Engine Controls - Self-Diagnostics - Eec-V - Diesel: Diagnosis

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 concerns and retrieve DTCs. 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 and diagnosis must be performed in the following order: Key On Engine Off (KOEO), Key On Engine Running (KOER) and Continuous Memory DTCs. See QUICK TEST for self-test procedures. DTCs may be cleared from PCM memory after DTCs have been recorded or fault has been repaired. See CLEARING CODES under SELF-DIAGNOSTIC SYSTEM. If fault is still present after clearing DTCs, fault will reset.

RETRIEVING DIAGNOSTIC TROUBLE CODES

Fault codes are retrieved from powertrain control system through Data Link Connector (DLC). (Scheme 11) DLC is located under left side of instrument panel, right side of steering column. If vehicle is equipped with an auxiliary PCM, ensure RPM control is off before performing any self-tests. Self-diagnostic test procedures are for use with Rotunda Worldwide Diagnostic System (WDS), New Generation Star (NGS) scan tool or equivalent. If a generic scan tool is used, ensure scan tool is certified to OBD-II standard. A generic scan tool may not be capable of performing all necessary test functions. Go to READING DIAGNOSTIC TROUBLE CODES.

Scheme 11

Scheme 11: RETRIEVING DIAGNOSTIC TROUBLE CODES

READING DIAGNOSTIC TROUBLE CODES

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

KOEO & KOER On-Demand Self-Test Codes

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

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 on models with Federal emissions, 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.

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.

Performing Self-Test

To perform self-test, turn ignition off. Ensure test equipment is properly attached. If vehicle is equipped with an auxiliary powertrain control system (RPM control), it must be turned off before performing self-test. Using NGS tester, perform the following steps

Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOEO ON-DEMAND SELF-TEST.
Turn ignition on.
Follow operating instructions from NGS tester menu.
Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) . After test has been completed, cycle ignition off before performing other self-tests or driving vehicle.

KOER ON-DEMAND SELF-TEST

Note. On F650-750, only Injection Control Pressure (ICP) check is performed.

Note. When performing KOER ON-DEMAND SELF-TEST, engine may run rough.

To perform self-test, turn ignition off. Ensure test equipment is properly attached and A/C is off. If vehicle is equipped with an auxiliary powertrain control system (RPM control), it must be turned off before performing self-test. Using NGS tester, perform the following steps

Start engine and allow to idle.
Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOER ON-DEMAND SELF-TEST.
Follow operating instructions from NGS tester menu.
Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) . After test has been completed, cycle ignition off before performing other self-tests or driving vehicle.

Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select RETRIEVE/CLEAR CONTINUOUS DTCs.
Turn ignition on.
Follow operating instructions from NGS tester menu.
Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) . After test has been completed, cycle ignition off before performing other self-tests or driving vehicle. Continuous Memory DTCs must be cleared after repair.

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

Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOEO INJECTOR ELECTRICAL SELF-TEST.
Turn ignition on.
Follow operating instructions from NGS tester menu.
Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) . After test has been completed, cycle ignition off before performing other self-tests or driving vehicle.

To perform self-test, turn ignition off. Ensure test equipment is properly attached and all accessories are off. If vehicle is equipped with an auxiliary powertrain control system (RPM control), it must be turned off before performing self-test. Using NGS tester, perform the following steps

Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOEO OUTPUT STATE SELF-TEST.
Turn ignition on.
Follow operating instructions from NGS tester menu.
Press and release accelerator pedal to cycle output state high on relays, solenoids, WAIT TO START light, CID, IDM EF, FDCS, and TCIL. When accelerator pedal is pressed for first time, glow plug relay will receive a 5 second on-command.
After test has been completed, cycle ignition off before performing other self-tests or driving vehicle.

KOER SWITCH SELF-TEST

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.

Start engine and allow it to idle.
Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOER SWITCH SELF-TEST.
Follow operating instructions from NGS tester menu. After pressing "Trigger" to start test, wait 5 seconds before running through driver-operated controls. Test may also take up to 5 minutes to complete.
After test has been completed, cycle ignition off before running other tests or driving vehicle.
On F650-750 with an Allison automatic transmission, shift from Neutral to Drive and back to Neutral to validate Neutral switch.
If vehicle is not equipped with speed control, ignore DTCs P0565-P0569.

Performing CCT Self-Test

Note. If KOER DTC P1464 is set during KOER cylinder contribution self-test, ensure A/C heater control switch is off and repeat KOER cylinder contribution self-test. See PERFORMING CCT SELF-TEST . If KOER DTC P1464 resets, go to TEST FA, step 2) to check for a short to voltage.

Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOER CYLINDER CONTRIBUTION SELF-TEST.
Start engine and allow it to idle.
Follow operating instructions from NGS tester menu.
After test has been completed, cycle ignition off before performing other self-tests or driving vehicle.

KOEO GLOW PLUG MONITOR SELF-TEST

Note. This test applies to F250-550 and Excursions with California emissions. This test is not performed on F650-750 models.

Note. When performing this self-test, ensure battery voltage is maintained at 10-14 volts, and that batteries and charging system are okay. If necessary, press accelerator pedal to maintain specified voltage.

To perform self-test, turn ignition off. Ensure test equipment is properly attached and that all accessories and A/C are off. If vehicle is equipped with an auxiliary powertrain control system (RPM control), it must be turned off before performing self-test. Using NGS tester, perform the following steps

Start engine and allow it to idle.
Select VEHICLE & ENGINE SELECTION menu.
Select VEHICLE, YEAR & MODEL.
Select DIAGNOSTIC DATA LINK.
Select PCM - POWERTRAIN CONTROL MODULE.
Select DIAGNOSTIC TEST MODE.
Select KOER GLOW PLUG MONITOR SELF-TEST.
Follow operating instructions from NGS tester menu.
Maintain system voltage until test is complete.
Record DTCs and perform appropriate system test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) .

Accessing OSR Test Mode (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.

Accessing OSR Test Mode (New Generation Star Tester)

To enter OSR test mode, turn ignition switch to OFF position. Ensure test equipment is properly attached. Using NGS tester, perform the following steps

Select VEHICLE & ENGINE SELECTION menu.
Select NEW VEHICLE, YEAR & MODEL.
Follow operating instructions from scan tool menu.
Select GENERIC OBD-II FUNCTIONS. Press TEST button if monitors are not complete.
Press TEST button to display OSR test.
Select ON-BOARD SYSTEM READINESS.

Accessing PID Data Monitor (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.

Accessing PID Data Monitor - Pending Codes (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.

Accessing Freeze Frame PID Data (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.

Resetting OBD-II DTCs (Generic Scan Tool)

To perform PCM reset using generic scan tool, follow scan tool manufacturer's operating instructions. If after clearing DTCs a concern has not been corrected, or a fault is still present, a hard code will immediately be reset in PCM memory.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

Note. Prior to performing any system test, see HOW TO USE SYSTEM TESTS under SYSTEM TESTS. If instructed to replace Powertrain Control Module (PCM) after performing a system test, new PCM must be programmed. See PROGRAMMING PCM .

If a DTC appears with an "x" in the numerator (example DTC P071x), "x" denotes any number between 0-9. If a "P" series DTC appears that is not listed in DIAGNOSTIC TROUBLE CODE DEFINITIONS table, diagnose by symptom in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article for symptom diagnosis. On some models, PCM is capable of storing some body DTCs. If any "B", "C" or "U" series DTCs are retrieved (example DTC B1213, C1702 or U2195), go to appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT to determine test to perform.

DIAGNOSTIC TROUBLE CODE DEFINITIONS (ECONOLINE, EXCURSION & F250-550)

DTC (1)		Go To
P0107 (2)		For KOEO Only, Test DG , Step 1) For Continuous Memory Only, Test DG , Step 3)
P0108 (2) (3)		For KOEO Only, Test DG , Step 2) For Continuous Memory Only, Test DG , Step 4)
P0112 (2)		For KOEO Only, Test DA , Step 5) For Continuous Memory Only, Test DA , Step 8)
P0113 (2)		For KOEO Only, Test DA , Step 1) For Continuous Memory Only, Test DA , Step 8)
P0117		For KOEO Only, Test DM , Step 1) For Continuous Memory Only, Test DM , Step 8)
P0118		For KOEO Only, Test DM , Step 3) For Continuous Memory Only, Test DM , Step 11)
P0122 (2)
Econoline (3)		For KOEO & Continuous Memory Only, Test DD , Step 5)
Excursion & F250-550		For KOEO & Continuous Memory Only, Test QC , Step 5)
P0123 (2)
Econoline (3)		For KOEO & Continuous Memory Only, Test DD , Step 1)
Excursion & F250-550		For KOEO & Continuous Memory Only, Test QC , Step 1)
P0197 (2) (3)		For KOEO Only, Test DB , Step 4) For Continuous Memory Only, Test DB , Step 6)
P0198 (2) (3)		For KOEO Only, Test DB , Step 1) For Continuous Memory Only, Test DB , Step 6)
P0220
Econoline		For KOER Only, Test FE , Step 1)
Excursion & F250-550		For KOER Only, Test QC , Step 13)
P0221 (2)
Econoline (3)		For Continuous Memory Only, Test FE , Step 1)
Excursion & F250-550		For Continuous Memory Only, Test QC , Step 13)
P0230		For KOEO Only, Test FK , Step 1) For Continuous Memory Only, Test FK , Step 16)
P0231 (2)		For KOEO Only, Test FK , Step 5) For Continuous Memory Only, Test FK , Step 18)
P0232		For KOEO Only, Test FK , Step 11) For Continuous Memory Only, Test FK , Step 20)
P0236 (2)		For KOEO & Continuous Memory Only, Test DH , Step 1)
P0237 (2) (3)		For KOEO Only, Test DH , Step 5) For Continuous Memory Only, Test DH , Step 12)
P0238 (2) (3)		For KOEO Only, Test DH , Step 10) For Continuous Memory Only, Test DH , Step 14)
P0261 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0262		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0263		For KOER Only, Test NA , Step 25)
P0264 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0265		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0266		For KOER, Test NA , Step 25)
P0267 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0268		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0269		For KOER Only, Test NA , Step 25)
P0270 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0271		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0272		For KOER Only, Test NA , Step 25)
P0273 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0274		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0275		For KOER Only, Test NA , Step 25)
P0276 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0277		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0278		For KOER Only, Test NA , Step 25)
P0279 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0280		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0281		For KOER Only, Test NA , Step 25)
P0282 (2) (3)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0283		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0284		For KOER Only, Test NA , Step 25)
P0301-P0308 (2)		For Continuous Memory Only, Test NA , Step 25)
P0340		For KOEO & Continuous Memory Only, Test DF , Step 1)
P0341 (2)		For KOER & Continuous Memory Only, Test DF , Step 1)
P0344 (2) (3)		For KOEO & Continuous Memory Only, Test DF , Step 1)
P0380 (2)		For KOEO & Continuous Memory Only, Test KC , Step 1)
P0381 (2)
Econoline		For KOEO & Continuous Memory Only, Test KD , Step 3)
Excursion & F250-550		For KOEO & Continuous Memory Only, Test KD , Step 1)
P0460		(4)
P0470		For KOEO Only, Test DE , Step 1) For Continuous Memory Only, Test DE , Step 3)
P0471 (2)		For Continuous Memory Only, Test DE , Step 5)
P0472		For KOEO & Continuous Memory Only, Test DE , Step 9)
P0473 (2)		For KOEO & Continuous Memory Only, Test DE , Step 15)
P0475 (2)		For KOEO Only, Test KB , Step 1)
P0476		For KOER & Continuous Memory Only, Test KB , Step 7)
P0478 (2)		For Continuous Memory Only, Test DE , Step 17)
P0500 (2)		For Continuous Memory Only, Test DL , Step 1)
P0503		For Continuous Memory Only, Test DL , Step 11)
P0541		For KOER & Continuous Memory Only, Test KL , Step 4)
P0542		For KOEO Only, Test KL , Step 7) For KOER Only, Test KL , Step 4)
P0560		For KOER Only, Test A , Step 1)
P0562 (2)		For KOEO & Continuous Memory Only, Test A , Step 1)
P0563		For KOEO & Continuous Memory Only, Test A , Step 1)
P0565 (5)		For KOER Only, Test FG , Step 1)
P0566 (5)		For KOER Only, Test FG , Step 1)
P0567 (5)		For KOER Only, Test FG , Step 1)
P0568 (5)		For KOER Only, Test FG , Step 1)
P0569 (5)		For KOER Only, Test FG , Step 1)
P0571 (5)		For KOER Only, Test FB , Step 1)
P0603		For KOEO & Continuous Memory Only, Test MA , Step 1)
P0605		For KOEO & Continuous Memory Only, Test MD , Step 1)
P0606		For KOEO Only, Test MC , Step 1)
P0640		For KOEO, KOER & Continuous Memory, Test KL , Step 1)
P0670		For KOEO & Continuous Memory Only, Test QB , Step 6)
P0671		For KOER & Continuous Memory Only, Test QB , Step 1)
P0672		For KOER & Continuous Memory Only, Test QB , Step 1)
P0673		For KOER & Continuous Memory Only, Test QB , Step 1)
P0674		For KOER & Continuous Memory Only, Test QB , Step 1)
P0675		For KOER & Continuous Memory Only, Test QB , Step 1)
P0676		For KOER & Continuous Memory Only, Test QB , Step 1)
P0677		For KOER & Continuous Memory Only, Test QB , Step 1)
P0678		For KOER & Continuous Memory Only, Test QB , Step 1)
P0683		For KOER & Continuous Memory Only, Test QB , Step 11)
P0703		For KOER, Test FD , Step 1)
P0704		For KOER, Test FC , Step 1)
P0705 (2) (6)		(7)
P0707 (2) (6)		(7)
P0708 (2) (6)		(7)
P0712 (6)		(7)
P0713 (6)		(7)
P0715 (6)		(7)
P0717 (6)		(7)
P0718		(7)
P0720 (2) (6)		(7)
P0721		(7)
P0722 (6)		(7)
P0732		(7)
P0733		(7)
P0741		(7)
P0743 (2) (6)		(7)
P0750 (6)		(7)
P0755 (2) (6)		(7)
P0781 (6)		(7)
P0782 (6)		(7)
P0783 (6)		(7)
P1000		For Continuous Memory Only, Test MB , Step 1)
P1105		(8)
P1106		(8)
P1107 (2)		(8)
P1108		(8)
P1118 (2)		For KOEO & Continuous Memory Only, Test DI , Step 4)
P1119 (2)		For KOEO & Continuous Memory, Test DI , Step 1)
P1139
Econoline		For KOEO & Continuous Memory Only, Test DK , Step 3)
Excursion & F250-550		For KOEO & Continuous Memory Only, Test DK , Step 1)
P1140		For Continuous Memory Only, Test DJ , Step 1)
P1184		For KOER Only, Test DB , Step 9)
P1209 (2)		For Continuous Memory Only, Test KE , Step 15)
P1210 (2)		For KOEO, Test DC , Step 12) For Continuous Memory, Test DC , Step 23)
P1211 (2) (3)		For KOEO & Continuous Memory, Test KE , Step 15) For KOER, Test KE , Step 7)
P1212		For Continuous Memory Only, Test DC , Step 15)
P1218 (2)		For KOEO & Continuous Memory Only, Test KA , Step 9)
P1219 (2)		For KOEO & Continuous Memory Only, Test KA , Step 12)
P1247 (2)		For Continuous Memory Only, Test DH , Step 1)
P1248 (2)		For Continuous Memory Only, Test DH , Step 1)
P1249 (2)		For Continuous Memory Only, Test KH , Step 6)
P1260 (9)		(10)
P1261		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1262		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1263		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1264		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1265		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1266		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1267		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1268		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1271		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1272		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1273		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1274		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1275		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1276		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1277		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1278		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1280 (2) (3)		For KOEO & Continuous Memory Only, Test DC , Step 2)
P1281 (2) (3)		For KOEO & Continuous Memory Only, Test DC , Step 9)
P1282 (2) (3)		For KOER & Continuous Memory Only, Test KE , Step 5)
P1283		For KOEO Only, Test KE , Step 1)
P1284		For KOER Only, Test DC , Step 22)
P1291		For KOEO & Continuous Memory Only, Test NA , Step 16)
P1292		For KOEO & Continuous Memory Only, Test NA , Step 16)
P1293		For KOEO & Continuous Memory Only, Test NA , Step 20)
P1294		For KOEO & Continuous Memory Only, Test NA , Step 20)
P1295 (3)		For KOEO & Continuous Memory Only, Test NA , Step 30)
P1296 (3)		For KOEO & Continuous Memory Only, Test NA , Step 30)
P1297		For KOEO & Continuous Memory Only, Test NA , Step 27)
P1298		For KOEO & Continuous Memory Only, Test KA , Step 1)
P1316 (2) (3)		For KOEO & Continuous Memory Only, Test FJ , Step 9)
P1464		For KOER Only, Test FA , Step 1)
P1501		For KOER Only, Test DL , Step 10)
P1502		For KOEO, KOER & Continuous Memory, Test QA , Step 1)
P1531		(11)
P1536		For KOER Only, Test FF , Step 1)
P1662		For KOEO Only, Test NC , Step 1)
P1663		For KOEO Only, Test KF , Step 1)
P1667		For KOEO Only, Test KA , Step 1)
P1668		For KOEO & Continuous Memory Only, Test FJ , Step 1)
P1670 (2)		For Continuous Memory Only, Test FJ , Step 1)
P1690 (2)		For KOEO & Continuous Memory Only, Test KH , Step 2)
P1702 (6)		(7)
P1704		(7)
P1705		(7)
P1711		(7)
P1713 (6)		(7)
P1714 (2)		(7)
P1715 (2)		(7)
P1718 (6)		(7)
P1728 (6)		(7)
P1729 (6)		For KOEO, KOER & Continuous Memory, Test FH , Step 1)
P1744 (2)		(7)
P1746 (6)		(7)
P1747 (2)		(7)
P1754		(7)
P1760 (6)		(7)
P1780		(7)
P1781		For KOEO, KOER & Continuous Memory, Test FH , Step 1)
P1783 (6)		(7)
No Code - No Communication		(12) For KOEO, KOER & Continuous Memory, TEST QA , Step 1)
No Code - Auxiliary Powertrain Control System		(12) For KOEO, KOER & Continuous Memory, TEST H , Step 1)
No Code - Tachometer (13)		(14) For KOEO, KOER & Continuous Memory, TEST KG , Step 1)
(1) DTCs apply to all models, unless otherwise indicated. (2) MIL illuminates when fault is detected in second drive cycle (California, OBD-II calibration). (3) MIL illuminates when fault is present (Federal). (4) Check for fuel tank level indicator circuit fault. See appropriate ANALOG INSTRUMENT PANELS article. (5) Speed control DTCs will be set during KOER SWITCH SELF-TEST. If vehicle is not equipped with speed control, ignore these DTCs. (6) Transmission control indicator light flashes when fault is present. (7) See appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS. (8) See appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS. (9) Applies to F250-550 only. (10) See appropriate PASSIVE ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT for test procedures. (11) Repeat KOER ON-DEMAND SELF-TEST under QUICK TEST. (12) If concern still exists, perform appropriate symptom test in appropriate MODULE COMMUNICATIONS NETWORK article. (13) Applies to Excursion and F250-550 only. (14) If concern still exists, perform appropriate system test in appropriate ANALOG INSTRUMENT PANELS article.

