in Yellow/Light Blue wire. If battery voltage is not present, go to step 7) .
6. 6) heck For Short To Ground Turn ignition off. Measure resistance between test pin No. 96 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground in Yellow/Light Blue wire.
7. 7) Perform Output State Check Ensure IDM is disconnected. Connect PCM connector to breakout box. Turn ignition on. Using NGS scan tool, perform «OUTPUT STATE SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . See «ADDITIONAL SYSTEM FUNCTIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__additional-system-functions) . Measure voltage between ground and test pin No. 96 at breakout box while depressing and releasing accelerator pedal. If voltage does not toggle between .5-.7 volt and zero volts, replace PCM. If voltage toggles between .5-.7 volt and zero volts, replace IDM. Clear DTCs and repeat QUICK TEST.
8. 8) Check For Intermittent Turn ignition off. Reconnect all connectors. Clear DTCs. Turn ignition key off, then on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If any DTC P1667 resets, replace PCM. If DTC P1667 does not reset, no problem is indicated at this time.
9. 9) DTC P1218: Open CID Circuit Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . Proceed as follows: If DTC P1218 is present without DTC P1667, go to next step. If DTCs P1218, P1663, P1667 and P1668 are present, go to TEST FJ, step 6) . If DTC P1218 and P1667 are present, go to step 2) . If DTC P1218 and P1298, replace IDM. If DTC P1218 and P1662 are present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) . .
10. 10) Check For Intermittent Open CID Circuit Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 16 (Yellow/Light Blue wire) at IDM connector and test pin No. 96 at breakout box. Resistance should be less than 5 ohms. Wiggle and bend small sections of wiring harness starting at IDM connector and work toward PCM. If resistance changes to more than 5 ohms at anytime, locate and repair open circuit in Yellow/Light Blue wire. If resistance stays at less than 5 ohms at all times, go to next step.
11. 11) Check For Intermittent Short To Power Turn ignition on. Measure voltage between ground and test pin No. 96 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM connector and work toward PCM. If any voltage is indicated, locate and repair short to power in Yellow/Light Blue wire in wiring harness. If no voltage is indicated, reconnect PCM and IDM. Road test vehicle. If DTC resets, replace IDM.
12. 12) DTC P1219: Short To Ground Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . Proceed as follows: If DTC P1219 is present without DTC P1667, go to next step. If DTCs P1219, P1663, P1667 and P1668 are present, go to TEST FJ, step 6 . If DTC P1219 and P1667 are present, go to step 2 . If DTC P1219 and P1298, replace IDM. If DTC P1219 and P1662 are present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) . .
13. 13) Check For Intermittent Short To Ground Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 96 and pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. Resistance should be more than 10,000 ohms. Wiggle and bend small sections of wiring harness starting at IDM connector and work toward PCM. If resistance changes to less than 10,000 ohms at anytime, locate and repair short to ground in Yellow/Light Blue wire. If resistance stays at more than 10,000 ohms at all times, reconnect PCM and IDM. Road test vehicle. If DTC resets, replace IDM.

TEST KB: EXHAUST BACKPRESSURE REGULATOR (EPR)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Diagnostic Procedures

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Exhaust Backpressure Regulator (EPR).
2. Wiring harness circuits (PWR GND and EPR Signal).
3. Powertrain Control Module (PCM).

1. 1) DTC P0475 This DTC indicates a circuit failure has occurred in EPR control solenoid circuit. Possible causes for this fault are: Faulty EPR solenoid. Open or shorted circuit. Faulty PCM. Disconnect EPR connector. EPR is located on top left rear of engine. Turn ignition off. Measure resistance between ground and Black/White wire at EPR wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black/White wire between ground and EPR. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
2. 2) Check EPR Coil Measure resistance between EPR terminals. If resistance is 2.5-12.0 ohms, go to next step. If resistance is not 2.5-12.0 ohms, replace EPR.
3. 3) Check For Short To Power Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. While shaking wiring harness, measure voltage between ground and Gray/Red wire at EPR wiring harness connector. If battery voltage is not present, go to next step. If battery voltage is present, locate and repair short to power in Gray/Red wire.
4. 4) Check For Short To Ground While shaking wiring harness, measure resistance between ground and Gray/Red wire at EPR wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Gray/Red wire.
5. 5) Check For Open Circuit Install Breakout Box (014-00950), leaving PCM disconnected. While shaking wiring harness, measure resistance between terminal Gray/Red wire at EPR wiring harness connector and test pin No. 42 at breakout box. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, locate and repair open circuit in Gray/Red wire.
6. 6) Perform Output State Check Reconnect PCM connector. Attach New Generation Star (NGS) scan tool. Turn ignition on. Connect DVOM between ground and Gray/Red wire at EPR wiring harness connector. Using NGS scan tool, perform «OUTPUT STATE SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). See «ADDITIONAL SYSTEM FUNCTIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__additional-system-functions). If voltage does not toggle between 12 volts and zero volts, replace PCM. If voltage toggles between 12 volts and zero volts, reconnect all components. No fault is indicated at this time. Testing is complete.
7. 7) KOER DTC P0476 This DTC indicates an Exhaust Backpressure Regulator (EPR) malfunction was detected during KOEO ON-DEMAND SELF-TEST. Possible causes for this fault are: Stuck or damaged butterfly. Misadjusted or damaged linkage. Restricted exhaust. Exhaust leaks. Faulty EPR. Faulty Exhaust Backpressure (EBP) sensor. Faulty PCM. Visually inspect butterfly tang. (Scheme 31) If tang is in Open position, go to next step. If tang is not in Open position, repair damaged linkage or butterfly as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
8. 8) Check For Exhaust Restriction Using scan tool, select EBP PID from PID/DATA monitor menu. Start engine. Briefly accelerate engine speed to Wide Open Throttle (WOT) while monitoring EBP PID. If EBP PID reading is less than 28 psi, go to next step. If EBP PID reading is 28 psi or more, repair restricted exhaust system.
9. 9) Check EBP Sensor Turn ignition on. Using scan tool, select EBP PID from PID/DATA monitor menu. Start engine and record EBP PID reading. While observing scan tool, briefly accelerate engine several times. If EBP PID reading increases 4 psi or more with each acceleration, go to next step. If EBP PID reading does not increase 4 psi or more, replace EBP sensor and retest system.
10. 10) Check For Exhaust Leaks Inspect turbo pipe, crossover pipe and exhaust manifolds for leaks. Repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If no exhaust leaks are found, go to next step.
11. 11) Check EBP During KOEO Disconnect EBP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between EBP sensor and sensor wiring harness connector. Start engine. Measure voltage between signal circuit and signal ground at ICP/EBP adapter cable. Perform «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If voltage increases 1.5-2.5 volts and then decreases as test ends, replace PCM. If voltage does not increase 1.5-2.5 volts and then decreases as test ends, go to next step.
12. 12) EPR Visual Inspection Observe EPR valve linkage while performing «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If linkage moves during test, adjust EPR linkage and retest. If linkage does not move during test, replace EPR valve. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).