(1)	DTCs apply to all models, unless otherwise indicated.

(2)	MIL illuminates when fault is detected in second drive cycle (California, OBD-II calibration).

(3)	MIL illuminates when fault is present (Federal).

(4)	Check for fuel tank level indicator circuit fault. See appropriate ANALOG INSTRUMENT PANELS article.

(5)	Speed control DTCs will be set during KOER SWITCH SELF-TEST. If vehicle is not equipped with speed control, ignore these DTCs.

(6)	Transmission control indicator light flashes when fault is present.

(7)	See appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

(8)	See appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS.

(9)	Applies to F250-550 only.

(10)	See appropriate PASSIVE ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT for test procedures.

(11)	Repeat KOER ON-DEMAND SELF-TEST under QUICK TEST.

(12)	If concern still exists, perform appropriate symptom test in appropriate MODULE COMMUNICATIONS NETWORK article.

(13)	Applies to Excursion and F250-550 only.

(14)	If concern still exists, perform appropriate system test in appropriate ANALOG INSTRUMENT PANELS article.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS (F650-750)

DTC		Go To
P0107 (1)		For KOEO Only, Test DG , Step 1) For Continuous Memory Only, Test DG , Step 3)
P0108 (1)		For KOEO Only, Test DG , Step 2) For Continuous Memory Only, Test DG , Step 4)
P0112 (1)		For KOEO Only, Test DA , Step 5) For Continuous Memory Only, Test DA , Step 8)
P0113 (1)		For KOEO Only, Test DA , Step 1) For Continuous Memory Only, Test DA , Step 8)
P0117		For KOEO Only, Test DM , Step 1) For Continuous Memory Only, Test DM , Step 8)
P0118		For KOEO Only, Test DM , Step 3) For Continuous Memory Only, Test DM , Step 11)
P0122 (1)
With AP Sensor (2)		For KOEO & Continuous Memory Only, Test DD , Step 5)
With ETC Sensor (3)		For KOEO & Continuous Memory Only, Test QC , Step 5)
P0123 (1)
With AP Sensor (2)		For KOEO & Continuous Memory Only, Test DD , Step 1)
With ETC Sensor (3)		For KOEO & Continuous Memory Only, Test QC , Step 1)
P0197 (1)		For KOEO Only, Test DB , Step 4) For Continuous Memory Only, Test DB , Step 6)
P0198 (1)		For KOEO Only, Test DB , Step 1) For Continuous Memory Only, Test DB , Step 6)
P0220
With IVS (4)		For KOER Only, Test FE , Step 1)
With ETC (3)		For Continuous Memory Only, Test QC , Step 13)
P0221 (1)
With IVS		For KOER Only, Test FE , Step 1)
With ETC (3)		For Continuous Memory Only, Test QC , Step 13)
P0236 (1)		For KOEO & Continuous Memory Only, Test DH , Step 1)
P0237 (1)		For KOEO Only, Test DH , Step 5) For Continuous Memory Only, Test DH , Step 12)
P0238 (1)		For KOEO Only, Test DH , Step 10) For Continuous Memory Only, Test DH , Step 14)
P0261 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0262		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0263		For KOER Only, Test NA , Step 25)
P0264 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0265		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0266		For KOER, Test NA , Step 25)
P0267 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0268		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0269		For KOER Only, Test NA , Step 25)
P0270 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0271		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0272		For KOER Only, Test NA , Step 25)
P0273 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0274		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0275		For KOER Only, Test NA , Step 25)
P0276 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0277		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0278		For KOER Only, Test NA , Step 25)
P0279 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0280		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0281		For KOER Only, Test NA , Step 25)
P0282 (1)		For KOEO & Continuous Memory Only, Test NA , Step 1)
P0283		For KOEO & Continuous Memory Only, Test NA , Step 6)
P0284		For KOER Only, Test NA , Step 25)
P0340		For KOEO & Continuous Memory Only, Test DF , Step 1)
P0341		For KOER & Continuous Memory Only, Test DF , Step 1)
P0344		For KOEO & Continuous Memory Only, Test DF , Step 1)
P0380		For KOEO & Continuous Memory Only, Test KC , Step 1)
P0381		For KOEO & Continuous Memory Only, Test KD , Step 3)
P0460		(5)
P0560		For KOER Only, Test A , Step 1)
P0562		For KOEO & Continuous Memory Only, Test A , Step 1)
P0563		For KOEO & Continuous Memory Only, Test A , Step 1)
P0565 (6)		For KOER Only, Test FG , Step 1)
P0566 (6)		For KOER Only, Test FG , Step 1)
P0567 (6)		For KOER Only, Test FG , Step 1)
P0568 (6)		For KOER Only, Test FG , Step 1)
P0569 (6)		For KOER Only, Test FG , Step 1)
P0571 (6)		For KOER Only, Test FB , Step 1)
P0603		For KOEO & Continuous Memory Only, Test MA , Step 1)
P0605		For KOEO & Continuous Memory Only, Test MD , Step 1)
P0606		For KOEO Only, Test MC , Step 1)
P0703		For KOER, Test FD , Step 1)
P0704		For KOER, Test FC , Step 1)
P1118		For KOEO & Continuous Memory Only, Test DI , Step 4)
P1119		For KOEO & Continuous Memory, Test DI , Step 1)
P1139		For KOEO & Continuous Memory Only, Test DK , Step 3)
P1140		For Continuous Memory Only, Test DJ , Step 1)
P1184		For KOER Only, Test DB , Step 9)
P1209		For Continuous Memory Only, Test KE , Step 15)
P1210		For KOEO, Test DC , Step 12) For Continuous Memory, Test DC , Step 23)
P1211 (1)		For KOEO & Continuous Memory, Test KE , Step 15) For KOER, Test KE , Step 7)
P1212		For Continuous Memory Only, Test DC , Step 15)
P1218		For KOEO & Continuous Memory Only, Test KA , Step 9)
P1219		For KOEO & Continuous Memory Only, Test KA , Step 12)
P1247		For Continuous Memory Only, Test DH , Step 1)
P1248		For Continuous Memory Only, Test DH , Step 1)
P1249		For Continuous Memory Only, Test KH , Step 6)
P1261		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1262		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1263		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1264		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1265		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1266		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1267		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1268		For KOEO & Continuous Memory Only, Test NA , Step 6)
P1271		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1272		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1273		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1274		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1275		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1276		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1277		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1278		For KOEO & Continuous Memory Only, Test NA , Step 11)
P1280 (1)		For KOEO & Continuous Memory Only, Test DC , Step 2)
P1281 (1)		For KOEO & Continuous Memory Only, Test DC , Step 9)
P1282 (1)		For KOER & Continuous Memory Only, Test KE , Step 5)
P1283		For KOEO Only, Test KE , Step 1)
P1284		For KOER Only, Test DC , Step 22)
P1291		For KOEO & Continuous Memory Only, Test NA , Step 16)
P1292		For KOEO & Continuous Memory Only, Test NA , Step 16)
P1293		For KOEO & Continuous Memory Only, Test NA , Step 20)
P1294		For KOEO & Continuous Memory Only, Test NA , Step 20)
P1295 (1)		For KOEO & Continuous Memory Only, Test NA , Step 30)
P1296 (1)		For KOEO & Continuous Memory Only, Test NA , Step 30)
P1297		For KOEO & Continuous Memory Only, Test NA , Step 27)
P1298		For KOEO & Continuous Memory Only, Test KA , Step 1)
P1316 (1)		For KOEO & Continuous Memory Only, Test FJ , Step 9)
P1464		For KOER Only, Test FA , Step 1)
P1502		For KOEO, KOER & Continuous Memory, Test QA , Step 1)
P1531		(7)
P1536		For KOER Only, Test FF , Step 1)
P1662		For KOEO Only, Test NC , Step 1)
P1663		For KOEO Only, Test KF , Step 1)
P1667		For KOEO Only, Test KA , Step 1)
P1668		For KOEO & Continuous Memory Only, Test FJ , Step 1)
P1670		For Continuous Memory Only, Test FJ , Step 1)
P1902		For KOEO & Continuous Memory Only, Test KJ , Step 1)
P1903		For KOEO Only, Test KJ , Step 4)
P1904		For KOEO & Continuous Memory Only, Test KJ , Step 9)
No Code - No Communication		(8) For KOEO, KOER & Continuous Memory, TEST QA , Step 1)
No Code - Auxiliary Powertrain Control System		(8) For KOEO, KOER & Continuous Memory, TEST H , Step 1)
No Code - Tachometer Fault		(9) For KOEO, KOER & Continuous Memory, TEST KG , Step 1)
(1) MIL illuminates when fault is present (Federal). (2) AP sensor has a 3-pin connector. (3) ETC sensor has a 10-pin connector. (4) Idle validation switch has a 2-pin connector. (5) Check for fuel tank level indicator circuit fault. See appropriate ANALOG INSTRUMENT PANELS article. (6) Speed control DTCs will be set during KOER SWITCH SELF-TEST. If vehicle is not equipped with speed control, ignore these DTCs. (7) Repeat KOER ON-DEMAND SELF-TEST under QUICK TEST. (8) If concern still exists, perform appropriate symptom test in appropriate MODULE COMMUNICATIONS NETWORK article. (9) If concern still exists, perform appropriate system test in appropriate ANALOG INSTRUMENT PANELS article.

(1)	MIL illuminates when fault is present (Federal).

(2)	AP sensor has a 3-pin connector.

(3)	ETC sensor has a 10-pin connector.

(4)	Idle validation switch has a 2-pin connector.

(5)	Check for fuel tank level indicator circuit fault. See appropriate ANALOG INSTRUMENT PANELS article.

(6)	Speed control DTCs will be set during KOER SWITCH SELF-TEST. If vehicle is not equipped with speed control, ignore these DTCs.

(7)	Repeat KOER ON-DEMAND SELF-TEST under QUICK TEST.

(8)	If concern still exists, perform appropriate symptom test in appropriate MODULE COMMUNICATIONS NETWORK article.

(9)	If concern still exists, perform appropriate system test in appropriate ANALOG INSTRUMENT PANELS article.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

TEST A: VEHICLE BATTERY

Enter this test only if directed here from QUICK TEST or another test. This test is only intended to diagnose the following components and circuits

Closed Loop Power Relay
Powertrain Control Module (PCM)
Battery Positive Voltage (B+)
Wiring Harness Circuits (SIG RTN, PWR GND, IGNITION SWITCH, VREF, KAPWR & VPWR)

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

Battery Cables
Ignition Switch
Voltage Regulator
Ground Straps
Generator

Testing

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0560		A1
P0562	A1		A1
P0563	A1		A1

FAULT CODE SETTING CONDITION

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1) KOEO, KOER & Continuous Memory DTC P0560, P0562 Or P0563: Check Battery Voltage DTC P0562 may be a temporary condition at crank with a low battery condition. DTC P0563 may be a temporary condition with a 24-volt jump start. Turn ignition on. Using DVOM, 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 (Excursion and F250-550), or step 8) (Econoline and F650-750).
2) Check PCM VPWR Fuse No. 22 (Excursion & F250-550) Ensure ignition is on. Remove and inspect PCM VPWR fuse No. 22 (20-amp) from central junction box. If fuse is blown, check VPWR circuit for short to ground. Repair wiring, replace fuse and retest. If fuse is okay, measure voltage between PCM VPWR fuse No. 22 and negative battery terminal. If voltage is more than 10.5 volts, go to step 6). If voltage is less than 10.5 volts, go to step 14). NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 2) to step 6). No test procedures have been omitted.
6) Check Supply Voltage From PCM Fuse To PCM Turn ignition off. Install 104-pin breakout box to PCM, leaving PCM disconnected. Using DVOM, measure resistance of Red wire between non-powered side of PCM fuse No. 22 and test pins No. 71 and 97. (Scheme 14)and (Scheme 13). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red wire between PCM and PCM fuse No. 22.
7) Check Power Ground (PWR GND) Continuity Ensure ignition is off. Using DVOM, measure resistance between negative battery terminal and test pins No. 25, 51, 77 and 103. If each resistance is less than 5 ohms, check PCM relay for proper operation. If PCM relay is good and DTC still exists, replace PCM and retest. If any resistance is 5 ohms or more, repair open in appropriate PWR GND circuit. See «WIRING DIAGRAMS»(ref-139134) article.
8) Check Battery Voltage At PCM Fuse (Econoline & F650-750) Turn ignition off. On Econoline, measure voltage between negative battery terminal and input side of PCM fuse No. 9 (30-amp), located in battery junction box. On F650-750, measure voltage between negative battery terminal and input side of PCM fuse No. 117 (20-amp), located in battery junction box. (Scheme 12)- (Scheme 17). Battery junction box is located on left front of engine compartment. If voltage is more than 10.5 volts, go to next step. If voltage is less than 10.5 volts, repair open in B+ circuit between battery and PCM fuse in battery junction box. See POWER DISTRIBUTION article in WIRING DIAGRAMS.
9) Check PCM Fuse Remove and inspect PCM fuse No. 9 (Econoline) or fuse No. 117 (F650-750) from battery junction box. If PCM fuse is okay, go to next step. If fuse is blown, locate and repair short to ground and replace PCM fuse.
10) Check VPWR Circuit To PCM Relay Remove PCM relay and fuse. Using DVOM, measure resistance of Yellow wire (Econoline) or Yellow/Black wire (F650-750) between output side of PCM fuse and PCM power relay cavity No. 30 in battery junction box. (Scheme 15)or (Scheme 17). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow or Yellow/Black wire.
11) Check Ignition Feed To PCM Relay Diode Ensure ignition is off. Remove PCM diode from battery junction box. Turn ignition on. Using DVOM, measure voltage between negative battery terminal and input side of PCM diode connector in battery junction box. If voltage is more than 10.5 volts, go to next step. If voltage is 10 volts or less, repair open in Red/Light Green wire between PCM relay diode and fuse No. 8 (Econoline) or fuse No. 30 (F650-750) in battery junction box.
12) Check PCM Diode Turn ignition off. Remove PCM diode from battery junction box. Using an ohmmeter, check PCM diode continuity. Ensure continuity exists in one direction only. Replace PCM diode as necessary and retest. If PCM diode is okay, go to step 7). NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 12) to step 14). No test procedures have been omitted.
14) Check PCM Relay Coil Ground (Excursion & F250-550) Turn ignition off. Remove PCM power relay from battery junction box. Using DVOM, measure resistance of ground circuit between PCM power relay cavity No. 85 in battery junction box and negative battery terminal. (Scheme 13)and (Scheme 14). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, go to step 18)
15) Check Circuit No. 361 (Red Wire) From PCM Relay To PCM Ensure ignition is off. Disconnect PCM 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 104-pin breakout box to PCM, leaving PCM disconnected. Using DVOM, measure resistance of Red wire between PCM power relay cavity No. 87 in battery junction box and test pins No. 71 and 97. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red wire between PCM power relay and PCM harness connector.
16) Check Power Ground (PWR GND) Circuit Continuity Ensure ignition is off. Using DVOM, measure resistance between negative battery terminal and test pins No. 25, 51, 77 and 103. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open in PWR GND circuit. See «WIRING DIAGRAMS»(ref-139134) article.
17) Check Ignition Feed To PCM Relay Turn ignition on. Using DVOM, measure voltage between negative battery terminal and PCM relay cavity No. 86 in battery junction box. If voltage is more than 10.5 volts, check PCM relay for proper operation. If PCM relay is good and DTC still exists, replace PCM and retest. If voltage is 10 volts or less, repair open in Red/Light Green wire between ignition switch and PCM relay in battery junction box.
18) Check PCM Diode Turn ignition off. Remove PCM diode from battery junction box. Using an ohmmeter, check PCM diode continuity. Ensure continuity exists in one direction only. Replace PCM diode as necessary and retest. If PCM diode is okay, repair open in Black wire. See «WIRING DIAGRAMS»(ref-139134) article.

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. Enter this pinpoint test only when a check for VREF has failed in sensor pinpoint tests for AP, BARO, CMP, EBP, ICP or MAP 3-wire sensors.

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.

3-Wire sensors.
Vehicle wiring harness circuits; (SIG RTN & VREF). (Scheme 18)
Faulty Powertrain Control Module (PCM).

Scheme 18

Scheme 19

Scheme 20

1) Check Vehicle Battery Power Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950) and connect PCM to breakout box. Turn ignition on. Using DVOM, measure voltage between PCM power test pins No. 55, 71 and 97 and PCM ground test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are more than 10.5 volts and within one volt of each other, go to next step. If any resistance is 10.5 volts or less or not within one volt of each other, go to TEST A, step 1).
2) Check VREF Voltage Using DVOM, 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) Check VREF & SIG RTN Circuits Turn ignition off. Disconnect suspect sensor connector. (Scheme 19)or (Scheme 20). Disconnect PCM from breakout box. Using DVOM, measure resistance between test pin No. 90 at breakout box and VREF circuit terminal at suspect sensor harness connector. (Scheme 18) Using DVOM, measure resistance between test pin No. 91 at breakout box and SIG RTN circuit terminal at suspect sensor harness connector. If both resistances are less than 5 ohms, no concern is indicated at this time. Fault may be intermittent. Clear DTCs and retest. If either resistance is 5 ohms or more, locate and repair open in VREF or SIG RTN circuit. Clear DTCs and retest.
4) Check For Excess Voltage On VREF Circuit Disconnect PCM connector from breakout box. Turn ignition on. Using DVOM, measure voltage between negative battery terminal and test pin No. 90 at breakout box. If voltage is less than.5 volt, replace PCM. Clear DTCs and retest. If voltage is.5 volt or more, locate and repair short to voltage. Clear DTCs and retest.
5) Check SIG RTN Circuit Turn ignition off. Using DVOM, measure resistance between test pin No. 91 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, replace PCM.
6) Check For Shorted Accelerator Pedal (AP) Sensor Disconnect AP sensor connector. Sensor is located above accelerator pedal and has a 3-pin connector. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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. Clear DTCs and retest.
7) Check For Shorted Camshaft Position (CMP) Sensor Turn ignition off. Disconnect CMP sensor connector. Sensor is located right on front of engine, above crankshaft pulley. (Scheme 19)or (Scheme 20). Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Injection Control Pressure (ICP) Sensor Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top center of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Exhaust Backpressure (EBP) Sensor Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Manifold Absolute Pressure (MAP) Sensor Turn ignition off. Disconnect MAP sensor connector. MAP sensor is mounted to cowl in engine compartment. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check VREF Circuit For Short To Ground Disconnect PCM connector from breakout box. Ensure all 3-wire sensors are still disconnected. Using DVOM, measure resistance between test pin No. 90 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace PCM and repeat «QUICK TEST»(ref-139800-S19570345092002050900000). If any resistance is 10 k/ohms or less, locate and repair short to ground. Clear DTCs and retest.

TEST DA: INTAKE AIR TEMPERATURE SENSOR

An IAT signal that is detected out of range high or low by PCM will cause engine to ignore IAT signal, disable exhaust backpressure operation and assume an ambient temperature of 59°F (15°C). This test is intended to diagnose the following components and circuits

Intake Air Temperature (IAT) Sensor
Wiring Harness Circuits; (IAT & SIG RTN)
Powertrain Control Module (PCM)

Temperature - °F (°C)	Resistance - k/Ohms	Volts
248 (120)	1.19	.28
230 (110)	1.56	.36
212 (100)	2.08	.47
194 (90)	2.80	.61
176 (80)	3.84	.80
158 (70)	5.34	1.04
140 (60)	7.55	1.34
122 (50)	10.93	1.72
104 (40)	16.11	2.15
86 (30)	24.25	2.63
68 (20)	37.34	3.09
50 (10)	58.99	3.52

IAT SENSOR SPECIFICATIONS

Scheme 21

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P0112 1	DA5	DA8
P0113 1	DA1	DA8
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) DTC P0113 DTC P0113 is set when IAT sensor signal voltage is out of range (high). Possible causes are: Open In Harness Faulty IAT Sensor Faulty Harness Connector Faulty PCM Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access IAT V PID from PID/DATA MONITOR & RECORD menu. If voltage is 4.95 volts or more, go to next step. If voltage is less than 4.95 volts, go to step 8).
2) Induce Opposite Failure Disconnect IAT sensor connector. IAT sensor is located under air filter housing. Connect a jumper wire between battery negative terminal and IAT sensor harness connector terminal No. 2 (Gray/Red wire). (Scheme 21) Turn ignition off. If IAT V PID reading is more than zero volt, go to step 4). If IAT V PID reading is zero volts, go to next step.
3) Check SIG RTN Circuit Disconnect jumper wire. Using DVOM, measure resistance between chassis ground and IAT sensor harness connector terminal No. 2 (Gray/Red wire). If resistance is less than 5 ohms, replace IAT sensor. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in Gray/Red wire. Clear DTCs and retest.
4) Check Continuity Of Sensor Signal Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between IAT sensor harness connector terminal No. 1 (Gray wire) and test pin No. 39 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in Gray wire. Clear DTCs and retest.
5) KOEO DTC P0112 DTC P0112 is set when IAT sensor signal is out of range (low). The following are possible causes for this fault: Circuit Grounded In Wiring Harness Faulty Sensor Faulty Harness Connector Faulty PCM Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access IAT V PID from PID/DATA MONITOR & RECORD menu. If IAT V PID reading is.13 volt or less, go to next step. If IAT V PID reading is more than.13 volt, go to step 8).
6) Induce Opposite Failure Observe scan tool and disconnect IAT sensor connector. IAT sensor is located under air filter housing. If IAT V PID reading goes to 4.59 volts or more, replace IAT sensor. Clear DTCs and retest. If IAT V PID reading stays less than 4.59 volts, go to next step.
7) Check IAT Sensor Signal Circuit For Short To Ground Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 39 and test pins No. 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short to ground in Gray wire. Clear DTCs and retest.
8) Continuous Memory DTC P0112 Or P1113: Check Sensor DTCs P0112 and/or P0113 are set when IAT sensor signal circuit was out of range (low or high). These DTCs are generated under normal driving conditions. The following are possible causes for these faults: Faulty Sensor Open Or Grounded Circuit In Harness Faulty PCM Ensure scan tool is connected to DLC. Turn ignition on. Using scan tool, access IAT V PID from PID/DATA MONITOR & RECORD menu. While observing scan tool, tap on sensor to simulate road shock. Wiggle sensor connector. If no change in IAT V PID reading occurs, go to next step. If any change in IAT V PID reading occurs, replace IAT sensor. Clear DTCs and retest.
9) Check Wiring Harness While observing IAT V PID, wiggle, bend and shake small sections of wiring harness starting at IAT sensor and working toward PCM. If IAT V PID reading fluctuates, isolate fault and repair as necessary. If IAT V PID reading does not fluctuate, go to next step.
10) Inspect PCM & Wiring Harness Connectors Turn ignition off. Disconnect PCM connector and IAT sensor connector. Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary. Clear DTCs and retest. If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete. Clear DTCs and retest.

TEST DB: ENGINE OIL TEMPERATURE SENSOR

An EOT sensor signal that is detected out of range (high or low) by PCM will cause PCM to ignore EOT sensor signal and assume an engine oil temperature of -4°F (-20°C) for starting, and a temperature of 212°F (100°C) for engine-running conditions. The Malfunction Indicator Light (MIL), or SERVICE ENGINE SOON light (F650-750) will also be illuminated as long as condition exists. This test is intended to diagnose the following components and circuits

Engine Oil Temperature (EOT) Sensor
Wiring Harness Circuits; (EOT & SIG RTN)
Powertrain Control Module (PCM)

Temperature - °F (°C)	Resistance - k/Ohms	Volts
248 (120)	1.19	.53
230 (110)	1.56	.67
212 (100)	2.08	.86
194 (90)	2.80	1.09
176 (80)	3.84	1.37
158 (70)	5.34	1.72
140 (60)	7.55	2.11
122 (50)	10.93	2.56
104 (40)	16.11	3.01
86 (30)	24.25	3.44
68 (20)	37.34	3.82
50 (10)	58.99	4.13

EOT SENSOR SPECIFICATIONS

Scheme 22

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0197 1	DB4		DB6
P0198 1	DB1		DB6
P1184		DB9
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO DTC P0198: Check SIG RTN For Open Circuit DTC P0198 is set when EOT sensor circuit input voltage is out of range (high). The following are possible causes for this fault: Faulty Sensor Faulty Harness Or Connector Faulty PCM Disconnect EOT sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Using DVOM, measure resistance between chassis ground and terminal No. 2 (Gray/Red wire) at EOT sensor harness connector. (Scheme 22) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Gray/Red wire. Clear DTCs and retest.
2) Induce Opposite Failure Turn ignition on. Connect a jumper wire between EOT sensor harness connector terminals. Check for DTCs. If DTC P0197 is not present, go to next step. If DTC P0197 is present, replace EOT sensor. Clear DTCs and retest.
3) Check Continuity Of Sensor Signal Circuit Turn ignition off. Disconnect jumper wire. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between EOT sensor harness connector terminal No. 1 (Light Green/Red wire) and test pin No. 38 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open circuit in Light Green/Red wire. Clear DTCs and retest.
4) KOEO DTC P0197: Induce Opposite Failure DTC P0197 is set when EOT sensor circuit input voltage is out of range (low). The following are possible causes for this fault: 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. (Scheme 19)or (Scheme 20). Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0198 is not present, go to next step. If DTC P0198 is present, replace EOT sensor. Clear DTCs and retest.
5) Check EOT Sensor Signal Circuit For Short To Ground Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 38 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short to ground in wiring harness. Clear DTCs and retest.
6) Continuous Memory DTC P0197 Or P0198: Check For Intermittent Faults DTCs P0197 and/or P0198 are set when EOT sensor signal circuit was out of range (low or high). These DTCs are generated under normal driving conditions. Possible causes are: Faulty Sensor Faulty Sensor Connector Open Or Grounded Circuit In Harness Faulty Powertrain Control Module (PCM) Ensure scan tool is connected to DLC. Turn ignition on. Using scan tool, access EOT PID from PID/DATA MONITOR & RECORD menu. While observing scan tool, tap on EOT sensor to simulate road shock. Wiggle EOT sensor connector. If EOT PID value defaults to 212°F (100°C), go to step 8). If EOT PID value does not default to 212°F (100°C), go to next step.
7) Check Wiring Harness Using scan tool, access EOT PID from PID/DATA MONITOR & RECORD menu. While observing EOT PID, wiggle and bend small sections of wiring harness starting at EOT sensor and working toward PCM. If EOT PID value defaults to 212°F (100°C), isolate fault and repair as necessary. If EOT PID value does not default to 212°F (100°C), go to next step.
8) Check PCM & Vehicle Harness Connectors Turn ignition off. Disconnect EOT and PCM connectors. Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary. Clear DTCs and retest. If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete. Clear DTCs and retest.
9) KOER DTC P1184: Warm Engine DTC P1184 is set when engine oil temperature is not warm enough to perform KOER CYLINDER CONTRIBUTION SELF-TEST. Engine oil temperature must be 68-242°F (20-117°C) or sensor voltage must be.53-3.82 volts or DTC P1184 will set. The following are possible causes for this fault: Engine Not At Normal Operating Temperature Low Oil Level Faulty Cooling System Faulty EOT Sensor Faulty Thermostat 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»(ref-139800-S26331301612002050900000) under QUICK TEST. If DTC P1184 is present, go to next step. If DTC P1184 is not present, repair any other DTCs that are present. Clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000).
10) Check EOT Sensor Ensure scan tool is connected to DLC. Turn ignition on. Using scan tool, access EOT PID from PID/DATA MONITOR & RECORD menu. While observing EOT PID, tap on sensor to simulate road shock. If EOT PID value fluctuates or changes to less than 68°F (20°C), or more than 3.82 volts, replace EOT sensor. Clear DTCs and retest. If EOT PID value does not fluctuate or change to less than 68°F (20°C), or more than 3.82 volts, go to next step.
11) Check Wiring Harness While observing EOT PID, wiggle and bend small sections of EOT sensor wiring harness starting at EOT sensor and working toward PCM. If EOT PID value fluctuates, isolate fault and repair as necessary. Clear DTCs and retest. If EOT PID value does not fluctuate, go to next step.
12) Check PCM & Vehicle Harness Connectors Turn ignition off. Disconnect PCM and EOT sensor connectors. PCM is located in left rear of engine compartment, near brake master cylinder. EOT sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary. Clear DTCs and retest. If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete. Clear DTCs and retest.
13) Check For Biased EOT Sensor Allow vehicle to sit overnight. Connect scan tool to Data Link Connector (DLC). DO NOT start engine. Using scan tool, access EOT and IAT PIDs. Turn ignition on. If EOT and IAT PIDs are within plus or minus 11°F (6°C) of each other, go to next step. If EOT and IAT PIDs are not within plus or minus 11°F (6°C) of each other, verify wiring harness and connectors are okay. If wiring and connectors are okay, replace EOT sensor.
14) EOT Sensor Rationality Check Start engine and warm to 59-158°F (15-70°C). Remove fill/check plug from high-pressure oil pump reservoir. Measure reservoir oil temperature with an A/C thermometer. Using scan tool or DVOM, measure EOT voltage. Compare EOT sensor voltage to temperature readings in «EOT SENSOR SPECIFICATIONS»(ref-139800-S41999396302002052100000) table. If temperature readings between EOT SENSOR SPECIFICATIONS table and thermometer agree within plus or minus 5.4°F (3°C), verify performance concern. Return to «SYMPTOM DIAGNOSIS»(ref-140363-S17926710052002052100000) under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article. If temperature readings between EOT SENSOR SPECIFICATIONS table and thermometer agree within plus or minus 5.4°F (3°C), verify wiring harness and connectors are okay. If wiring and connectors are okay, replace EOT sensor.