TEST KC: GLOW PLUG SYSTEM

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. Glow plug relay controls current flow to glow plugs. Glow plug relay "on" time is controlled by Powertrain Control Module (PCM) and is a function of engine oil temperature, barometric pressure and battery voltage. Glow plug "on" time varies between 10-120 seconds. This test is intended to diagnose

1. Glow plug relay.
2. Harness circuits (GP/RELAY coil).
3. Powertrain Control Module (PCM).

Scheme 48

Scheme 49

1. 1) DTC P1391, P1393, P1395 & P1396 DTC P1395 or P1396 will set if a cylinder bank has a voltage reading of less than 32-amps or if a cylinder bank has a voltage reading of 8.5 volts less than the other cylinder bank. DTC P1391 or P1393 indicates all 4 glow plugs on one bank are not being powered. Both P1391 and P1393 output together indicates all 8 glow plugs are not being powered. Possible causes for this fault are: Faulty glow plug relay. Faulty glow plug shunt. Open in glow plug circuit(s). Faulty glow plug(s). Faulty Powertrain Control Module (PCM). Turn ignition on. Using scan tool, select VPWR, EOT, GPCTM, GPMR and GPML PIDs from PID/DATA monitor menu. Verify EOT PID value is less than 86°F (30°C) on Econoline or less than 131°F (55°C) on Pickup. On all models, verify GPCTM PID value is more than 35 seconds. Compare GPMR and GPML PID values and record both readings. Measure voltage between ground and Black/Orange wire at glow plug relay. (Scheme 48)or (Scheme 49). Relay is located on top right of engine. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Black/Orange wire or replace fusible links.
2. 2) Check For DTC P0380 Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Retrieve DTCs. If DTC P0380 is present, go to next step. If DTC P0380 is not present, go to step 8).
3. 3) DTC P0380 This DTC indicates that PCM has detected a glow plug relay control circuit malfunction. Possible causes for this fault are: Short to power. Blown fuse. Faulty glow plug relay. Open or grounded circuit. Faulty Powertrain Control Module (PCM). Turn ignition on. Measure voltage between ground and terminal "B" (Red/Light Green wire on Econoline or Red wire on Pickup) at glow plug relay. (Scheme 48)or (Scheme 49). If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Red/Light Green wire (Econoline) or Red wire (Pickup). If fuse is blown, check for short to ground.
4. 4) Check Glow Plug Relay Turn ignition off. Disconnect terminal "A" (Purple/Orange wire) at glow plug relay. Measure resistance between terminals "A" and "B" at glow plug relay. If resistance is 1-8 ohms, go to next step. If resistance is not 1-8 ohms, replace glow plug relay.
5. 5) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 101 at breakout box. If battery voltage is present, repair short to power. If battery voltage is not present, go to next step.
6. 6) Check For Short To Ground Turn ignition off. Ensure terminal "A" (Purple/Orange wire) at glow plug relay is disconnected. Measure resistance between ground and disconnected Purple/Orange wire. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Purple/Orange wire.
7. 7) Check For Open Circuit Measure resistance between disconnected Purple/Orange wire and test pin No. 101 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Purple/Orange wire.
8. 8) Check Glow Plug Relay Turn ignition on. Using scan tool, select EOT and GPCTM PIDs from PID/DATA monitor menu. Verify EOT PID value is less than 86°F (30°C) on Econoline or less than 131°F (55°C) on Pickup. Measure voltage between ground and terminal "C"at glow plug relay. (Scheme 48)or (Scheme 49). If voltage is present for 30 seconds or more, go to next step. If voltage is not present for 30 seconds or more, replace glow plug relay.
9. 9) Check Glow Plug Turn ignition off. On cylinder bank that set DTC, disconnect both valve cover gasket connectors. Install Glow Plug Injector Adapter (418-F221) to valve cover gasket. Measure resistance between ground and each of the 4 glow plug circuits on glow plug injector adapter. If any resistance reading is 2 ohms or more, go to next step. On Econoline, if all resistance readings are less than 2 ohms, go to step 12) (for DTCs P1391 and P1395) or step 13) (for DTCs P1393 and DTC P1396). On Pickup, if all resistance readings are less than 2 ohms, go to step 11).
10. 10) Check Valve Cover Gasket Remove valve cover and check glow plug connections. Repair as necessary. If connections are okay, disconnect suspect glow plug connector. Measure resistance between ground and suspect glow plug. If resistance is less than 2 ohms, replace valve cover gasket or Under Valve Cover (UVC) wiring harness. If resistance is 2 ohms or more, replace glow plug.
11. 11) Check Glow Plug Monitoring Circuit (Pickup) Disconnect all 4 valve cover connectors at both left and right cylinder banks. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 8 at breakout box and all 8 glow plug circuits at left and right cylinder banks. If all readings are within 2 ohms of each other, replace PCM. If any reading is not within 2 ohms of each other, locate and repair open circuit between valve cover connector and PCM. Verify glow plug shunt nuts are clean and tight. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
12. 12) Check Glow Plug Monitoring Circuit - DTCs P1391 & P1395 (Econoline) Disconnect all 4 valve cover connectors at both left and right cylinder banks. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 9 at breakout box and all 4 glow plug circuits at right cylinder bank. If all readings are within 2 ohms of each other, go to step 14. If any reading is not within 2 ohms of each other, locate and repair open circuit between valve cover connector and PCM. Verify glow plug shunt nuts are clean and tight. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
13. 13) Check Glow Plug Monitoring Circuit - DTCs P1393 & P1396 (Econoline) Measure resistance between test pin No. 34 at breakout box and all 4 glow plug circuits at left cylinder bank. If all readings are within 2 ohms of each other, go to next step. If any reading is not within 2 ohms of each other, locate and repair open circuit between valve cover connector and PCM. Verify glow plug shunt nuts are clean and tight. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
14. 14) Check For Open Circuit Measure resistance of White/Violet wire between center terminal of glow plug shunt and test pin No. 8 at breakout box. If resistance is less than 2 ohms, go to next step. If resistance is 2 ohms or more, locate and repair open circuit in White/Violet wire.
15. 15) Compare Right Bank To Left Bank Measure resistance between all 4 glow plug circuits at left cylinder bank and test pins No. 8, 9 and 34 at breakout box. Also, measure resistance between all 4 glow plug circuits at right cylinder bank and test pins No. 8, 9 and 34 at breakout box. If all readings are within 2 ohms of each other, replace PCM. If any reading is not within 2 ohms of each other, repair open in circuit with higher resistance reading. Verify glow plug shunt nuts are clean and tight.
16. 16) DTC P1397 This DTC will set if system voltage is more than 14 volts or less than 11.8 volts at any time during KOEO GLOW PLUG MONITOR SELF-TEST. Connect a DVOM to battery. Perform «KOEO GLOW PLUG MONITOR SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Maintain system voltage until test is complete. If P1397 is still present, go to «TEST A»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-a-vehicle-battery). If P1397 is not present, no problem is indicated at this time. Testing is compete.

TEST KD: GLOW PLUG LIGHT (GPL)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. Glow plugs are energized during and after WAIT TO START light is on. When WAIT TO START light turns off, engine is ready to be started. This test is intended to diagnose

1. Warning light.

1. 1) DTC P0381 This DTC indicates that PCM has detected a glow plug warning light circuit malfunction. Possible causes for this fault are: Open WAIT TO START light. Open or grounded circuit. Blown fuse. Faulty Powertrain Control Module (PCM). Start engine and observe WAIT TO START light. If light stays on, go to next step. If light does not stay on, turn ignition off and go to step 3) .
2. 2) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. If WAIT TO START light is on, locate and repair short to ground in Black/Pink wire between WAIT TO START light and PCM. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If WAIT TO START light is off, replace PCM.
3. 3) Check For Intermittent P0381 Turn ignition on and observe WAIT TO START light. If light turns on for at least one second, fault is intermittent. Go to step 9) . If light does not turn on for at least one second, go to next step.
4. 4) Check Fuse Turn ignition off. Check fuse No. 2 (Econoline) or fuse No. 19 (Pickup). If fuse is okay, go to next step. If fuse is blown, go to step 6) .
5. 5) Check Bulb Remove and inspect WAIT TO START bulb. If bulb is okay, go to next step. If bulb is bad, replace bulb. Reconnect all connectors, clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) .
6. 6) Check For Short To Ground Ensure WAIT TO START bulb is removed. Measure resistance between ground and Red/Yellow wire at WAIT TO START bulb socket. If resistance is more than 10,000 ohms, replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If resistance is 10,000 ohms or less, locate and repair short to ground in Red/Yellow wire.
7. 7) Check For Open Circuit Access instrument cluster connectors. Turn ignition on. On Econoline, measure voltage between ground terminal No. 11 (Red/Yellow wire) at instrument cluster White 16-pin connector. On Pickup, measure voltage between ground terminal No. 12 (Red/Yellow wire) at instrument cluster White 12-pin connector. On all models, if battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Red/Yellow wire between fuse and instrument cluster connector.
8. 8) Check For Open Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Black/Pink wire at instrument cluster Black 12-pin connector and test pin No. 70 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Black/Pink wire between PCM and instrument cluster connector.
9. 9) Continuous Memory DTC P0381 Clear DTCs. Road test vehicle. Retrieve DTCs. If P0381 is present, go to next step. If P0381 is not present, DTC was not cleared after a previous repair. Testing is complete.
10. 10) Check For WAIT TO START Light Flicker If during road test in step 9) WAIT TO START light flickered on and off, locate and repair intermittent short to ground in Black/Pink wire between WAIT TO START light and PCM. If WAIT TO START light did not flickered on and off, go to next step.
11. 11) Check For Intermittent Open Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Using a jumper wire, ground test pin No. 70 at breakout box. WAIT TO START light should be on. Observe WAIT TO START light and tap on instrument panel. Also, wiggle and bend small sections of wiring harness starting at engine compartment 76-pin bulkhead connector and work toward PCM. If WAIT TO START light ever flickers on and off, locate and repair intermittent open circuit in wiring harness. If WAIT TO START light does not flicker on and off, fault cannot be located at this time. An intermittent fault may exist in PCM.