TEST DC: INJECTION CONTROL PRESSURE SENSOR

Perform this test when directed by QUICK TEST. If PCM detects ICP sensor out of range high or low, Malfunction Indicator Light (MIL) or SERVICE ENGINE SOON light (F650-750) will be illuminated and PCM will go to open loop control of injection control pressure (operate from an estimated injection control pressure.) This test is intended to diagnose the following components and circuits

Injection Control Pressure (ICP) Sensor
Wiring Harness Circuits; (ICP, SIG RTN & VREF)
Powertrain Control Module (PCM)

Pressure - Psi (kPa)	Voltage
0 (0)	.02
200 (1.4)	.40
400 (2.8)	.73
600 (4.1)	.96
800 (5.5)	1.20
1000 (6.9)	1.40
1200 (8.3)	1.60
1400 (9.7)	1.90
1600 (11.0)	2.10
1800 (12.4)	2.30
2000 (13.8)	2.60
2200 (15.2)	2.80
2400 (16.5)	3.00
2600 (17.9)	3.30
2800 (19.3)	3.50
3000 (20.7)	3.8

ICP SENSOR SPECIFICATIONS

Scheme 23

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1210	DC12		DC23
P1212			DC15
P1280 1	DC2		DC2
P1281 1	DC9		DC9
P1284		DC22
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) Check For Biased ICP Sensor Connect scan tool to Data Link Connector (DLC). Start engine and warm to normal operating temperature. Turn ignition off for one minute, then turn ignition back on. Using scan tool, access ICP and ICP V PIDs from PID/DATA MONITOR & RECORD menu. If ICP PID value is more than zero psi (zero kPa), or ICP V PID value is more than.30 volt, go to next step. If ICP PID value is zero psi (zero kPa), or ICP V PID value is.30 volt or less, return to «SYMPTOM DIAGNOSIS»(ref-140363-S17926710052002052100000) under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article.
2) KOEO & Continuous Memory DTC P1280: Check VREF Circuit Voltage DTC P1280 indicates injector control signal circuit was out of range (low) during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault: Biased ICP Sensor Open ICP, SIG RTN Or VREF Circuit Short To Ground In ICP Circuit Faulty PCM Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Turn ignition on. Using DVOM, measure voltage between chassis ground and ICP sensor harness connector terminal "B" (Brown/White wire). (Scheme 23) 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 (Brown/White wire) between PCM and ICP sensor. Clear DTCs and retest.
3) SIG RTN Circuit Check Using DVOM, measure voltage between ICP sensor harness connector terminal "A" (Gray/Red wire) and terminal "B" (Brown/White wire). 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 SIG RTN circuit (Gray/Red wire) between PCM and ICP sensor. Clear DTCs and retest.
4) ICP Signal Circuit Check Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between ICP sensor harness connector terminal "C" (Dark Blue/Light Green wire) 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 in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.
5) VREF Circuit Check Using DVOM, measure resistance between ICP sensor harness connector terminal "B" (Brown/White wire) 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 Brown/White wire between PCM and ICP sensor. Clear DTCs and retest.
6) SIG RTN Circuit Check Using DVOM, measure resistance between ICP sensor harness connector terminal "A" (Gray/Red wire) 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 between PCM and ICP sensor. Clear DTCs and retest.
7) Check For Sensor Signal Circuit Short To Ground Using a DVOM, measure resistance between test pin No. 87 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.
8) Check For Short To Ground In PCM (Pin No. 87) Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 87 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace ICP sensor. Clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Clear DTCs and retest.
9) KOEO & Continuous Memory DTC P1281: Check ICP Sensor DTC P1281 is set when injector control pressure circuit is out of range (high) during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault: Biased ICP Sensor ICP Circuit Shorted To VREF Faulty Powertrain Control Module (PCM) Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Turn ignition on. Repeat «QUICK TEST»(ref-139800-S19570345092002050900000). If DTC P1280 is now present, replace ICP sensor. Clear DTCs and retest. If DTC P1280 is not present, go to next step.
10) Check For Short To PWR Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 87 and No. 55, 71, 90 and 97 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.
11) Check For Short To PWR In PCM (Pin No. 87) Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all resistances are more than 10 k/ohms, replace ICP sensor. Clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Clear DTCs and retest.
12) KOEO DTC P1210 DTC P1210 is set when signal voltage was greater than expected during KOEO ON-DEMAND SELF-TEST. The following are possible causes for this fault: Biased ICP Sensor ICP SIG RTN Circuit Open ICP Circuit Shorted To PWR Faulty Powertrain Control Module (PCM) Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Using DVOM, measure resistance between chassis ground and ICP sensor harness connector terminal "A" (Gray/Red wire). (Scheme 23) 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 between PCM and ICP sensor. Clear DTCs and retest.
13) Check Signal Circuit For Short To PWR Turn ignition on. Using DVOM, measure voltage between chassis ground and ICP sensor harness connector terminal "C" (Dark Blue/Light Green wire). If voltage is less than.25 volt, go to next step. If voltage is.25 volt or more, locate and repair short to voltage in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.
14) ICP Sensor Check Turn ignition off. Reconnect ICP sensor connector. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. If ICP PID reading indicates zero psi (zero kPa), replace PCM. Clear DTCs and retest. If ICP PID reading does not indicate zero psi (zero kPa), replace ICP sensor. Clear DTCs and retest.
15) Continuous Memory DTC P1212: Verify KOEO DTCs DTC P1212 is set when PCM does not detect Injection Control Pressure (ICP) present during cranking (long crank time). The following are possible causes for this fault: Empty/Low Oil Reservoir Injection Pressure Regulator (IPR) Circuit Fault Faulty IPR Valve Faulty ICP Sensor Faulty High Pressure Oil Pump Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If any KOEO DTCs are present, service DTCs as necessary before continuing with this test. If Continuous Memory DTC P1212 is still present or if no KOEO DTCs are present, go to next step.
16) Check Oil Reservoir Level Remove plug in top of oil reservoir and check oil level. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000). If oil level is within 1" (25.4 mm) of top of reservoir, check fuel pressure. See TEST 5: ELECTRIC FUEL PUMP PRESSURE under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If fuel pressure is okay, check FUEL PW, ICP, RPM and VPWR PID values while cranking engine. See TEST 9A, 9B, 9C and 9D under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If PID values are okay, clear DTCs. Using scan tool, access ICP V PID from PID/DATA MONITOR & RECORD menu. Observe ICP V PID on scan tool, while cranking engine for 5 seconds. If ICP V PID voltage is less than.85 volt, go to next step. If ICP V PID voltage is.85 volt or more, fault is intermittent. Service all other DTCs first. If no other DTCs are set, go to step 20).
17) Check ICP Sensor Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Attempt to start vehicle. If vehicle starts, replace ICP sensor. Clear DTCs and retest. If vehicle does not start, go to next step.
18) High Pressure Leakage Test Reconnect ICP sensor connector. Clear ICP DTCs. Check for pressurized oil leaks. Perform TEST 10A: INJECTION CONTROL PRESSURE TESTS (OIL AERATION/POOR IDLE) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. Clear DTCs and retest. If no leaks are found, go to next step.
19) IPR Valve Check Ensure all hoses and ICP sensor are reconnected. Replace IPR valve. (Scheme 19)or (Scheme 20). Ensure oil reservoir level is full. Attempt to start vehicle. If vehicle starts, IPR valve was faulty. Clear DTCs and retest. If vehicle does not start, replace high pressure oil pump. Clear DTCs and retest.
20) Check For Intermittent Circuit Faults Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. While observing ICP PID, wiggle and bend small sections of wiring harness starting at ICP sensor and working toward PCM. PCM is located in left rear of engine compartment, near brake master cylinder. If ICP PID reading fluctuates, isolate fault and repair as necessary. Clear DTCs and retest. If ICP PID does not fluctuate, go to next step.
21) Check IPR Circuit Inspect wiring harness and connectors between IPR valve and PCM. See «WIRING DIAGRAMS»(ref-139134) article. Repair as necessary. Clear DTCs and retest. If wiring harness and connectors are okay, no concern is indicated at this time. Clear DTCs and retest.
22) KOER DTC P1284: Perform KOEO On-Demand Self-Test DTC P1284 is set when an Injection Control Pressure (ICP) circuit failure has occurred while performing KOER CYLINDER CONTRIBUTION SELF-TEST. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If an ICP circuit fault is indicated, go to appropriate system test and service DTC as necessary. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). Clear DTCs and retest. If no ICP fault is indicated, replace PCM. Clear DTCs and retest.
23) Continuous Memory DTC P1210: Perform KOEO On-Demand Self-Test DTC P1210 is set when Injection Control Pressure (ICP) sensor signal voltage was more than expected with ignition on during normal driving conditions. The following are possible causes for this fault: Biased ICP Sensor ICP SIG RTN Circuit Open ICP Signal Circuit Shorted To PWR Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. Service all other KOEO DTCs first. If Continuous Memory DTC P1210 is still present or no DTCs are present, go to next step.
24) ICP Signal Ground Circuit Check Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. (Scheme 19)or (Scheme 20). Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between ICP sensor harness connector terminal "A" (Gray/Red wire) and test pin No. 91 at breakout box. Observe resistance reading on DVOM, while wiggling and bending 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 intermittent open and repair as necessary. Clear DTCs and retest.
25) ICP Signal Circuit Short To PWR Check Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 87 at breakout box. No voltage should be present. Observe DVOM voltage reading while wiggling and bending small sections of wiring harness starting at ICP sensor and working toward PCM. If no voltage is indicated, go to next step. If any voltage is indicated, repair intermittent short to PWR and repair as necessary. Clear DTCs and retest.
26) ICP Sensor Circuit Check Turn ignition off. Reconnect ICP sensor connector. Remove breakout box and reconnect PCM to harness connector. Clear ICP DTCs. Turn ignition on. Lightly tap on ICP sensor. Check for DTCs. If DTC P1210 is present, replace ICP sensor. Clear DTCs and retest. If DTC P1210 is not present, fault cannot be duplicated at this time. Testing is complete. Clear DTCs and retest.

Any detected malfunction of AP sensor will illuminate MIL (Econoline) or SERVICE ENGINE SOON indicator (F650-750). An AP signal that is detected out of range (high or low) by PCM will cause engine to ignore AP signal and will only allow engine to operate at low idle. If a disagreement in state of Idle Validation Switch (IVS) and AP sensor is detected by PCM, engine will only be allowed to operate at low idle. Perform this test when directed by QUICK TEST. This test is only intended to diagnose the following components and circuits

AP Sensor
Wiring Harness Circuits; (AP, AP GND & VREF)
Powertrain Control Module (PCM)

Scheme 24

Scheme 25

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P0122 1 & 2	DD5	DD5
P0123 1 & 2	DD1	DD1
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected. () For vehilces with an Electronic Throttle Control see FAULT CODE SETTING CONDITION .

()

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P0123: Check AP PID DTC P0123 is set when PCM detects AP sensor circuit input high. The following are possible causes for this fault: Damaged Accelerator Pedal Assembly AP Sensor Not Installed Properly Faulty AP Sensor Short To PWR In Wiring Harness Faulty PCM Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access AP PID from PID/DATA MONITOR & RECORD menu. Slowly depress accelerator pedal while observing scan tool. If voltage reading changes to more than 4.5 volts, leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If voltage reading does not change to more than 4.5 volts, fault cannot be duplicated at this time. Clear DTCs and retest.
2) Induce Opposite Failure Continue to monitor AP PID voltage on scan tool and disconnect AP sensor connector. AP sensor is mounted above accelerator pedal. (Scheme 24) Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. If AP PID voltage reading changes from more than 4.5 volts to zero volt when connector is disconnected, AP circuit is okay. Replace accelerator pedal assembly. Clear DTCs and retest. If voltage reading does not change from more than 4.5 volts to zero volt when connector is disconnected, go to next step.
3) Check AP Sensor Signal Wire Ensure AP sensor is disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and AP sensor harness connector terminal No. 2 (Gray/White wire). (Scheme 25) If voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, replace PCM. Clear DTCs and retest.
4) Check AP Circuit For Short To Voltage Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, check for voltage between chassis ground and test pin No. 89 at breakout box. If voltage is present, locate and repair short to voltage in Gray/White wire between PCM and AP sensor. Clear DTCs and retest. If voltage is not present, replace PCM. Clear DTCs and retest.
5) KOEO & Continuous Memory DTC P0122 DTC P0122 is set when PCM detects AP sensor circuit input low. The following are possible causes for this fault: AP Sensor Not Installed Properly Faulty AP Sensor Grounded Or Open Wiring Harness Faulty Powertrain Control Module (PCM) Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access AP PID from PID/DATA MONITOR & RECORD menu. Slowly depress accelerator pedal while observing scan tool. If voltage reading changes to less than.37 volt, leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If voltage reading does not change to less than.37 volt, fault cannot be duplicated at this time. Clear DTCs and retest.
6) Induce Opposite Failure Disconnect AP sensor connector. AP sensor is mounted above accelerator pedal. Turn ignition on. Continue to monitor AP PID voltage on scan tool. Connect a jumper wire between AP sensor harness connector VREF terminal No. 3 (Brown/White wire) and AP signal terminal No. 2 (Gray/White wire). (Scheme 25) If voltage reading changes to more than 4.5 volts with jumper connected, circuits are okay. Replace accelerator pedal assembly. Clear DTCs and retest. If voltage reading does not change to more than 4.5 volts with jumper connected, disconnect jumper wire and go to next step.
7) Check VREF Circuit Voltage Ensure ignition is on. Using DVOM, measure voltage between chassis ground and AP sensor harness connector VREF terminal No. 3 (Brown/White wire). 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 Brown/White wire between PCM and AP sensor. Clear DTCs and retest.
8) Check AP GND Circuit Turn ignition off. Using DVOM, measure resistance between chassis ground and AP sensor harness connector terminal No. 1 (Yellow/Black wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/Black wire between PCM and AP sensor. Clear DTCs and retest.
9) Check AP Signal Circuit Continuity Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Gray/White wire between AP sensor harness connector terminal No. 2 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 Gray/White wire between PCM and AP sensor. Clear DTCs and retest.
10) Check AP Signal Circuit For Short To Ground Turn ignition off. Ensure AP sensor is disconnected. Using DVOM, measure resistance between test pin No. 89 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in AP signal circuit (Gray/White wire). Clear DTCs and retest.
11) Check VREF Circuit Continuity Using a DVOM, measure resistance of Brown/White wire between AP sensor harness connector terminal No. 3 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, repair open in Brown/White wire between PCM and AP sensor. Clear DTCs and retest.
12) Check AP GND Circuit Continuity Using a DVOM, measure resistance of Yellow/Black wire between AP sensor harness connector terminal No. 1 and test pin No. 24 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Yellow/Black wire between PCM and AP sensor. Clear DTCs and retest.

TEST DE: EXHAUST BACKPRESSURE SENSOR

An EBP signal that is detected out of range (high or low) by PCM will cause engine to ignore EBP signal and disable exhaust backpressure operation. Perform this test when directed by QUICK TEST. This test is only intended to diagnose the following components and circuits

Exhaust Backpressure (EBP) Sensor
Wiring Harness Circuits; (EBP, SIG RTN & VREF)
Powertrain Control Module (PCM)

Note. F650-750 models are not equipped with EBP.

Scheme 26

Psi (kPa)	In. Hg	Volts
0 (0)	0	0
8 (55)	16.3	.25
20 (138)	40.7	1.45
50 (345)	101.8	4.45
53 (365)	108.0	4.75
60 (414)	122.2	5.00

EBP SENSOR SPECIFICATIONS

Scheme 27

Scheme 27: Testing

Scheme 28

1) KOEO DTC P0470: Monitor EBP PID DTC P0470 is set when PCM detects an EBP sensor malfunction during KOEO ON-DEMAND SELF-TEST. The following are possible causes for this fault: Faulty EBP Sensor Open EBP Signal Circuit Faulty PCM Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. If EBP reading is 18.5 psi (127 kPa) or more, go to next step. If EBP reading is less than 18.5 psi (127 kPa), clear DTCs and repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC is still present, replace PCM. Clear DTCs and retest.
2) Signal Ground Circuit Check Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Using DVOM, measure resistance between chassis ground and EBP sensor harness connector terminal "A" (Gray/Red wire). (Scheme 26) If resistance is less than 5 ohms, replace EBP sensor. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in SIG RTN circuit (Gray/Red wire) between PCM and EBP sensor. Clear DTCs and retest.
3) Continuous Memory DTC P0470: Monitor EBP PID DTC P0470 is set when PCM detects an EBP sensor malfunction during normal driving conditions. The following are possible causes for this fault: Faulty EBP Sensor Faulty Connection Faulty Powertrain Control Module (PCM) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD 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. Clear DTCs and retest. If reading does not fluctuate, go to next step.
4) Check Connector Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Disconnect PCM connector. Inspect connectors for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connectors as necessary. Clear DTCs and retest. If both connectors are okay, no concern is indicted at this time. Clear DTCs and retest.
5) Continuous Memory DTC P0471: Monitor EBP PID DTC P0471 is set when PCM detects an EBP sensor malfunction during normal driving conditions and with EBP sensor enabled. The following are possible causes for this fault: Faulty EBP Sensor. Plugged Or Restricted Sensor Supply Tube Damaged Exhaust Pressure Regulator (EPR) Linkage Or Butterfly Faulty PCM Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If any KOEO DTCs are present, repair fault(s) before continuing with this test. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. Road test vehicle performing hard accelerations while monitoring EBP PID. If EBP PID reading increases to more than 25 psi with EBP device on, no concern is indicated at this time. Clear DTCs and retest. If EBP reading does not increase to more than 25 psi, go to next step.
6) Check For Exhaust Leaks Inspect turbo pipe, crossover pipes and exhaust manifolds for leaks. Repair as necessary. Clear DTCs and retest. If no exhaust leaks are present, go to next step.
7) Check Sensor Supply Tube Inspect EBP sensor supply tube from exhaust manifold to sensor bracket. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Ensure tube is not restricted or plugged. Replace tube as necessary. Clear DTCs and retest. If tube is okay, go to next step.
8) EBP Sensor Check Disconnect EBP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between EBP sensor and sensor harness connector. Start engine and allow it to idle. Using DVOM, 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 1.35 volt or more, clear DTCs and retest. If DTC is still present, replace PCM. If voltage reading during acceleration is 1.35 volt or less, replace EBP sensor. Clear DTCs and retest.
9) KOEO & Continuous Memory DTC P0472: Check For Open In VREF Circuit DTC P0472 is set when PCM detects EBP sensor circuit input low during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault: Open EBP Signal, SIG RTN Or VREF Circuit Biased Sensor EBP Circuit Shorted To SIG RTN Or PWR GND Faulty PCM Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Turn ignition on. Using DVOM, measure voltage between chassis ground and EBP sensor harness connector VREF terminal "B" (Brown/White wire). (Scheme 26) If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, repair open in Brown/White wire between PCM and EBP sensor. Clear DTCs and retest.
10) SIG RTN Circuit Check Using DVOM, measure resistance between chassis ground and EBP sensor harness connector SIG RTN circuit terminal "A" (Gray/Red wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Red wire between PCM and EBP sensor. Clear DTCs and retest.
11) EBP Signal Circuit Check Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Purple/Light Blue wire between EBP sensor harness connector terminal "C" 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, repair open in Purple/Light Blue wire between PCM and EBP sensor. Clear DTCs and retest.
12) VREF Circuit Check Using DVOM, measure resistance of Brown/White wire between at EBP sensor harness connector terminal "B" 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, repair open in Brown/White wire between PCM and EBP sensor. Clear DTCs and retest.
13) Check For Grounded EBP Signal Circuit Using DVOM, measure resistance between test pin No. 30 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is less than 10 k/ohms, locate and repair short to ground in Purple/Light Blue wire between PCM and EBP sensor. Clear DTCs and retest.
14) Check For Internal PCM Short Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 30 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace EBP sensor. Clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Clear DTCs and retest.
15) KOEO & Continuous Memory DTC P0473: Induce Opposite Failure DTC P0473 is set when PCM detects EBP sensor circuit input high during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault: Biased Sensor/PCM EBP Circuit Shorted To VREF Disconnect EBP sensor connector. Turn ignition on. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0472 is now present, replace EBP sensor. Clear DTCs and retest. If KOEO DTC P0472 is not present, go to next step.
16) Check EBP Circuit For Short To PWR Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 30 and test pins No. 55, 71, 90 and 97 at breakout box. If all resistances are more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short to PWR in EBP signal circuit (Violet/Light Blue wire) between PCM and EBP sensor. Clear DTCs and retest.
17) Continuous Memory DTC P0478: Check MGP & RPM PIDs DTC P0478 is set when PCM detects excessive backpressure existing during normal driving. The following are possible causes for this fault: Stuck EBP Butterfly Valve Restricted Exhaust Plugged EBP Sensor Tube Misadjusted EPR Linkage Wastegate Turbo Possible Overboost (F250-550 Only) Connect scan tool to Data Link Connector. Turn ignition on. Using scan tool, access MGP and RPM PIDs from PID/DATA MONITOR & RECORD menu. Road test vehicle in best gear to accelerate at 2500-3000 RPM. Note highest boost pressure. If MGP PID reading is less than 18 psi (124 kPa) for more than 5 seconds, go to next step. If MGP PID reading is 18 psi (124 kPa) or more for more than 5 seconds, go to TEST KH, step 6).
18) Inspect Butterfly Tang Visually inspect EBP butterfly valve (note tang position). (Scheme 27) If valve is in open position, go to next step. If valve is not in open position, repair damaged linkage or butterfly as necessary. Clear DTCs and retest.
19) Check For Exhaust Restriction Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD 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 (193 kPa), go to next step. If EBP PID reading is 28 psi (193 kPa) or more, repair restricted exhaust system. Clear DTCs and retest.
20) 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. Clear DTCs and retest. 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 28) Clear DTCs and retest.
21) Check For Biased EBP Sensor Turn ignition on. Using scan tool, monitor EBP, MAP and BARO PIDs. If EBP PID value does not deviate from atmospheric pressure (dependent on altitude) by more than 1.5 psi (10 kPa), return to RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY, step 21) in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article. If EBP PID value deviates from atmospheric pressure (dependent on altitude) by more than 1.5 psi (10 kPa), check wiring and Powertrain Control Module (PCM). If wiring and PCM are okay, replace EBP sensor.

TEST DF: CAMSHAFT POSITION SENSOR

An inactive CMP signal during cranking is detectable by PCM and will cause a no-start condition. Electrical noise can also be detected by PCM and if noise level effects engine operation, a corresponding DTC will be set. Perform this test when directed by QUICK TEST. This test is only intended to diagnose the following components and circuits

Camshaft Position (CMP) Sensor
Wiring Harness Circuits; (CMP, CMP GND & VREF)
Powertrain Control Module (PCM)

Scheme 29

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0340	DF1		DF1
P0341		DF1	DF1
	P0344	DF1	DF1

FAULT CODE SETTING CONDITION

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, access RPM PID from PID/DATA MONITOR & RECORD menu. Crank engine while monitoring RPM PID. If RPM PID indicates cranking RPM, go to next step. If RPM PID does not indicate cranking RPM, go to step 3).
2) Check For DTC P0341 Or P0344 Start and run engine until coolant is at normal operating temperature. Raise engine speed to 3300 RPM (2500 RPM for F650-750) for 2 minutes. Cycle ignition off, then on. Check for DTCs. If DTC P0341 or P0344 is present, go to next step. If DTC P0341 or P0344 is not present, go to step 12).
3) Check CMP SIG RTN Circuit Turn ignition off. Disconnect CMP sensor connector. Sensor is located on right front of engine, above crankshaft pulley. (Scheme 19)or (Scheme 20). Using DVOM, measure resistance between chassis ground and CMP sensor harness connector terminal "A" (Light Blue wire). (Scheme 29) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, go to step 9).
4) Check CMP Circuit For VREF Turn ignition on. Using DVOM, measure voltage between chassis ground and CMP sensor harness connector terminal "B" (Brown/White wire). If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, repair VREF circuit as necessary. Go to «TEST C: REFERENCE VOLTAGE»(ref-139800-S26336520532002050900000).
5) Check CMP Circuit For Short To Battery PWR (PCM Connected) Using DVOM, measure voltage between chassis ground and CMP sensor harness connector terminal "C" (Dark Green wire). If battery voltage is present, go to next step. If battery voltage is not present, go to step 7).
6) Check CMP Circuit For Short To Battery PWR (PCM Disconnected) Turn ignition off. Disconnect PCM 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. Turn ignition on. Using DVOM, measure voltage between chassis ground and CMP sensor harness connector terminal "C" (Dark Green wire). If battery voltage is present, locate and repair short to voltage in Dark Green wire. Clear DTCs and retest. If battery voltage is not present, replace CMP sensor. Clear DTCs and retest.
7) Check CMP Circuit For Short To Ground Turn ignition off. Disconnect PCM 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. Using DVOM, measure resistance between chassis ground and CMP sensor harness connector terminal "C" (Dark Green wire). If resistance is less than 5 ohms, locate and repair short to ground in Dark Green wire. Clear DTCs and retest. If resistance is 5 ohms or more, go to next step.
8) Check CMP Circuit For Open Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Dark Green wire between CMP sensor harness connector terminal "C" 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 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, repair open in Dark Green wire. Clear DTCs and retest.
9) Check For Open In CMP GND Circuit Ensure ignition is off and CMP sensor is disconnected. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Light Blue wire between CMP sensor harness connector terminal "A" 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, repair open in Light Blue wire between PCM and CMP sensor. Clear DTCs and retest.
10) Check For CMP Sensor Ground Through PCM Connect PCM to breakout box. Using DVOM, measure resistance between chassis ground and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances 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 resistance is 5 ohms or more, repair open in ground circuit. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
11) Confirm PCM Fault Repeat steps 1) and 2). If fault is still present, replace PCM. Clear DTCs and retest. If fault is not present, no concern is indicated at this time. Testing is complete.
12) Check For Intermittent Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950) and connect PCM. To prevent vehicle from starting, disconnect Injector Driver Module (IDM) relay. Relay is located in battery junction box on left front of 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, leave DVOM connected to test pins and go to next step. If lower voltage reading is not.3-2.7 volts, go to step 3).
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 voltage reading jumps to battery voltage or goes to zero volts, locate and repair intermittent in wiring harness. Clear DTCs and retest. If voltage reading does not jump to battery voltage or go to zero volt, no concern is indicated at this time. Clear DTCs and retest.

TEST DG: BAROMETRIC PRESSURE SENSOR

Note. Barometric Pressure (BARO) sensor is integral to PCM. BARO sensor cannot be serviced separately. PCM replacement is required if a BARO sensor failure is identified.

Perform this test when directed by QUICK TEST. BARO sensor is part of PCM and is not serviced separately. If BARO sensor is faulty, PCM must be replaced. BARO sensor functions are as follows

Timing Control The BARO signal affects injection timing and fuel quantity to optimize engine operation and control smoke throughout all altitude conditions.
Glow Plug Control The BARO signal is one of the variables used to calculate glow plug ON time. At higher altitudes, glow plug ON time is increased to reduce start-up smoke.
Detection & Management A BARO signal that is detected out of range (high or low) by PCM will cause PCM to ignore BARO signal and use Manifold Absolute Pressure (MAP) signal generated at low idle as an indication of barometric pressure.

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P0107 1	DG1	DG3
P0108 1	DG2	DG4
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

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»(ref-139800-S08685095592002050900000) under QUICK TEST. 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) KOEO DTC P0108: BARO Circuit High Input This DTC indicates BARO sensor circuit high input was detected during KOEO on-demand self-test. Repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. 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) 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»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0107 is present, BARO sensor is defective. Replace PCM. If KOEO DTC P0107 is not present, fault is intermittent. If DTC P0107 reappears, replace PCM.
4) Continuous Memory DTC P0108: BARO Circuit High Input This DTC indicates BARO sensor circuit high input was detected during normal operation. Repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0108 is present, BARO sensor is defective. Replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000) . If KOEO DTC P0108 is not present, fault is intermittent. If DTC P0108 resets, replace PCM.