TEST KE: INJECTION PRESSURE REGULATOR (IPR)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Injection Pressure Regulator (IPR).
2. Injection Control Pressure (ICP) sensor.
3. Powertrain Control Module (PCM).
4. Wiring harness circuit (IPR).

Scheme 50

1. 1) DTC P1283: Check Power Feed Circuit This DTC indicates that PCM has detected an IPR circuit malfunction. Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. Remove PCM power relay from power distribution box in engine compartment. Measure resistance of Red wire between IPR connector and PCM power relay wiring harness connector. (Scheme 50) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red wire.
2. 2) Check IPR Coil Resistance Measure resistance between IPR terminals. If resistance is 5-20 ohms, go to next step. If resistance is not 5-20 ohms, replace IPR.
3. 3) Check IPR Control Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 83 and test pins No. 71 and 97 at breakout box. Also, measure resistance between test pin No. 83 and test pins No. 25 (Econoline), 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, locate and repair short to ground or short to power in Yellow/Red wire.
4. 4) Check Wiring Harness Continuity Check for continuity in Yellow/Red wire between test pin No. 83 at breakout box and IPR wiring harness connector. If continuity exists, replace PCM. If continuity does not exist, locate and repair open circuit in Red/Yellow wire.
5. 5) DTC P1282: Excessive Injection Control Pressure This DTC indicates excessive injection control pressure was detected during continuous diagnostic monitoring. Possible causes for this fault are: Intermittent short to ground in IPR circuit. Stuck IPR. Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. Attempt to start vehicle. If engine starts, replace IPR. If engine does not start, go to next step.
6. 6) Check For Intermittent Short To Ground Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between ground and test pin No. 83 at breakout box. Resistance should be more than 10,000 ohms. Wiggle and bend small sections of wiring harness starting at IPR connector and work toward PCM. If fault is indicated (resistance changes to 10,000 ohms or less), isolate fault and repair as necessary. If no fault is indicated, no problem is indicated at this time. If DTC resets, replace PCM.
7. 7) KOER DTC P1211 This DTC indicates that control pressure was high/low during SELF-TEST. Possible causes for this fault are: Low reservoir oil level. Poor oil quality. Poor fuel quality. Injector "O" ring leak. Faulty IPR valve. Faulty Injection Control Pressure (ICP) sensor. Faulty oil pressure pump. Faulty Powertrain Control Module (PCM). Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil/fuel as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If oil/fuel are okay, go to next step.
8. 8) Check Fuel Pressure Measure fuel pressure at regulator block. Check pressure with engine idling and while driving vehicle with a full load. Fuel pressure should be a minimum of 20 psi (138 kPa) at idle and 30-70 psi (206-482 kPa) while driving vehicle with a full load. If fuel pressure is as specified, go to next step. If fuel pressure is not as specified, repair fuel system as necessary.
9. 9) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm), go to next step. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
10. 10) Check Injection Control Pressure (ICP) Sensor Using scan tool, select ICP PID from PID/DATA monitor menu. Turn ignition on. If ICP PID reading indicates zero psi, go to next step. If ICP PID reading does not indicate zero psi, replace ICP sensor.
11. 11) Check For Oil Aeration Again, using scan tool, select ICP PID from PID/DATA monitor menu. Start engine. Raise engine speed to 3300 RPM for 3 minutes. If ICP PID reading increases to more than 1250 psi, change engine oil and repeat test. If ICP PID reading does not increase to more than 1250 psi, go to next step.
12. 12) Check ICP Sensor Disconnect ICP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between ICP sensor and sensor wiring harness connector. Start engine. Measure voltage between ICP signal circuit and ground at ICP/EBP adapter cable. Perform «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If voltage increases to more than 3 volts and then decreases to about one volt during ICP portion of test, replace PCM. If voltage does not increase to more than 3 volts and then decrease to about one volt during ICP portion of test, go to next step.
13. 13) Injector Leak Check Disconnect high pressure hose from right cylinder head. Using Oil High Pressure Leakage Adapter Set (D94T-6600-A), plug right high pressure hose. Using scan tool, monitor IPR PID reading. Start engine and record IPR PID reading. Turn ignition off. Reconnect right cylinder head high pressure hose. Disconnect high pressure hose from left cylinder head. Using oil high pressure leakage adapter set, plug left high pressure hose. Again, monitor IPR PID reading. Start engine and record IPR PID reading. If IPR PID readings are not within 2 percent of each other, repair internal oil leak on cylinder head with the higher IPR PID reading. If both IPR PID readings are within 2 percent of each other, replace IPR and retest system. If DTC P1211 is still set, go to next step.
14. 14) Check Oil System Pressure Check for pressurized oil leaks. See INJECTION CONTROL PRESSURE LEAK TEST under HARD START/NO START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article. Repair as necessary. If no leaks are found, replace high pressure oil pump.
15. 15) DTC P1209 Or P1211 These DTCs indicate that injector control pressure was not to specification during normal driving conditions. Possible causes for this fault are: Low reservoir oil level. Poor oil quality. Injector "O" ring leak. Faulty IPR valve. Faulty oil pressure pump. Faulty Powertrain Control Module (PCM). Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil/fuel as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If oil/fuel are okay, go to next step.
16. 16) Check Fuel Pressure Measure fuel pressure at regulator block. Check pressure with engine idling and while driving vehicle with a full load. Fuel pressure should be a minimum of 20 psi (138 kPa) at idle and 30-70 psi (206-482 kPa) while driving vehicle with a full load. If fuel pressure is as specified, go to next step. If fuel pressure is not as specified, repair fuel system as necessary.
17. 17) Perform KOER ON-DEMAND SELF-TEST Perform «KOER ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1211 is present, go to step 9). If DTC P1211 is not present, go to next step.
18. 18) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm), go to next step. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
19. 19) Check Injection Control Pressure (ICP) Sensor Turn ignition on. Using scan tool, select ICP PID from PID/DATA monitor menu. If ICP PID reading indicates zero psi, go to next step. If ICP PID reading does not indicate zero psi, replace ICP sensor.
20. 20) Check For Oil Aeration Again, using scan tool, select ICP PID from PID/DATA monitor menu. Start engine. Raise engine speed to 3300 RPM and hold for 3 minutes. If ICP PID reading increases to more than 1250 psi, change oil and repeat test. If ICP PID reading does not increase to more than 1250 psi, go to next step.
21. 21) Check IPR Duty Cycle Using scan tool, select IPR PID from PID/DATA monitor menu. Road test vehicle at wide open throttle and full load condition. If IPR PID value increases to 65 percent, replace IPR valve. If IPR PID value does not increase to 65 percent, no problem is indicated at this time.