TEST DH: MANIFOLD ABSOLUTE PRESSURE SENSOR

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

Manifold Absolute Pressure (MAP) sensor.
Wiring Harness Circuits (VREF, SIG RTN & MAP SIG) (Scheme 30)
Powertrain Control Module (PCM).

Manifold Absolute Pressure (MAP) sensor functions are as follows

Smoke Control MAP signal is used to control smoke by limiting fuel quantity during acceleration until a specified boost pressure is obtained.
Dynamic Injection Timing Optimizes injection timing for boost pressure measured.
Fault Detection & Management A MAP signal that is detected by PCM to be out of range or at an incorrect value for specific conditions will cause PCM to ignore MAP signal and operate engine from an inferred boost pressure signal.

Scheme 30

Psi (kPa)	(1) Volts
11.5 (80)	1.1
14.7 (101)	1.5
20 (138)	2.2
25 (172)	2.8
30 (206)	3.6
35 (242)	4.3
(1) A variation of plus or minus .3 volt is acceptable.

(1)	A variation of plus or minus .3 volt is acceptable.

MAP SENSOR SPECIFICATIONS

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P0236 1	DH1	DH1
P0237 1	DH5	DH12
P0238 1	DH10	DH14
P1247		DH1
P1248		DH1
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO &/Or Continuous Memory DTC P0236, P1247 Or P1248: Boost Pressure Is Low Or Not Detected DTC P0236 indicates faulty turbo boost sensor circuit performance. DTCs P1247 and P1248 indicate turbo boost pressure is low or not detected. The following are possible causes for these faults: Damaged MAP Hose Low Turbo Boost Intake Manifold Or Crossover Leaks Damaged MAP Sensor Damaged PCM Inspect MAP sensor hose and manifolds for damage, misrouting or restriction. MAP sensor is mounted to cowl in engine compartment. Replace hose and manifolds as necessary. If hose and manifolds are okay, go to next step.
2) Check MAP Sensor Disconnect PCM 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 Rotunda Breakout Box (014-00950), connect PCM to breakout box. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 79 at breakout box. Note voltage reading and compare to specification. See «MAP SENSOR SPECIFICATIONS»(ref-139800-S42848488852002050900000) table. If voltage is within is .5 volt for given altitude (psi), go to next step. If voltage is not as specified, replace MAP sensor. Clear DTCs and retest.
3) MAP Sensor Voltage Check Disconnect vacuum hose from MAP sensor. Turn ignition on. Using Pressure Adapter Kit (014-00761), apply 10 psi (69 kPa) of pressure to MAP sensor. Using DVOM, measure voltage between chassis ground and test pin No. 79 at breakout box. If voltage is 2.5-3.1 volts, go to next step. If voltage is not 2.5-3.1 volts, replace MAP sensor. Clear DTCs and retest.
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 so gauge will be visible during a road test. Road test vehicle and accelerate vehicle to achieve full boost. If boost is 12 psi or more, clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000) . 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.
5) KOEO DTC P0237: Boost Pressure Circuit Low Input DTC P0237 indicates low input to turbo boost sensor. The following are possible causes for this fault: MAP Signal Circuit Open Or Shorted To Ground VREF Circuit Open SIG RTN Circuit Open Or Shorted Faulty MAP Sensor Faulty PCM Turn ignition off. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0237 is present, go to next step. If DTC P0237 is not present, go to step 12) .
6) Check SIG RTN Circuit For Open Turn ignition off. Disconnect MAP sensor connector. MAP sensor is mounted to cowl in engine compartment. Using DVOM, measure resistance between chassis ground and Gray/Red wire at MAP sensor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Red wire between PCM and MAP sensor. Clear DTCs and retest.
7) Check VREF Circuit For Open Using DVOM, measure voltage between chassis ground and Brown/White wire at MAP sensor harness connector. If voltage is 5 volts or more, go to next step. If voltage is less than 5 volts, repair open in Brown/White wire between PCM and MAP sensor. Clear DTCs and retest.
8) Check MAP Signal Circuit For Open Disconnect PCM 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 Rotunda Breakout Box (014-00950), leave PCM disconnected. Using DVOM, measure resistance between test pin No. 79 at breakout box and Light Green/Black wire at MAP sensor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Green/Black wire between PCM and MAP sensor. Clear DTCs and retest.
9) Check MAP Signal Circuit For Short To SIG RTN Or Chassis Ground Using DVOM, measure resistance between test pin No. 79 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If each reading is more than 10 k/ohms, go to next step. If any resistance is less than 10 k/ohms, repair short to SIG RTN circuit or chassis ground in Light Green/Black wire between PCM and MAP sensor. Clear DTCs and retest.
10) KOEO DTC P0238 DTC P0238 indicates high input in turbo boost sensor circuit. The following are possible causes for this fault: Faulty MAP Sensor Short To Voltage In MAP Signal Circuit Faulty PCM Disconnect MAP sensor connector. MAP sensor is mounted to cowl in engine compartment. Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0238 is present, go to next step. If DTC P0238 is not present, replace MAP sensor. Clear DTCs and retest.
11) Check MAP Signal Circuit For Short To Voltage Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 79 and test pins No. 55, 71, 91 and 97 at breakout box. If all resistances are more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is less than 10 k/ohms, locate and repair short to voltage in Light Green/Black wire. Clear DTCs and retest.
12) Continuous Memory DTC P0237: Boost Pressure Circuit Low Input Continuous Memory DTC P0237 indicates low input to turbo boost sensor during normal driving conditions. The following are possible causes for this fault: Manifold Absolute Pressure (MAP) Sensor Signal Circuit Open Or Shorted To Ground Open VREF Circuit Open SIG RTN Circuit Faulty MAP Sensor Faulty PCM Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0237 is present, go to step 5) . If KOEO DTC P0237 is not present, go to next step.
13) Check For Intermittent Circuit Fault Clear Continuous Memory DTCs. Wiggle and bend small sections of wiring harness starting at MAP sensor harness connector and working toward PCM. PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve Continuous Memory DTCs. If DTC P0237 is present, locate and repair intermittent circuit fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0237 is not present, fault cannot be duplicated at this time and testing is complete. Reconnect all components, clear DTCs and retest.
14) Continuous Memory DTC P0238: Boost Pressure Circuit High Input Continuous Memory DTC P0238 indicates high input to turbo boost sensor during normal driving conditions. Possible causes are: Short To Voltage In MAP Signal Circuit Faulty MAP Sensor Faulty PCM Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0238 is present, go to step 10) . If KOEO DTC P0238 is not present, go to next step.
15) Check For Intermittent Circuit Fault Clear Continuous Memory DTCs. Wiggle and bend small sections of wiring harness starting at MAP sensor harness connector and working toward PCM. Retrieve DTCs. If Continuous Memory DTC P0238 is present, locate and repair intermittent circuit fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0238 is not present, fault cannot be duplicated at this time and testing is complete. Reconnect all components, clear DTCs and retest.

TEST DI: MANIFOLD AIR TEMPERATURE SENSOR (EXCEPT ECONOLINE)

Note. MAT sensor may also be referred to as Air Charge Temperature (ACT) sensor.

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

Manifold Air Temperature (MAT) Sensor
Wiring Harness Circuits (VREF, SIG RTN & MAT SIG)
Powertrain Control Module (PCM)

MAT sensor is used to measure intake air temperature after being cooled through intercooler. MAT sensor signal is used to determine injection timing.

Scheme 31

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1118	DI1		DI1
P1119	DI1		DI1

FAULT CODE SETTING CONDITION

1) DTC P1119: MAT Sensor Circuit High Input DTC P1119 indicates that MAT sensor signal voltage is more than self-test maximum. The following are possible causes for this fault: Open SIG RTN Circuit Faulty MAT Sensor Or Connector Faulty PCM Disconnect MAT sensor connector. MAT sensor is located at center front of engine. MAT sensor 2-pin connector has Red/Yellow and Gray/Red wires. Using DVOM, measure resistance between chassis ground and MAT sensor harness connector terminal No. 1 (Gray/Red wire). (Scheme 31) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Red wire between PCM and MAT sensor.
2) Induce Opposite Failure Turn ignition on. Connect a jumper wire between MAT sensor harness connector terminals. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1118 is not present, go to next step. If DTC P1118 is present, replace MAT sensor. Clear DTCs and retest.
3) Check MAT Signal Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 62 at breakout box and MAT sensor harness connector terminal No. 2 (Red/Yellow wire). If resistance is less than 5 ohms, go to step 6). If resistance is 5 ohms or more, repair open in Red/Yellow wire between PCM and MAT sensor. Clear DTCs and retest.
4) KOEO & Continuous Memory Only DTC P1118: Induce Opposite DTC P1119 DTC P1118 indicates that Manifold Air Temperature (MAT) sensor signal voltage is less than self-test maximum. MAT sensor may also be referred to as Air Charge Temperature (ACT) sensor. The following are possible causes for this fault: MAT Signal Circuit Shorted To Ground MAT SIG RTN Circuit Open Faulty MAT Sensor Faulty Powertrain Control Module (PCM) Disconnect MAT sensor connector. MAT sensor is located at center front of engine and has a 2-pin connector with Red/Yellow and Gray/Red wires. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1119 is not present, go to next step. If DTC P1119 is present, replace MAT sensor. Clear DTCs and retest.
5) Check MAT Sensor Signal For Short To Ground Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 62 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If each resistance is more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short to ground in MAT signal circuit (Red/Yellow wire) between PCM and MAT sensor. Clear DTCs and retest.
6) Check SIG RTN Circuit For Open Using DVOM, measure resistance of SIG RTN circuit (Gray/Red wire) between MAT sensor harness connector terminal No. 1 and test pin No. 91 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Gray/Red wire between PCM and MAT sensor. Clear DTCs and retest.

TEST DJ: WATER IN FUEL SENSOR

Note. Water In Fuel (WIF) sensor may also be referred to as fuel heater.

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

WIF Sensor Output To Powertrain Control Module (PCM)
WIF Sensor Wiring Harness Circuits
PCM

Water In Fuel (WIF) sensor is used to detect water in fuel system and is located in fuel filter housing. WIF sensor is monitored by PCM. If PCM detects water for more than 5 seconds, it will set a Continuous Memory DTC P1140 and turn on WATER IN FUEL Indicator Light (WIFIL).

Scheme 32

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1140			DJ1

FAULT CODE SETTING CONDITION

1) Continuous Memory DTC P1140: Check For Fuel Contaminants DTC P1140 indicates PCM detected water in fuel filter housing or a short to ground in monitoring circuit. The following are possible causes for this fault: WIF Filter Housing WIF Signal Circuit Shorted To Ground 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 housing. Fuel filter is located on top of engine. Place other 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 no water or other contaminants are 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) Check WIF Sensor For Short To Ground Turn ignition on. Disconnect WIF sensor connector. WIF sensor is located on top left of engine and has a 2-pin connector with Gray/Red and Red/Light Green wires. 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) Check WIF Signal Circuit For Short To Ground Turn ignition off. Disconnect PCM 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. Using DVOM, measure resistance between chassis ground and Gray/Red wire at WIF sensor harness connector. If resistance is more than 10 k/ohms, replace PCM. Clear DTCs and retest. If resistance is 10 k/ohms or less, repair short to ground in Gray/Red wire between PCM and WIF sensor. Clear DTCs and retest.
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

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

Water In Fuel (WIF) Indicator Light Circuit To Powertrain Control Module (PCM)
Power Circuit To WIF Indicator Light
WIF Sensor Wiring Harness Circuits
Faulty PCM

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1139	DK3		DK3

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P1139: Verify WIFIL Indicator Self-Test DTC P1139 indicates that instrument cluster has identified a failure of WIFIL indicator. Instrument cluster sends information to PCM to set DTC P1139. Possible causes for this fault are: Faulty WIFIL Indicator Faulty Instrument Cluster Faulty PCM Turn ignition on. WIFIL indicator should illuminate for about 2 seconds then turn off (self-test). If WIFIL operates as specified (performs self-test), clear DTC and retest. If DTC resets, go to TEST W under SYSTEM TESTS in ANALOG INSTRUMENT PANELS - EXCURSION & F250-550 article in ACCESSORIES & EQUIPMENT. If WIFIL does not operate as specified (self-test), go to next step.
2) Verify KOEO DTC P1139: Perform KOEO Self-Test Turn ignition on. Perform KOEO on-demand self-test. If DTC P1139 is present, go to TEST W under SYSTEM TESTS in ANALOG INSTRUMENT PANELS - EXCURSION & F250-550 article in ACCESSORIES & EQUIPMENT to diagnose instrument cluster. Restore vehicle, clear DTCs and retest. If DTC P1139 is not present, DTC is intermittent. Restore vehicle.
3) KOEO & Continuous Memory DTC P1139: Verify WIFIL Indicator Self-Test DTC P1139 indicates PCM detected a WIF indicator light circuit failure. The following are possible causes for this fault: Open Or Shorted Wiring Harness Circuit Faulty Light Bulb Faulty PCM Turn ignition on and observe WIFIL. If WIFIL illuminates for about 2 seconds then turns off, clear DTCs and retest. If DTC P1139 resets, check for an intermittent open or short to ground in Red wire between PCM and WIFIL. Repair as necessary. If WIFIL does not illuminate for about 2 seconds then turn off, go to next step.
4) Check State Of Indicator Light Turn ignition off. If WIFIL stayed on in step 3), go to next step. If WIFIL did not stay on in step 3), go to step 6).
5) Check WIFIL Circuit For Short To Ground Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Turn ignition on. If WIFIL illuminates, repair short to ground in Red wire between PCM and WIFIL. Clear DTCs and retest. If WIFIL does not illuminate, replace PCM. Clear DTCs and retest.
6) Check Fuse Check fuse No. 2 (Econoline) or fuse No. 29 (F650-750) at central junction box. On all models, central junction box is located behind lower left side of instrument panel. If fuse is okay, go to next step. If fuse is blown, check for short to ground in instrument cluster PWR circuit (Red/Yellow wire) between instrument cluster and central junction box. Replace fuse. Clear DTCs and retest.
7) Check Power To Instrument Cluster Turn ignition off. Disconnect instrument cluster connectors. Turn ignition on. Using DVOM, measure voltage between chassis ground and instrument cluster White 12-pin connector terminal No. 12 (Red/Yellow wire). see scheme 26or see scheme 28. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in Red/Yellow wire between instrument cluster and central junction box. Clear DTCs and retest.
8) Check WIFIL Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of WIFIL circuit between appropriate instrument cluster 12-pin connector terminal No. 12 (Red wire) and test pin No. 28 at breakout box. see scheme 26or see scheme 28. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Red wire between PCM and instrument cluster. Clear DTCs and retest.