TEST KF: FUEL DELIVERY COMMAND SIGNAL (FDCS)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. FDCS controls fuel injection timing and controls fuel quantity with Injection Pressure Regulator (IPR). This signal is sent with the Cylinder Identification (CID) signal to the Injector Driver Module (IDM) which provides power and distributes the proper signal to appropriate injector. This test is intended to diagnose

1. Injector driver module.
2. Wiring harness circuit (FDCS).
3. Powertrain Control Module (PCM).

1. 1) DTC P1663 This DTC indicates that PCM has detected a FDCS circuit malfunction. Possible causes for this fault are: Faulty Injector Driver Module (IDM). Open or grounded circuit. Faulty Powertrain Control Module (PCM). Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) again. If DTC P1663 is only code present, go to next step. If DTCs P1663 and P1667 are present together with or without DTC P1668, go to step 6) . If DTCs P1663 and P1298 are present, replace IDM. If DTCs P1663 and P1662 are present, go to «TEST NC»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-nc-injector-driver-module-enable) .
2. 2) Check FDCS Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM connector to breakout box. Turn ignition on. Measure voltage between ground and test pin No. 95 at breakout box. If voltage is .5-.7 volt, go to next step. If voltage is less than .5 volt, go to next step. If voltage is more than .7 volt, go to step 4) .
3. 3) Perform Output State Check Turn ignition on. Using NGS scan tool, perform «OUTPUT STATE SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . See «ADDITIONAL SYSTEM FUNCTIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__additional-system-functions) . Measure voltage between ground and test pin No. 95 at breakout box while depressing and releasing accelerator pedal. If voltage does not toggle between .5-.7 volt and 12 volts, replace PCM. If voltage toggles between .5-.7 volt and 12 volts, fault is intermittent. Go to step 7) .
4. 4) Check Circuit No. 821 Turn ignition off. Disconnect PCM connector from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between terminal No. 17 (Brown/Orange wire) at IDM connector and test pin No. 95 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/Orange wire.
5. 5) Check For Short To Power Turn ignition on. Measure voltage between ground and test pin No. 95 at breakout box. If battery voltage is not present, go to next step. If battery voltage is present, locate and repair short to power in Brown/Orange wire between PCM connector and IDM connector.
6. 6) Check For Short To Ground Turn ignition off. Measure resistance between test pin No. 95 and pins No. 25 (Econoline), 51, 76 (Pickup), 77, 91 and 103 at breakout box. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in Brown/Orange wire.
7. 7) Check PCM Connect PCM to breakout box. Ensure IDM is disconnected. Turn ignition on. Using NGS scan tool, perform «OUTPUT STATE SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . See «ADDITIONAL SYSTEM FUNCTIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__additional-system-functions) . Measure voltage between ground and test pin No. 95 at breakout box while depressing and releasing accelerator pedal. If voltages does not toggle between .5-.7 volt and zero volts, replace PCM. If voltage toggles between .5-.7 volt and zero volts, replace IDM.
8. 8) Check For Intermittent Clear DTCs. Start engine and allow it to idle. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . IF DTC 1663 is present, locate and repair intermittent fault in wiring harness. If DTC P1663 is not present, no problem is indicated at this time.

TEST KG: TACHOMETER (PICKUP)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test only when directed by QUICK TEST or if no DTCs are present and tachometer is inoperative. This test is intended to diagnose

1. Wiring harness circuits (KEY PWR, GND and TACH signal).
2. Tachometer.

1. 1) Check Fuse Remove and inspect fuse No. 19 in instrument panel fuse block. If fuse is blown, locate and repair short to ground in Red/Yellow wire (circuit No. 640). Replace fuse. If fuse is okay, go to next step.
2. 2) Check Ground Circuit Turn ignition off. Access connectors behind instrument cluster. Disconnect instrument cluster Black 12-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and terminal No. 12 (Black wire) at instrument cluster wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Black wire. Restore vehicle and check system for normal operation.
3. 3) Check Power To Tachometer Disconnect instrument cluster White 16-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between ground and terminal No. 11 (Red/Yellow wire) at instrument cluster wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in Red/Yellow wire.
4. 4) Check Signal Circuit To Tachometer Connect New Generation Star (NGS) scan tool to Data Link Connector (DLC). Connect a jumper wire between terminal No. 12 (Black wire) at instrument cluster Black 12-pin wiring harness connector and COM port at NGS scan tool. Connect another jumper wire between terminal No. 12 (White/Pink wire) at instrument cluster White 16-pin wiring harness connector and SIG port at NGS scan tool. Start engine. Using NGS scan tool, perform the following: Select VEHICLE and ENGINE. Select DIGITAL MEASUREMENT SYSTEM. Select FREQUENCY METER. Change level to 4 volt DC. Press LINK button to select a PID. Select PID/DATA MONITOR. Select RPM PID. Press START. Observe PID reading at specified engine RPM. See «RPM PID FREQUENCY SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table. If frequency is as specified, inspect instrument cluster printed circuit board for damage or open circuits. Repair as necessary. If printed circuit board is okay, replace tachometer. If frequency is not as specified, go to next step. RPM PID FREQUENCY SPECIFICATIONS RPM Hz 650 33-53 1500 90-110 3000 190-210
5. 5) Check For Open In TACH Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 12 (White/Pink wire) at instrument cluster White 16-pin wiring harness connector and test pin No. 19 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in White/Pink wire.
6. 6) Check For Short To Ground Measure resistance between ground and terminal No. 12 (White/Pink wire) at instrument cluster White 16-pin wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in White/Pink wire.
7. 7) Check For Short To Power Turn ignition on. Measure voltage between ground and terminal No. 12 (White/Pink wire) at instrument cluster White 16-pin wiring harness connector. If battery voltage is present, locate and repair short to power in White/Pink wire. If battery voltage is not present, replace PCM.

TEST KH: WASTEGATE CONTROL (WGC) SOLENOID (PICKUP)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test only when directed by QUICK TEST or if no DTCs are present and tachometer is inoperative. This test is intended to diagnose

1. Wiring harness circuits (KEY PWR and WGC signal).
2. WGC Solenoid.
3. WGC Actuator.

Scheme 51

1. 1) DTC P1690 This DTC indicates PCM has detected a WGC circuit fault. Possible causes for this fault are: Blown fuse. Open or shorted circuit. Faulty WGC solenoid. Faulty Powertrain Control Module (PCM). Turn ignition off. Disconnect WGC solenoid. Solenoid is located on turbocharger wastegate. Turn ignition on. Measure voltage between ground and Red/Light Green wire at WGC solenoid wiring harness connector. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, replace fuse No. 30 in instrument panel fuse block or repair open circuit in Red/Light Green wire.
2. 2) Check For Open Circuit Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between White/Red wire at WGC solenoid wiring harness connector and test pin No. 47 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in White/Red wire.
3. 3) Check For Short To Ground Measure resistance between ground and White/Red wire at WGC solenoid wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground in White/Red wire.
4. 4) Check WGC Solenoid Measure resistance between WGC solenoid terminals. If resistance is 50 ohms or more, replace WGC solenoid. If resistance is less than 50 ohms, replace PCM.
5. 5) DTC P1249: Check For DTC P1690 This DTC indicates turbo was overboosting. Possible causes for this fault are: Short to ground. Plugged WGC vacuum hose or port. Faulty WGC solenoid. Faulty WGC actuator. Faulty Powertrain Control Module (PCM). Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1690 is present, go to step 1). If DTC P1690 is not present, go to next step.
6. 6) Check Vacuum Hose Disconnect Red hose from WGC actuator. (Scheme 51) Connect a vacuum pump to end of disconnected Red hose. Apply vacuum. If vacuum does not hold, go to step 8). If vacuum holds, go to next step.
7. 7) Verify Fault Disconnect Red hose from charge air cooler housing. If vacuum now releases, hose is okay. Clean plugged charge air cooler housing hose port. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If hose still holds vacuum, replace plugged hose.
8. 8) Check Intake Port Disconnect Red hose from charge air cooler housing. Connect vacuum pump to intake port and apply vacuum. If vacuum does not hold, go to next step. If vacuum holds, clean plugged charge air cooler housing hose port.
9. 9) Check WGC Actuator Connect vacuum pump to WGC actuator. Apply vacuum. If vacuum does not hold, actuator diaphragm is faulty, replace actuator. If vacuum holds, check for sticking actuator linkage. Repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).

TEST KL: MANIFOLD INTAKE AIR HEATER

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is only intended to diagnose the following components and circuits.

1. Wiring Harness Circuits
2. Manifold Intake Air Heater (MIAH) Relay
3. MIAH
4. Powertrain Control Module (PCM)

PCM will activate intake air heater to reduce White smoke during long idle periods under the following conditions

1. Ambient Temperature Must Be Less Than 32°F (0°C)
2. Engine Oil Temperature (EOT) Must Be Less Than 131°F (55°C)
3. Vehicle Power (IVPWR) Must Be 11.8-15.0 Volts

Scheme 52

1. 1) DTC P0640: Relay Coil Circuit Fault - Check Power Feed To Relay Coil Turn ignition on. Measure voltage between ground and Manifold Intake Air Heater (MIAH) relay battery feed terminal (Red wire). (Scheme 52) MIAH relay is located on top of engine, right of fuel filter assembly. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in Red wire.
2. 2) Isolate Relay Turn ignition off. Disconnect Violet wire from terminal at MIAH relay. Connect a jumper wire between ground and MIAH relay Violet wire terminal. Cycle ignition on and off. If MIAH relay clicked, go to next step. If MIAH relay did not click, replace relay.
3. 3) Isolate PCM Disconnect PCM 104-pin connector and inspect connector for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Measure resistance between test pin No. 98 at breakout box and disconnected Violet wire for MIAH relay. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in Violet wire.
4. 4) DTC P0541: Monitor Circuit Fault Turn ignition on. Measure voltage between ground and Red wire (battery feed terminal) at Manifold Intake Air Heater (MIAH) relay. (Scheme 52) MIAH relay is located on top of engine, right of fuel filter assembly. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in Red wire.
5. 5) Isolate Relay Contacts Turn ignition off. Connect a jumper wire between MIAH relay contact terminals. If DTC is still present, go to next step. If DTC is no longer present, replace MIAH relay.
6. 6) Check Monitor Circuit For Open Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 3 at breakout box and Red/Yellow wire at MIAH relay. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in Red/Yellow wire between PCM and MIAH relay.
7. 7) DTC P0542: Monitor Power Short Fault - Isolate Relay Turn ignition on. Measure voltage between ground and Manifold Intake Air Heater (MIAH) relay contact terminal on heater side of relay. (Scheme 52) MIAH relay is located on top of engine, right of fuel filter assembly. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, go to step 9).
8. 8) Check Relay Coil Ground Circuit Turn ignition off. Disconnect Violet wire from terminal at MIAH relay. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between ground and test pin No. 98 at breakout box. If resistance is less than 5 ohms, repair short to ground in Violet wire. If resistance is 5 ohms or more, replace PCM.
9. 9) Check Monitor Circuit For Short To Battery Turn ignition off. Disconnect MIAH relay contact terminal (Red/Yellow wire) on heater side of relay. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 3 at breakout box. If voltage is more than 10.5 volts, repair short to voltage in Red/Yellow wire. If voltage is 10.5 volts or less, problem is intermittent. Retest system.

TEST MA: CONTINUOUS MEMORY FAILURE

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Wiring harness circuit (KAPWR).
2. Powertrain Control Module (PCM).

Note. Installing a breakout box or disconnecting battery terminals will interrupt Keep Alive Power (KAPWR) to PCM. DTC P0603 may be stored in continuous memory.

1. 1) Confirm DTC P0603 Clear DTCs. Turn ignition switch key off, then on. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0603 is still present, go to next step. If DTC P0603 is not present, no problem is indicated at this time. Service any other DTCs that are present. If no other DTCs are present, testing is complete.
2. 2) Check Fuse On Econoline, check fuse No. 4 (10-amp) in power distribution box located on left side of engine compartment. On Pickup, check fuse No. 2 (5-amp) in instrument panel fuse block. On all models, if fuse is okay, go to next step. If fuse is blown, check for short to ground in Yellow wire (Econoline) or Red/White wire (Pickup) between fuse block and PCM. Repair as necessary and replace fuse.
3. 3) Check Voltage To PCM Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure voltage between ground and test pin No. 55 at breakout box. If battery voltage is not present, locate and repair open circuit in Yellow wire (Econoline) or Red/White wire (Pickup) between fuse block and PCM. Repair as necessary and replace fuse. If battery voltage is present, reconnect all connectors. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P0603 resets, replace PCM.

TEST MB: OBD-II READINESS CODE

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

1. 1) DTC P1000 This DTC indicates operating conditions have not been satisfied for all of the OBD-II monitors to run. Possible causes for this fault are: Drive conditions not satisfied. Keep Alive Memory (KAM) cleared. Faulty Powertrain Control Module (PCM). NOTE: If power to PCM is disconnected, P1000 will be set until OBD-II monitors have run and cleared. Perform all SELF-TESTS and check for DTCs. If any DTCs other than P1000 are present, perform appropriate system test and repair as necessary. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) . If DTC P1000 is only DTC present, go to next step.
2. 2) Perform Drive Cycle Perform drive cycle. See «DRIVE CYCLE PROCEDURE»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) under ADDITIONAL SYSTEM FUNCTIONS. If DTC P1000 is present, go to next step. If DTC P1000 is not present, no problem is indicated at this time.
3. 3) Verify Certain Operating Conditions Have Been Satisfied Using scan tool, select EOT, VPWR and GPC PIDs from PID/DATA monitor menu. If engine is started and EOT PID value is less than 86°F (30°C) on Econoline or less than 131°F (55°C) on Pickup, VPWR value must be 11.5-14.0 volts until GPC PID value is zero percent. Using scan tool, monitor MFDES PID value and engine RPM with engine under full load. MDFDES PID value must be more than 37 milligrams/stroke for 12 or more seconds with engine speed at more than 2300 RPM. With engine at normal operating temperature, monitor MFDES PID. MFDES PID value must be less than 12 milligrams/stroke for 12 seconds or more. With all the conditions met in this step, if DTC P1000 is cleared, no problem is indicated at this time. If DTC P1000 is still present, determine DTC clearing fault. Perform all engine performance diagnosis tests. See ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.

DTC P0606: Inactive Background Fault

This DTC indicates an internal failure of PCM. If any other DTCs are present, service other DTCs before continuing with this test. If DTC P0606 is still present after servicing other DTCs, replace PCM. Clear DTCs and repeat QUICK TEST . If DTC P0606 is not present, no problem is indicated at this time.

TEST MD: PCM ROM FAILURE

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

DTC P0605: PCM ROM Failure

This DTC indicates that an internal failure has occurred in PCM. Perform this test only when directed by QUICK TEST. Repeat QUICK TEST . If DTC P0605 is set, replace PCM. Clear DTCs and repeat QUICK TEST. If DTC P0605 is not set, no problem is indicated at this time.

TEST NA: INJECTOR DRIVER CIRCUIT OPERATION

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present. Each valve cover gasket has 2 fuel injector connectors that are part of the gasket. Each connector is responsible for 2 fuel injectors. If connector is faulty, replace valve cover gasket.

Perform this test when directed by QUICK TEST. Injector Driver Module (IDM) is capable of detecting individual injector open and shorts to either ground or power while engine is running. IDM is also capable of detecting right or left bank high side circuit opens or shorts to ground.