TEST DL: VEHICLE SPEED SENSOR

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

Vehicle Speed Sensor (VSS)
VSS (+) & VSS (-) Circuits
Powertrain Control Module (PCM)

1) Continuous Memory DTC P0500: Check Continuity Of VSS Circuits DTC P0500 indicates PCM detected a VSS circuit failure. Possible causes are: Open In VSS (+) Or VSS (-) Circuits Short To Ground Or SIG RTN In VSS (+) Or VSS (-) Circuits Short To PWR In VSS (+) Or VSS (-) Circuits Faulty VSS Faulty PCM Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Disconnect VSS connector located on left side of transmission extension housing. Using DVOM, measure resistance of VSS (+) circuit (Gray/Black wire) between VSS harness connector and test pin No. 58 at breakout box. Using DVOM, measure resistance of VSS (-) circuit (Pink/Orange wire) between VSS harness connector and test pin No. 33 at breakout box. If both resistances are less than 5 ohms, go to next step. If either resistance is 5 ohms or more, repair open in appropriate wire between VSS and PCM. Clear DTCs and retest.
2) Check VSS Circuits For Short To Ground, SIG RTN & Power Ensure ignition is off. Using DVOM, measure resistance between the following test pins at breakout box: Test pin No. 58 and test pins No. 51, 76, 77 and 103 (PWR GND) at breakout box. Test pin No. 58 and test pin No. 33 (VSS-) at breakout box. Test pin No. 58 and test pin No. 91 (SIG RTN) at breakout box. Test pin No. 58 and test pin No. 71 (VPWR) at breakout box. Test pin No. 33 and test pin No. 71 (VPWR) at breakout box. If all resistances are more than 500 ohms, go to next step. If any resistance is 500 ohms or less, repair short circuit as necessary. See «WIRING DIAGRAMS»(ref-139134) article. Restore vehicle. Clear DTCs and retest.
3) Check VSS Resistance Ensure ignition is off. Using DVOM, measure resistance between VSS terminals. If resistance is not 190-250 ohms, replace VSS. Restore vehicle. Clear DTCs and retest. If resistance is 190-250 ohms, replace PCM. Restore vehicle. Clear DTCs and retest. 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.
10) KOER DTC P1501: Check PCM VSS PID For Input Signal DTC P1501 is set when PCM detects VSS input signal is out of self-test range during KOER ON-DEMAND SELF-TEST. Possible causes for this fault are: Noisy VSS input signal from Radio Frequency Interference (RFI). Noisy VSS input signal from Electromagnetic Interference (EMI) external source (ignition wires, charging circuits, etc.). Connect scan tool to Data Link Connector (DLC). Start engine and allow to idle. Using scan tool, access 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 value 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 retest.
11) Continuous Memory DTC P0503: Check VSS & VSS Circuit For Intermittent Fault DTC P0503 indicates poor or noisy VSS performance. Possible causes for this fault are: Noisy VSS input signal from Radio Frequency Interference (RFI). Noisy VSS input signal from Electromagnetic Interference (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 extension housing. 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 any faults are found, repair as necessary. If no faults are found, go to next step.
12) Check PCM VSS PID For Input Signal Using scan tool, access VSS PID from PID/DATA MONITOR & RECORD menu. Test drive vehicle at several steady speeds at more than 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 no such variations occur, fault cannot be duplicated at this time. DTC P0503 may have been set from sources external of vehicle. Service any other DTCs. Clear DTCs and retest.
13) Check VSS Wiring Harness Routing Visually inspect VSS wiring harness. Ensure wiring is not routed near high current wires (ignition wiring or alternator wiring). Verify VSS wiring harness is shielded and grounded (if applicable). Go to step 1) to check VSS circuit continuity. If any faults are found, service as necessary. Clear DTCs and retest. If no faults are found, fault cannot be duplicated at this time. Repeat «QUICK TEST»(ref-139800-S19570345092002050900000) .

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

Engine Coolant Temperature (ECT) Sensor
Wiring Harness Circuits (ECT & SIG RTN)
Powertrain Control Module (PCM)

Scheme 33

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0117	DM1		DM8
P0118	DM3		DM11

FAULT CODE SETTING CONDITION

1) KOEO DTC P1117: Induce Opposite DTC P0118 DTC P0117 indicates ECT sensor is out of range low. Possible causes for this fault are: ECT Signal Circuit Shorted To Ground Faulty Harness Connector Faulty ECT Sensor Faulty PCM Disconnect ECT sensor connector. Sensor is located in top of water pump assembly. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0118 is not present, go to next step. If DTC P0118 is present, replace ECT sensor. Clear DTCS and retest.
2) Check ECT Signal Circuit For Short To Ground Turn ignition off. Disconnect PCM 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. Leave PCM disconnected. Using DVOM, measure resistance between chassis ground and ECT sensor harness connector terminal No. 2 (Orange/Black wire). (Scheme 33) If resistance is more than 10 k/ohms, replace PCM. Clear DTCs and retest. If resistance is 10 k/ohms or less, repair short to ground in Orange/Black wire between ECT sensor and PCM. Clear DTCs and retest.
3) KOEO DTC P0118: Check SIG RTN Circuit For Open DTC P0118 indicates ECT sensor is out of range high. Possible causes for this fault are: ECT Signal Circuit Open Or Shorted To PWR SIG RTN Circuit Open Faulty ECT Sensor Faulty Harness Connector Faulty PCM Turn ignition off. Disconnect ECT sensor connector. Sensor is located in top of water pump assembly. Turn ignition on. Using DVOM, measure resistance between chassis ground and ECT sensor harness connector terminal No. 1 (Gray/Red wire). (Scheme 33) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in SIG RTN circuit (Gray/Red wire) between PCM and ECT sensor. Clear DTCs and retest.
4) Induce Opposite Failure Ensure ignition is on. Connect a jumper wire between ECT sensor harness connector terminals. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0117 is not present, disconnect jumper wire and go to next step. If DTC P0117 is present, replace ECT sensor. Clear DTCs and retest.
5) Check ECT Signal Circuit For Short To Power Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 37 and test pins No. 55, 71, 91 and 97 at breakout box. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, repair ECT signal circuit (Orange/Black wire) for short to PWR or VREF between PCM and ECT sensor. Clear DTCs and retest. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 5) to step 7). No test procedures have been omitted.
7) Check ECT Signal Circuit For Open Ensure ignition is off. Using DVOM, measure resistance of Orange/Black wire between ECT sensor harness connector terminal No. 2 and test pin No. 37 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Orange/Black wire between PCM and ECT sensor. Clear DTCs and retest.
8) Continuous Memory DTC P0117: Perform KOEO Self-Test DTC P0117 indicates ECT sensor out of range low was detected and DTC was set during normal driving conditions. Possible causes for this fault are: ECT Signal Circuit Shorted To Ground Faulty Harness Connector Faulty ECT Sensor Faulty PCM Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0117 is present, go to step 1). If KOEO DTC P0117 is not present, go to next step.
9) Intermittent Circuit Failure Check: DTC P0117 Clear Continuous Memory DTCs. Turn ignition on. Wiggle and bend small sections of wiring harness starting at ECT sensor and working toward PCM. Sensor is located in top of water pump assembly. PCM is located in left rear of engine compartment, near brake master cylinder. Recheck DTCs. If Continuous Memory DTC P0117 is not present, go to next step. If Continuous Memory DTC P0117 is present, isolate fault and repair wiring as necessary. Clear DTCs and retest.
10) Intermittent ECT Sensor Check Ensure ignition is on. Lightly tap on ECT sensor to simulate road shock. Wiggle sensor connector. Recheck Continuous Memory DTCs. If Continuous Memory DTC P0117 is not present, no concern is indicated at this time. Testing is complete. If Continuous Memory DTC P0117 is present, replace ECT sensor. Check ECT sensor harness connector for damaged pins. Repair as necessary. Clear DTCs and retest.
11) Continuous Memory DTC P0118: Perform KOEO Self-Test DTC P0118 indicates ECT sensor out of range high was detected and DTC was set during normal driving conditions. Possible causes for this fault are: ECT Signal Circuit Open Or Shorted To PWR SIG RTN Circuit Open Faulty ECT Sensor Faulty Harness Connector Faulty PCM Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0118 is present, go to step 3). If KOEO DTC P0118 is not present, go to next step.
12) Intermittent Circuit Failure Check: DTC P0118 Clear Continuous Memory DTCs. Turn ignition on. Wiggle and bend small sections of wiring harness starting at ECT sensor and working toward PCM. Sensor is located in top of water pump assembly. PCM is located in left rear of engine compartment, near brake master cylinder. Recheck Continuous Memory DTCs. If Continuous Memory DTC P0118 is not present, go to next step. If Continuous Memory DTC P0118 is present, isolate fault and repair wiring as necessary. Clear DTCs and retest.
13) Intermittent ECT Sensor Check Turn ignition on. Lightly tap on ECT sensor to simulate road shock. Wiggle sensor connector. Recheck Continuous Memory DTCs. If Continuous Memory DTC P0118 is not present, no concern is indicated at this time. Testing is complete. If Continuous Memory DTC P0118 is present, isolate fault and repair wiring as necessary. Clear DTCs and retest.

TEST FA: AIR CONDITIONING

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

A/C Wiring Harness Circuits
A/C Clutch
Powertrain Control Module (PCM)

Scheme 34

Scheme 35

Scheme 36

1) KOER DTC P1464: Perform KOER Cylinder Contribution Self-Test 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»(ref-139800-S26331301612002050900000) under QUICK TEST. Retrieve DTCs. If DTC P1464 is present, go to next step. If DTC P1464 is not present, fault may be intermittent. Go to step 9).
2) Check A/C Clutch PWR Circuit For Short To Voltage Turn ignition on. Turn A/C heater control switch off. Disconnect A/C clutch connector. Using DVOM, check for battery voltage between chassis ground and Black/Yellow wire (Econoline and F650-750) or Gray/White wire (Excursion and F250-550) at A/C clutch harness connector. (Scheme 34)- (Scheme 36). If battery voltage is not present, go to step 8). If battery voltage is present, repair short to voltage in Black/Yellow wire (Econoline and F650-750), or go to next step (Excursion and F250-550).
3) Check A/C Pressure Switch Circuit For Short To Voltage Turn ignition off. Disconnect A/C refrigerant containment switch. Refrigerant containment switch is located on right front side of engine compartment, near radiator. Using DVOM, check for battery voltage between chassis ground and refrigerant containment switch harness connector terminal No. 1 (Red/Yellow wire). (Scheme 35)or (Scheme 36). If battery voltage is not present, go to next step. If battery voltage is present, repair short to voltage in A/C switch circuit or climate mode switch. If vehicle is equipped with EATC, see appropriate symptom under SYMPTOM TESTS in AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING to diagnose concern with EATC module. Clear DTCs and retest.
4) Check For Short In ACCS Circuit To PCM Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, check for battery voltage between chassis ground and test pin No. 41 at breakout box. If battery voltage exists, repair Tan/Light Green wire between PCM and refrigerant containment switch for short to voltage. Clear DTCs and retest.
5) Check A/C Clutch Relay Circuit Remove A/C clutch relay located in relay block under hood. Ensure A/C compressor clutch is disconnected. Using DVOM, measure voltage between chassis ground and Gray/White wire at A/C clutch compressor connector. If battery voltage is not present, go to next step. If battery voltage is present, repair short to voltage in Gray/White wire. Clear DTCs and retest.
6) Check PCM A/C Relay Control Circuit Turn ignition off. Using a DVOM, measure resistance between negative battery terminal and A/C clutch relay cavity No. 1 in relay block. (Scheme 35)or (Scheme 36). If resistance is less than 5 ohms, repair short to ground in A/C clutch relay control circuit (Pink/Yellow wire) between A/C clutch relay and PCM. If resistance is 5 ohms or more, go to next step.
7) Check A/C Relay Connect PCM to breakout box. Install A/C clutch relay. Turn ignition on. Perform KOER self-test where DTC was set. If DTC P1464 is still present, check A/C clutch relay for correct operation. Replace relay as necessary. If A/C clutch relay is okay, replace PCM. Clear DTCs and retest. If DTC P1464 is not present, no concern is indicated at this time. Testing is complete.
8) Check For Short To Voltage At Breakout Box Test Pin No. 41 Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Ensure A/C heater control switch is off. Using DVOM, check for battery voltage between chassis ground and test pin No. 41 at breakout box. If battery voltage is present, locate and repair short to voltage in Black/Yellow wire (Econoline and F650-750) or Tan/Light Green wire (Excursion and F250-550). If battery voltage is not present, replace PCM. Clear DTCs and retest.
9) Check For Intermittent Short To Voltage Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 41 at breakout box. Wiggle and bend small sections of wiring harness starting at A/C high pressure switch and working toward PCM. If fault is indicated (voltage present), isolate fault and repair short to voltage. Clear DTCs and retest. If no fault is found, no concern is indicated at this time. Testing is complete. Clear DTCs and retest.

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 Brake On/Off (BOO) switch to provide a back-up to deactivate cruise control.

Note. BPA switch equipped on F650-750 with cruise control only.

Scheme 37

Scheme 37: Diagnostic Aids

Scheme 38

Scheme 39

Scheme 40

1) DTC P0571: Check BPA PID DTC P0571 indicates BPA switch circuit malfunction. Possible causes for this fault are: BPA Circuit Open, Or Shorted To Ground Or PWR BPA PWR Circuit Open Or Shorted To Ground Faulty BPA Switch Faulty Harness Connector Faulty PCM Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. While observing BPA PID reading, firmly apply then release brake pedal. If BPA PID reading indicates ON only, leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If BPA PID reading does not indicate ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to step 4).
2) Check BPA Switch Turn ignition off. Disconnect BPA switch connector located above brake pedal. If BPA PID changes to OFF when switch is disconnected, replace BPA switch. Clear DTCs and retest. If BPA PID does not change to OFF when switch is disconnected, go to next step.
3) Check For Short To Voltage In Switch To PCM Circuit Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Turn ignition on. Using DVOM, check for battery voltage between chassis ground and Red/Light Green wire (Econoline) or Black/Yellow wire (all others) at BPA switch harness connector. (Scheme 37)- (Scheme 40). If battery voltage is present, repair short to voltage in Red/Light Green wire or Black/Yellow wire between PCM terminal No. 31 and BPA switch. If battery voltage is not present, inspect PCM terminal No. 31 for short to voltage. Check for damaged pin, corrosion or loose wire. Repair as necessary.
4) Check BPA PID While observing BPA PID, apply and release brake pedal several times. If BPA PID reading indicates OFF only, go to next step. If BPA PID reading cycles between ON and OFF, fault may be intermittent. Leave scan tool connected to DLC and go to step 12).
5) Check Fuse Remove and inspect BPA PWR feed circuit fuse. Refer to appropriate fuse in illustrations. (Scheme 37)- (Scheme 40). If BPA PWR feed circuit fuse is okay, go to step 8). If BPA PWR feed circuit fuse is blown, replace fuse. If fuse blows again, remove fuse and go to next step.
6) Check BPA PWR Feed Circuit For Short To Ground Disconnect BPA switch connector. Ensure BPA PWR circuit fuse is removed. Using DVOM, measure resistance between chassis ground and appropriate PWR feed circuit at BPA switch harness connector. For proper wire colors, refer to «BPA PWR FEED CIRCUIT WIRE IDENTIFICATION»(ref-139800-S11815219942002060700000) table. (Scheme 37)- (Scheme 40). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in appropriate BPA PWR feed circuit. Restore vehicle, clear DTCs and retest. BPA PWR FEED CIRCUIT WIRE IDENTIFICATION Application Wire Color Econoline Light Green/Red Excursion & F250-550 Red F650-750 Tan/Black
7) Check BPA Circuit For Short To Ground Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 31 at breakout box. If resistance is more than 10 k/ohms, leave breakout box installed and go to step 19). If resistance is 10 k/ohms or less, repair short to ground in Red/Light Green wire (Econoline) or Black/Yellow wire (all others) between PCM and BPA switch. Clear DTCs and retest.
8) Check For Open BPA Switch Reinstall BPA PWR feed circuit fuse. Disconnect BPA switch harness connector. Turn ignition on. Connect a jumper wire between BPA switch harness connector terminals. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. If BPA PID reading indicates ON, replace BPA switch. Clear DTCs and retest. If BPA PID reading indicates OFF, disconnect jumper wire and go to next step.
9) Check BPA PWR Feed Circuit For Open Turn ignition off. Using DVOM, measure resistance of BPA PWR feed circuit between output side of BPA PWR circuit fuse and BPA switch harness connector. For proper wire colors, refer to «BPA PWR FEED CIRCUIT WIRE IDENTIFICATION»(ref-139800-S11815219942002060700000) table. (Scheme 37)- (Scheme 40). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in appropriate BPA PWR feed circuit. Restore vehicle, clear DTCs and retest.
10) Check BPA Circuit For Open Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Red/Light Green wire (Econoline) or Black/Yellow wire (all others) between BPA switch harness connector and test pin No. 31 at breakout box. If resistance is less than 5 ohms, inspect PCM terminal No. 31 for open. Check for damaged pin, corrosion or loose wire. Repair as necessary, then go to next step. If resistance is 5 ohms or more, repair open in Red/Light Green wire or Black/Yellow wire between PCM and BPA switch. Clear DTCs and retest.
11) Confirm PCM Fault Disconnect breakout box. Reconnect all components and reinstall BPA PWR circuit fuse. Turn ignition on. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. While observing BPA PID reading, firmly apply then release brake pedal several times. If BPA PID reading cycles between ON and OFF, system is okay. Testing is complete. If BPA PID reading does not cycle between ON and OFF, replace PCM. Clear DTCs and retest.
12) Check For Intermittent Open Or Short Turn ignition off. Disconnect BPA switch. Turn ignition on. Connect a jumper wire between both BPA switch harness connector terminals. (Scheme 37)- (Scheme 40). Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. BPA PID reading should indicate ON. While observing BPA PID, wiggle and bend small sections of wiring harness working from BPA switch toward PCM. BPA PID reading changes to OFF if fault is present. If fault is indicated, isolate fault and repair as necessary. Clear DTCs and retest. If no fault is indicated, leave scan tool connected to DLC and go to next step.
13) Check For Intermittent Short To Voltage Turn ignition off. Ensure jumper wire is still connected. Remove BPA PWR circuit fuse. Turn ignition on. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. BPA PID should indicate OFF. While observing BPA PID, wiggle and bend small sections of wiring harness working from BPA switch toward PCM. BPA PID reading changes to ON if fault is present. If fault is indicated, isolate short to voltage and repair as necessary. Reinstall fuse, clear DTCs and retest. If no fault is indicated, system is okay at this time. Reinstall fuse, clear DTCs and retest. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 13) to step 19). No test procedures have been omitted.
19) Check PCM For Internal Short Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 31 and test pins No. 25, 76, 77 and 103 at breakout box. If all resistances are more than 10 k/ohms, no concern is indicated at this time. Replace fuse, clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Reinstall fuse, clear DTCs and retest.