Scheme 53

Scheme 54

1. 1) DTC P0261, P0264, P0267, P0270, P0273, P0276, P0279 Or P0282 These DTCs indicate a short to ground between Injector Driver Module (IDM) and injector. For DTC and related circuit identification, see «INJECTOR DTCS P0261-P0282 CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table. INJECTOR DTCS P0261-P0282 CIRCUIT IDENTIFICATION Cylinder No. DTC Circuit No. (Wire Color) 1 P0261 555 (TAN) 2 P0264 556 (WHT) 3 P0267 557 (BRN/YEL) 4 P0270 558 (BRN/LT BLU) 5 P0273 559 (TAN/BLK) 6 P0276 560 (LT GRN/ORG) 7 P0279 561 (TAN/RED) 8 P0282 562 (LT BLU) Turn ignition off. Disconnect suspect injector connector at valve cover gasket. Measure resistance between ground and suspect circuit terminal at engine wiring harness 42-pin connector. (Scheme 53)and (Scheme 54). Connector is located in left rear of engine compartment, behind engine (Econoline) or on left side of engine compartment, near air vent (Pickup). See «INJECTOR DTCS P0261-P0282 CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, go to step 4).
2. 2) Check For Short To Ground Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between ground and suspect circuit at glow plug injector adapter. If resistance is more than 10,000 ohms, fault may be intermittent. Go to step 5). If resistance is 10,000 ohms or less, go to next step.
3. 3) Inspect Wiring Harness For Short Remove valve cover. Disconnect suspect injector connector. Inspect Under Valve Cover (UVC) wiring harness for a short to ground. Replace wiring harness as necessary. If wiring harness is okay, replace injector. Clear DTCs and repeat QUICK TEST.
4. 4) Check For Short Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance at IDM wiring harness connector between suspect injector circuit terminal, and all other circuits of IDM connector and to ground. If all readings are more than 10,000 ohms, replace IDM. If any reading is 10,000 ohms or less, locate and repair short between injector connector at valve cover and IDM connector.
5. 5) Check For Intermittent Short To Ground Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Reconnect all other connectors. Connect DVOM between ground and suspect injector circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to less than 10,000 ohms at any time, isolate fault and repair as necessary. If resistance does not change to less than 10,000 ohms, replace IDM.
6. 6) DTC P0262, P0265, P0268, P0271, P0274, P0277, P0280, P0283 Or P1261-P1268 These DTCs indicate that low side circuit is shorted to power or high side circuit is shorted between IDM and fuel injector. Identify DTC and use «INJECTOR DTCS & CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table to determine which circuit to check. Also (Scheme 53)and (Scheme 54). Turn ignition on. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect suspect injector connector at valve cover gasket. Also, disconnect remaining injector connector on same cylinder bank. Measure resistance between positive battery terminal and low side circuit terminal at suspect injector connector at valve cover gasket. Also, measure resistance between positive battery terminal and high side circuit terminal at suspect injector connector at valve cover gasket connector. If both readings are less than 10,000 ohms, go to next step. If any reading is 10,000 ohms or more, locate and repair short to power in suspect circuit between IDM and injector connector at valve cover gasket. INJECTOR DTCS & CIRCUIT IDENTIFICATION Cyl. No. DTC Low Side Ckt (Wire Color) High Side Ckt (Wire Color) 1 P1261-P0262 555 (Tan) 1087 (Orange) 2 P1262-P0265 556 (White) 878 (Pink/Yellow) 3 P1263-P0268 557 (Brown/Yellow) 1087 (Orange) 4 P1264-P0271 558 (Brown/Lt. Blue) 878 (Pink/Yellow) 5 P1265-P0274 559 (Tan/Black) 1087 (Orange) 6 P1266-P0277 560 (Lt. Grn/Orange) 878 (Pink/Yellow) 7 P1267-P0280 561 (Tan/Red) 1087 (Orange) 8 P1268-P0283 562 (Lt. Blue) 878 (Pink/Yellow)
7. 7) Check For Short To Injector Cover Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 2 ohms (engine cold), go to next step. If resistance is 2 ohms or more, fault may be intermittent. Go to step 10).
8. 8) Check For Short Remove valve cover. Disconnect suspect injector connector. Measure resistance of both high and low side circuits between glow plug injector adapter and suspect injector connector. If both readings are more than 10,000 ohms, replace injector. If any reading is 10,000 ohms or less, go to next step.
9. 9) Check Wiring Harness Remove Under Valve Cover (UVC) wiring harness. Measure resistance between low side and high side circuits at valve cover gasket wiring harness. If resistance is less than 5 ohms, replace gasket wiring harness. If resistance is 5 ohms or more, replace UVC wiring harness.
10. 10) Check For Intermittent Short To Power Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect all 4 injector connectors at valve cover gaskets. Connect DVOM between positive battery terminal and suspect injector low side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. Repeat wiggle test for suspect injector high side circuit. If resistance changes to less than 10,000 ohms at any time, isolate fault and repair as necessary. If resistance does not change to less than 10,000 ohms, replace IDM.
11. 11) DTC P1271-P1278: Check For Open Circuit These DTCs indicate an open in low side circuit or high side circuit between IDM and fuel injector. Identify DTC and use «INJECTOR DTCS P1271-P1278 CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table to determine which circuit to check. Also (Scheme 53)and (Scheme 54). Turn ignition off. Disconnect suspect injector connector at valve cover gasket. Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 5 ohms, go to step 13). If resistance is 5 ohms or more, go to next step. INJECTOR DTCS P1271-P1278 CIRCUIT IDENTIFICATION Cyl. No. DTC Low Side Ckt (Wire Color) High Side Ckt (Wire Color) 1 (1) P1271 555 (Tan) 1087 (Orange) 2 (2) P1272 556 (White) 878 (Pink/Yellow) 3 (1) P1273 557 (Brown/Yellow) 1087 (Orange) 4 (2) P1274 558 (Brown/Lt. Blue) 878 (Pink/Yellow) 5 (1) P1275 559 (Tan/Black) 1087 (Orange) 6 (2) P1276 560 (Lt. Grn/Orange) 878 (Pink/Yellow) 7 (1) P1277 561 (Tan/Red) 1087 (Orange) 8 (2) P1278 562 (Lt. Blue) 878 (Pink/Yellow) (1) Right cylinder head. (2) Left cylinder head.
12. 12) Check For Open In Injector Remove valve cover. Disconnect suspect injector connector. Measure resistance of high side circuit between injector connector and glow plug injector adapter. Also, measure resistance of low side circuit between injector connector and glow plug injector adapter. If both readings are less than 5 ohms, replace injector. If any reading is 5 ohms or more, go to step 23).
13. 13) Check For Open In Low Side Circuit Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance of suspect low side circuit between wiring harness side of injector connector at valve cover gasket and IDM connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in low side circuit.
14. 14) Check For Open In High Side Circuit Measure resistance of suspect high side circuit between wiring harness side of injector connector at valve cover gasket and IDM connector. If resistance is less than 5 ohms, fault may be intermittent. Go to next step. If resistance is 5 ohms or more, repair open in high side circuit.
15. 15) Check For Intermittent Open Injector Circuit Ensure IDM is disconnected. Reconnect all other connectors. Connect DVOM between suspect injector low side circuit terminal and high side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to more than 5 ohms at any time, isolate fault and repair as necessary. If resistance does not change to more than 5 ohms, replace IDM.
16. 16) DTC P1291 Or P1292: Check For Short In High Side Circuit These DTCs indicate a short to ground or short to power in high side circuit between IDM and fuel injector. Identify DTC and use «INJECTOR DTCS P1291 OR P1292 CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table to determine which circuit to check. Also (Scheme 53)and (Scheme 54). Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between ground and suspect high side circuit terminal at IDM wiring harness connector. If resistance is more than 10,000 ohms, go to step 18). If resistance is 10,000 ohms or less, go to next step. INJECTOR DTCS P1291 OR P1292 CIRCUIT IDENTIFICATION DTC Circuit No. (Wire Color) Bank P1291 1087 (Orange) Right P1292 878 (Pink/Yellow) Left
17. 17) Check For Short To Ground In High Side Circuit Disconnect both injector connectors at appropriate valve cover gasket (bank with DTC). Measure resistance between ground and suspect high side circuit terminal at IDM wiring harness connector. If resistance is more than 10,000 ohms, go to step 2). If resistance is 10,000 ohms or less, locate and repair short to ground between IDM connector and injector connector.
18. 18) Check For Short To Power In High Side Circuit Turn ignition on. Measure resistance between positive battery terminal and suspect high side circuit terminal at IDM wiring harness connector. Also, measure resistance between positive battery terminal and other high side circuit terminal at IDM wiring harness connector. If both readings are more than 10,000 ohms, fault may be intermittent. Go to next step. If any reading is 10,000 ohms or less, repair short to power in high side circuit.
19. 19) Check For Intermittent Short To Power Ensure IDM is disconnected and ignition is on. Connect DVOM between positive battery terminal and suspect injector high side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. Repeat wiggle test for other injector high side circuit. If resistance changes to less than 10,000 ohms at anytime, isolate fault and repair as necessary. If resistance does not change to less than 10,000 ohms, replace IDM.
20. 20) DTC P1293-P1294: Check High Side Circuit These DTCs indicate an open in high side circuit between IDM and fuel injector. Identify DTC and use «INJECTOR DTC P1293 OR P1294 CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) table to determine which circuit to check. Also (Scheme 53)and (Scheme 54). Turn ignition off. Disconnect both injector connectors at appropriate valve cover gasket (bank with DTC). Turn ignition on. Measure voltage of high side circuit between ground terminal "E" at injector connector. If battery voltage is present, go to next step. If battery voltage is not present, go to step 24). INJECTOR DTC P1293 OR P1294 CIRCUIT IDENTIFICATION DTC Circuit No. (Wire Color) Bank P1293 1087 (ORG) Right P1294 878 (PNK/YEL) Left
21. 21) Check Injector Resistance Turn ignition off. Install Glow Plug Injector Adapter (014-00935) to suspect injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 5 ohms, fault may be intermittent. Go to step 15). If resistance is 5 ohms or more, go to next step.
22. 22) Check For Open In Wiring Harness Remove valve cover. Disconnect suspect injector connector. Measure resistance between injector connector and exterior valve cover gasket connector. If resistance is less than 5 ohms, replace injector. If resistance is 5 ohms or more, go to next step.
23. 23) Determine Wiring Fault Disconnect Under Valve Cover (UVC) wiring harness from connector at valve cover gasket. Measure resistance between each terminal in valve cover gasket connector. If all readings are less than 5 ohms, connector is okay. Replace UVC wiring harness. If any reading is 5 ohms or more, an open circuit exists in connector. Replace valve cover gasket.
24. 24) Check For Open Circuit Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located on left side of engine compartment. Ensure both injector connectors are disconnected at appropriate valve cover gasket. Measure resistance of suspect high side circuit between IDM wiring harness connector and terminal "C" at both suspect injector connectors. If all readings are less than 5 ohms, fault may be intermittent. Go to step 15). If any reading is 5 ohms or more, locate and repair open in high side circuit.
25. 25) DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281, P284 Or P0301-P0308: Cylinder Non-Contributing These DTCs indicate a cylinder is not contributing equally during KOER CYLINDER CONTRIBUTION SELF-TEST. Possible causes for this fault are: Broken compression rings. Faulty injector assembly. Leaking or bent valve. Bent push rod. Broken rocker arm bolts. Bent connecting rod. Perform «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel), «KOER CYLINDER CONTRIBUTION SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) and «CONTINUOUS MEMORY SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). Record any DTCs. If any DTCs are present, service DTCs as necessary. If no DTCs are present, go to next step. CYLINDER CONTRIBUTION DTC IDENTIFICATION KOER DTC (1) Continuous Memory DTC Cylinder No. P0263 P0301 1 P0266 P0302 2 P0269 P0303 3 P0272 P0304 4 P0275 P0305 5 P0278 P0306 6 P0281 P0307 7 P0284 P0308 8 (1) Only vehicles with California emissions can set the following Continuous Memory DTCs.
26. 26) Cylinder Non-Contributing Perform ELECTRIC FUEL PUMP PRESSURE TEST, INJECTION CONTROL PRESSURE TESTS, CRANKCASE PRESSURE TEST and CHECK CYLINDER PERFORMANCE test. See ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article. Repair as necessary. If no problems are found, check engine mechanical condition. Repair as necessary. If engine mechanical condition is okay, replace injector assembly.
27. 27) DTC P1297: Injector High Side Circuit Short Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between both high side circuit terminals (No. 23 and 24) at IDM wiring harness connector. (Scheme 53) If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short between high side circuits.
28. 28) Check For Intermittent Between High Side Circuits Turn ignition off. Connect DVOM between both high side circuit terminals (No. 23 and 24) at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at IDM connector and working toward injector connectors. If resistance changes to less than 10,000 ohms at anytime, isolate fault and repair as necessary. If resistance does not change to less than 10,000 ohms, replace IDM.
29. 29) DTC P1295 Or P1926: Check For Short To Ground These DTCs indicate that more than one fault exists on right or left cylinder bank. A short and open on both low side and high side circuits can exist on bank with DTC. DTC P1295 Or P1296 IDENTIFICATION DTC Bank P1295 Right P1296 Left Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between ground and each injector circuit terminal at IDM wiring harness connector. (Scheme 53) If all readings are more than 10,000 ohms, go to next step. If any reading is 10,000 ohms or less, perform the following: If low side circuit short to ground was found, go to step 1). Repair short then return to this step. If high side circuit short to ground was found, go to step 16). Repair short then return to this step.
30. 30) Check For Short To Power Turn ignition on. Measure voltage between negative battery terminal and each injector circuit terminal at IDM wiring harness connector. If all readings indicate zero volts, go to next step. If any reading indicates voltage, perform the following: If low side circuit short to power was found, go to step 6). Repair short then return to this step. If high side circuit short to power was found, go to step 16). Repair short then return to this step.
31. 31) Check For Short Turn ignition off. Measure resistance between high side circuit terminals (No. 23 and 24) at IDM wiring harness connector. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, repair short between high side circuits.
32. 32) Check For Open Circuit Disconnect all 4 injector connectors at valve cover gaskets. Measure resistance of each injector circuit between valve cover gasket connector and IDM wiring harness connector. If all readings are less than 10,000 ohms, go to next step. If any reading is 10,000 ohms or more, repair open in suspect circuit.
33. 33) Check For Open Circuit Under Valve Cover Install Glow Plug Injector Adapter (014-00935) to valve cover gasket injector connector. Using glow plug injector adapter, measure resistance of each injector circuit through valve cover. (Scheme 53) If any reading is more than 5 ohms, go to step 12). If all readings are 5 ohms or less, reconnect all connectors. Clear DTCs and repeat «KOEO INJECTOR ELECTRICAL SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__koeo-injector-electrical-self-test) and «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1295 or P1296 resets, replace IDM. Clear DTCs and repeat the «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).

TEST NB: MALFUNCTION INDICATOR LIGHT (MIL)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Note. Malfunction Indicator Light (MIL) is also known as CHECK ENGINE light.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. STO/MIL circuit.
2. Powertrain Control Module (PCM).

Scheme 55

1. 1) Check MIL Fault In any Key On Engine Off (KOEO) or CONTINUOUS MEMORY DTCs are present, service DTCs prior to continuing with this test. If MIL is always on, go to next step. If MIL is not always on, go to step 3).
2. 2) Check Circuit No. 658 For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. If MIL is on, locate and repair short to ground in circuit No. 658 (Pink/Light Green wire). (Scheme 55) If MIL is off, replace PCM. Reconnect all connectors and repeat QUICK TEST.
3. 3) MIL Always Off Disconnect Manifold Absolute Pressure (MAP) sensor. Sensor is mounted on firewall in engine compartment. Start engine. If MIL is on, no problem is indicated at this time. Reconnect MAP sensor and clear memory. If MIL is off, reconnect MAP sensor, turn engine off and go to next step.
4. 4) Check Ignition Feed Circuit Turn ignition on. Measure voltage between ground and power side of No. 2 fuse (Econoline) or fuse No. 19 (Pickup) at instrument panel fuse block. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in power circuit between ignition switch and instrument panel fuse block or replace defective ignition switch.
5. 5) Check Fuse Remove and inspect fuse No. 2 (Econoline) or fuse No. 19 (Pickup) at instrument panel fuse block. If fuse is okay, go to next step. If fuse is blown, locate and repair short to ground in Red/Yellow wire. Replace fuse. Clear memory and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
6. 6) Check For Open In Circuit No. 640 Ensure fuse No. 2 (Econoline) or fuse No. 19 (Pickup) is removed. Remove MIL bulb. Measure resistance of Red/Yellow wire between non-powered side of No. 2 fuse holder (Econoline) or fuse No. 19 holder (Pickup) and power side of MIL bulb socket. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red/Yellow wire.
7. 7) Check MIL Bulb Check MIL bulb. If bulb is okay, go to next step. If bulb is bad, replace bulb. Clear DTCs and check MIL operation.
8. 8) Check Circuit No. 658 Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Pink/Light Green wire at MIL bulb socket and test pin No. 2 at breakout box. If resistance is less than 5 ohms, circuit No. 658 is okay. Replace PCM and check MIL operation. If resistance is 5 ohms or more, locate and repair open circuit in Pink/Light Green wire. Reconnect all components, clear DTCs and check MIL operation.

TEST NC: INJECTOR DRIVER MODULE ENABLE (IDM-EN)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Injector Driver Module (IDM) relay.
2. Powertrain Control Module (PCM).
3. Wiring harness circuit (IDM-EN).

1. 1) DTC P1662 This DTC indicates that PCM has detected a IDM-EN circuit malfunction. Possible causes for this fault are: Faulty IDM relay. Open IDM-EN circuit. Blown fuse. Faulty Powertrain Control Module (PCM). Remove IDM relay from engine compartment power distribution box. Turn ignition on. Measure voltage between ground and Red/Light Green wire (Econoline) or White/Light Blue wire (Pickup) at IDM relay wiring harness connector. see scheme 37or see scheme 38. If battery voltage is present, go to step 4). If battery voltage is not present, check fuse No. 8 (Econoline) or fuse No. 30 (Pickup) in instrument panel fuse block. If fuse is okay, check for open circuit in Red/Light Green wire (Econoline) or White/Light Blue wire (Pickup). Repair as necessary. If fuse is blown, replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If fuse blows again, check for short to ground in Red/Light Green wire (Econoline) or White/Light Blue wire (Pickup). Repair as necessary. If circuit is okay, go to next step.
2. 2) Check For Short To Ground Turn ignition off. Measure resistance between ground and White/Black wire at IDM relay wiring harness connector. If resistance is more than 10,000 ohms, go to step 4). If resistance is 10,000 ohms or less, go to next step.
3. 3) Verify Short Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between ground and White/Black wire at IDM relay wiring harness connector. If resistance is more than 10,000 ohms, replace PCM. If resistance is 10,000 ohms or less, locate and repair short to ground in White/Black wire between PCM and IDM relay.
4. 4) Verify PCM Is Enabling IDM Relay Turn ignition off. Measure resistance between ground and White/Black wire at IDM relay wiring harness connector. Note resistance reading. While observing DVOM, turn ignition on. If resistance changes to less than 5 ohms, replace IDM relay. If resistance does not change to less than 5 ohms, go to next step.
5. 5) Check For Open Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between White/Black wire at IDM relay wiring harness connector and test pin No. 80 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in White/Black wire between PCM and IDM relay.
6. 6) DTC 1663 & P1667: Check For DTC P1662 Ensure PCM and IDM are connected. Turn ignition on. Repeat «KOEO ON-DEMAND SELF-TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel). If DTC P1662 is present, go to step 1). If DTC P1662 is not present, go to next step.
7. 7) Check Fuse Remove and inspect fuse No. 11 (Econoline) or fuse No. 27 (Pickup) in instrument panel fuse block. If fuse is okay, go to next step. If fuse is blown, check for short to ground in Yellow wire (Econoline) or Dark Green/Light Green wire (Pickup) between fuse block and IDM relay. Repair as necessary and replace fuse. Clear DTCs and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
8. 8) Check For Open Circuit Remove IDM relay from engine compartment power distribution box. On Econoline, measure resistance of Yellow wire between output side of fuse No. 11 in instrument panel fuse block and IDM relay wiring harness connector. On Pickup, measure resistance of Dark Green/Light Green wire between output side of fuse No. 27 in instrument panel fuse block and IDM relay wiring harness connector. On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit.
9. 9) Check For Open Circuit Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance of Dark Green/Light Green wire between ground and terminal No. 14 at IDM connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Dark Green/Light Green wire.
10. 10) IDM Relay Check Reinstall IDM relay in engine compartment power distribution box. Ensure fuse No. 11 (Econoline) or fuse No. 27 (Pickup) is removed. On Econoline, measure resistance between output side of fuse No. 11 (Yellow wire) in instrument panel fuse block and terminal No. 14 (Dark Green/Light Green wire) at IDM connector. On Pickup, measure resistance of Dark Green/Light Green wire between output side of fuse No. 27 in instrument panel fuse block and terminal No. 14 at IDM relay wiring harness connector. On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace IDM.
11. 11) Check IDM Ground Circuit Measure resistance of Black/White wire between ground and terminal No. 26 at IDM connector. If resistance is less than 5 ohms, replace IDM. If resistance is 5 ohms or more, repair open circuit in Black/White wire.

TEST QA: UNABLE TO ACTIVATE SELF-TEST/DTC NOT LISTED

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all electronic engine control systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose

1. Standard Corporate Protocol (SCP) communication wiring harness circuits BUS (+) and BUS (-).
2. Wiring harness circuits (chassis ground, PWR GND and VBAT).
3. Powertrain Control Module (PCM).

Scheme 56

1. 1) DTC P1502: Verify Self-Test Method Used Verify that correct procedure was used to activate KOEO and KOER ON-DEMAND SELF-TEST for New Generation Star (NGS) scan tool. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel) under SELF-DIAGNOSTIC SYSTEM. Verify NGS scan tool operation on another vehicle before proceeding with this test. If correct procedure was used, go to next step. If correct procedure was not used, repeat QUICK TEST.
2. 2) Check PCM Output Ensure battery is fully charged and is not the cause of communication error. Attempt to start engine. If engine starts, go to next step. If engine does not start, go to «TEST C»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel__test-c-reference-voltage).
3. 3) Check B+ At Data Link Connector (DLC) Turn ignition off. Inspect DLC for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between positive battery terminal and terminal No. 16 at DLC. (Scheme 56) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in DLC B+ circuit.
4. 4) Check DLC Ground Circuit Turn ignition off. Measure resistance between ground and terminal No. 4 (Black wire) at DLC. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black wire.
5. 5) Check PWR GND Circuit Disconnect PCM 104-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 5 at DLC wiring harness connector and test pins No. 51, 76 (Pickup), 77 and 103 at breakout box. If all readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, locate and repair open circuit in PWR GND circuit.
6. 6) Check BUS (-) Circuit Measure resistance between terminal No. 10 (Pink/Light Blue wire) at DLC wiring harness connector and test pin No. 15 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Pink/Light Blue wire.
7. 7) Check For Short To Ground Measure resistance between ground and test pin No. 15 at breakout box. If resistance is more than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, locate and repair short to ground Pink/Light Blue wire (BUS (-) circuit). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wcodes-diesel).
8. 8) Check For Short To Power Turn ignition on. Measure voltage between test pin No. 15 and test pins No. 51, 76 (Pickup), 77 or 103 at breakout box. If voltage is more than one volt, locate and repair short to power in Pink/Light Blue wire (BUS (-) circuit). If voltage is one volt or less, go to next step.
9. 9) Check DLC BUS (+) Circuit Resistance Turn ignition off. Measure resistance between terminal No. 2 (Tan/Orange wire) at DLC wiring harness connector and test pin No. 16 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Tan/Orange wire (BUS (+) circuit).
10. 10) Check BUS (+) Circuit For Short To Power Turn ignition on. Measure voltage between terminal No. 16 (Tan/Orange wire) at DLC wiring harness connector and test pins No. 51, 76 (Pickup), 77 or 103 at breakout box. If voltage is more than one volt, locate and repair short to power in Tan/Orange wire (BUS (+) circuit). If voltage is one volt or less, go to next step.
11. 11) Check For BUS (-) & BUS (+) Circuits Shorted Together Turn ignition off. Measure resistance between test pins No. 15 and 16 at breakout box. If resistance is more than 10,000 ohms, replace PCM. If resistance is 10,000 ohms or less, locate and repair short between BUS (-) and BUS (+) circuits.

See also:
• QUICK TEST
• CLEARING CODES
• DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE CHART
• TEST QA
• VISUAL CHECK
• VEHICLE PREPARATION & EQUIPMENT HOOKUP
• KOEO (KEY ON ENGINE OFF) INJECTOR ELECTRICAL SELF-TEST
• TEST NA, step 29)
• PARAMETER IDENTIFICATION (PID)
• MD1
• H
• TEST A
• TEST C
• TEST DG: BAROMETRIC PRESSURE (BARO) SENSOR (1999 1/2 MODELS)
• TEST DJ
• TEST KA
• TEST KF
• TEST NC
• TEST FD
• ADDITIONAL SYSTEM FUNCTIONS