TEST FC: CLUTCH PEDAL POSITION SWITCH/NEUTRAL START SWITCH

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

Clutch Pedal Position (CPP) Switch
Powertrain Control Module (PCM)
Neutral Start Switch (F650-750 W/Allison AT545)
Wiring Harness Circuits (CPP & SIG RTN)

Clutch Pedal Position Switch Is a normally closed switch that detects when clutch pedal is depressed (manual transmissions) to disable speed control system and PTO, and raised-idle mode. CPP switch actuation occurs as clutch is initially depressed prior to disengaging transmission at top of travel.
Neutral Start Switch Is a normally closed switch that is used by PCM to enable raised-idle modes and Auxiliary Powertrain Control Module (APCM) functions.

Scheme 41

Scheme 42

1) KOER DTC P0704: Check CPP PID DTC P0704 indicates CPP/NSS circuit malfunction. Possible causes for this fault are: CPP/NSS Circuit Open, Or Shorted To Ground Or PWR CPP/NSS PWR Circuit Open Or Shorted To Ground Faulty CPP/NS Switch Faulty Harness Connector Faulty PCM Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. While observing CPP PID reading, apply and release clutch pedal several times (manual transmissions) or move transmission gearshift lever between Neutral and any other gear (F650-750 with AT545). Observe CPP PID reading. If CPP PID reading indicates ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If CPP PID reading does not indicate ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to step 4).
2) Check For CPP/NS Switch Failed Closed Disconnect CPP switch located at top of clutch pedal, or NS switch located on right side of transmission. If CPP PID reading changes to OFF, replace CPP/NS switch. Clear DTCs and retest. If CPP PID reading does not change to OFF, leave CPP/NS switch disconnected and go to next step.
3) Check For Short To Battery Voltage In CPP/NS Switch Output Circuit Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, check for battery voltage between chassis ground and test pin No. 29 at breakout box. (Scheme 41)or (Scheme 42). If battery voltage is present, repair short to voltage in CPP/NS switch output circuit between CPP/NS switch and PCM. If battery voltage is not present, check for short to battery voltage at terminal No. 29 at PCM connector. Repair as necessary, reconnect all connectors and go to step 12).
4) Check CPP PID Release clutch pedal (manual transmissions) or place transmission in Neutral (F650-750 with AT545). Check CPP PID reading. If CPP PID reading indicates OFF only, go to next step. If CPP PID reading indicates ON only, fault may be intermittent. Go to step 13).
5) Check Fuse Turn ignition off. Remove and inspect CPP/NSS PWR feed circuit fuse from central junction box. Central junction box is located under left side of instrument panel. (Scheme 41)or (Scheme 42). If CPP/NSS PWR feed circuit fuse is blown, replace fuse. If fuse blows again, remove fuse and go to next step. If CPP/NSS PWR feed circuit fuse is okay, go to step 9).
6) Check CPP/NSS PWR Feed Circuit For Short To Ground Ensure ignition is off. Disconnect CPP/NS switch connector. Ensure CPP/NSS PWR feed circuit fuse is removed. Using DVOM, measure resistance between chassis ground and appropriate PWR feed circuit at CPP/NS switch harness connector. For wire colors, see «CPP/NSS PWR FEED CIRCUIT WIRE IDENTIFICATION»(ref-139800-S02725983122002061000000) table. (Scheme 41)or (Scheme 42). If resistance is 10 k/ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in appropriate CPP/NSS PWR feed circuit. Restore vehicle, clear DTCs and retest. CPP/NSS PWR FEED CIRCUIT WIRE IDENTIFICATION Application Wire Color F250-750 With Manual Transmission Red/Yellow F650-750 With Allison AT545 Dark Blue/Orange
7) Check CPP/NSS Output Circuit For Short To Ground Ensure ignition is off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 29 at breakout box. If resistance is 10 k/ohms or more, leave breakout box installed and go to next step. If resistance is less than 10 k/ohms, locate and repair short to ground in Tan/Light Blue wire (F250-550) or Pink wire (F650-750) between PCM and CPP/NS switch. Clear DTCs and retest.
8) Check PCM For Internal Short Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 29 and test pins No. 25, 76, 77 and 103 at breakout box. If each resistance is 10 k/ohms or more, no concern is indicated at this time. Replace fuse, clear DTCs and retest. If any resistance is less than 10 k/ohms, replace PCM. Reinstall fuse, clear DTCs and retest.
9) Check For Open CPP/NS Switch Reinstall CPP/NSS PWR feed circuit fuse. Disconnect CPP/NS switch harness connector. Turn ignition on. Connect a jumper wire between PWR circuit and output circuit terminals at CPP/NS switch harness connector. Using scan tool, access CPP PID reading from PID/DATA MONITOR & RECORD menu. If CPP PID reading indicates ON, replace CPP/NS switch. If CPP PID reading indicates OFF, go to next step.
10) Check CPP/NSS PWR Feed Circuit For Open Turn ignition off. Using DVOM, measure resistance of CPP/NSS PWR feed circuit between output side of CPP/NSS PWR circuit fuse and CPP/NS switch harness connector. For wire colors, see «CPP/NSS PWR FEED CIRCUIT WIRE IDENTIFICATION»(ref-139800-S02725983122002061000000) table. (Scheme 41)or (Scheme 42). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in appropriate CPP/NSS PWR feed circuit. Restore vehicle, clear DTCs and retest.
11) Check CPP/NS Switch Output Circuit For Open Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Tan/Light Blue wire (F250-550) or Pink wire (F650-750) between CPP/NS switch harness connector and test pin No. 29 at breakout box. If resistance is less than 5 ohms, inspect PCM terminal No. 29 for open. Check for damaged pin, corrosion or loose wire. Repair as necessary, then go to next step. If resistance is 5 ohms or more, repair open in Tan/Light Blue wire or Pink wire between PCM and CPP/NS switch. Clear DTCs and retest.
12) Confirm PCM Fault Disconnect breakout box. Reconnect all connectors. Turn ignition on. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. While observing CPP PID reading, apply and release clutch pedal several times (manual transmissions) or move transmission gearshift lever between Neutral and any other gear (F650-750 with AT545). If CPP PID cycles between ON and OFF, system is okay. Testing is complete. If CPP PID does not cycle between ON and OFF, replace PCM. Clear DTCs and retest.
13) Check For Intermittent Open Or Short Turn ignition off. Disconnect CPP/NS switch. Turn ignition on. Connect a jumper wire between PWR circuit and output circuit terminals at CPP/NS switch harness connector. (Scheme 41)or (Scheme 42). Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. CPP PID reading should indicate ON. While observing CPP PID, wiggle and bend small sections of wiring harness working from CPP/NS switch toward PCM. CPP PID reading changes to OFF if fault is present. If fault is indicated, isolate fault and repair as necessary. Clear DTCs and retest. If no fault is indicated, leave scan tool connected to DLC and go to next step.
14) Check For Intermittent Short To Voltage Turn ignition off. Ensure jumper wire is still connected. Remove CPP/NSS PWR feed circuit fuse from central junction box. Central junction box is located under left side of instrument panel. Turn ignition on. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. CPP PID should indicate OFF. While observing CPP PID, wiggle and bend small sections of wiring harness working from CPP/NS switch toward PCM. CPP PID reading changes to ON if fault is present. If fault is indicated, isolate short to voltage and repair as necessary. Reinstall fuse, clear DTCs and retest. If no fault is indicated, system is okay at this time. Reinstall fuse, clear DTCs and retest.

TEST FD: BRAKE PEDAL POSITION SWITCH

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

Perform this test when directed by QUICK TEST. This test is intended to diagnose a faulty BPP switch circuit or PCM. This test is only intended to diagnose the following components and circuits

Brake Pedal Position (BPP) Wiring Harness Circuit
Powertrain Control Module (PCM)

Brakelight switch or BPP input is wired to brakelight circuit and informs PCM when brake pedal is applied. BPP input is used to disengage speed control or auxiliary powertrain control systems.

Scheme 43

Scheme 44

Scheme 45

1) KOER DTC P0703: Check BPP/BOO PID DTC P0703 indicates brakelight switch circuit malfunction. Possible causes for this fault are: BPP Circuit Open, Or Shorted To Ground Or PWR BPP PWR Circuit Open Or Shorted To Ground Faulty BPP Switch Faulty Harness Connector Faulty PCM Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, access BPP/BOO PID from PID/DATA MONITOR & RECORD menu. Turn ignition on. While observing PID, firmly apply and release brake pedal several times. If PID reading indicates ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If PID reading does not indicate ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to step 4).
2) Check BPP Switch Failed Closed Disconnect BPP switch connector. Switch is located at top of brake pedal and has a 2-pin connector (Econoline and F650-750 with air brakes) or 5-pin connector (Excursion and F250-750 with hydraulic brakes). If BPP/BOO PID reading changes to OFF, replace BPP switch. If PID reading does not change to OFF, go to next step.
3) Check For Short To Voltage In Switch Output Circuit Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Turn ignition on. Using DVOM, check for battery voltage between chassis ground and specified output circuit at BPP switch harness connector. For wire colors, see «BPP OUTPUT CIRCUIT WIRE IDENTIFICATION»(ref-139800-S13340805132002061200000) table. (Scheme 43)- (Scheme 45). If battery voltage is present, repair short to voltage in appropriate BPP output circuit. If battery voltage is not present, check for short to battery voltage at terminal No. 92 at PCM connector. Repair as necessary, reconnect all connectors and go to step 11). BPP OUTPUT CIRCUIT WIRE IDENTIFICATION Application Wire Color Econoline & F650-750 W/Air Brakes Light Green Excursion & F250-750 W/Hydraulic Brakes Red/Light Green
4) Check BPP/BOO PID While observing BPP/BOO PID reading, apply and release brake pedal several times. If BPP/BOO PID reading indicates OFF only, go to next step. If BPP/BOO PID cycles between OFF and ON, fault is intermittent. Leave scan tool connected to DLC and go to step 12).
5) Check Fuse Turn ignition off. Remove and inspect BPP PWR feed circuit fuse from central junction box (Econoline, Excursion and F250-750 with hydraulic brakes), or battery junction box (F650-750 with air brakes). Central junction box is located behind lower left side of instrument panel. Battery junction box is located on left front of engine compartment. (Scheme 43)- (Scheme 45). If BPP PWR feed circuit fuse is okay, check for open BPP output circuit. Leave fuse removed and go to step 8). If fuse is blown, go to next step.
6) Check BPP PWR Feed Circuit For Short to Ground Ensure ignition is off. Disconnect BPP switch connector. Switch is located at top of brake pedal and has a 2-pin connector (Econoline and F650-750 with air brakes) or 5-pin connector (Excursion and F250-750 with hydraulic brakes). Using DVOM, measure resistance between chassis ground and specified BPP PWR feed circuit at BPP switch harness connector. See «BPP PWR FEED CIRCUIT WIRE IDENTIFICATION»(ref-139800-S04370798342002061200000) table. (Scheme 43)- (Scheme 45). If resistance is less than 10 k/ohms, repair short to ground in appropriate BPP PWR feed circuit between BPP switch and central junction box or battery junction. Replace fuse, clear DTCs and retest. If resistance is 10 k/ohms or more, go to next step. BPP PWR FEED CIRCUIT WIRE IDENTIFICATION Application Wire Color Econoline & F650-750 W/Air Brakes Light Green/Red Excursion & F250-750 W/Hydraulic Brakes Light Blue/Black
7) Check BPP Output Circuit For Short To Ground Ensure ignition is off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Using DVOM, measure resistance between chassis ground and specified BPP output circuit at BPP switch harness connector. See «BPP OUTPUT CIRCUIT WIRE IDENTIFICATION»(ref-139800-S13340805132002061200000) table. (Scheme 43)- (Scheme 45). If resistance is less than 10 k/ohms, repair short to ground in appropriate BPP output circuit. Clear DTCs and retest. If resistance is 10 k/ohms or more, check for short to ground at terminal No. 92 at PCM connector. Repair as necessary, reconnect all connectors and go to step 11).
8) Check BPP PWR Feed Circuit For Open Turn ignition off. Disconnect BPP switch connector. Switch is located at top of brake pedal and has a 2-pin connector (Econoline and F650-750 with air brakes) or 5-pin connector (Excursion and F250-750 with hydraulic brakes). Using DVOM, measure resistance of BPP PWR feed circuit between BPP switch harness connector and output side of BPP PWR fuse. If resistance is less than 5 ohms, reinstall BPP PWR feed circuit fuse and go to next step. If resistance is 5 ohms or more, repair open in appropriate BPP PWR feed circuit between BPP switch and central junction box (Econoline, Excursion and F250-750 with hydraulic brakes), or battery junction box (F650-750 with air brakes). Clear DTCs and retest.
9) Check For Open BPP Switch Ensure BPP PWR feed circuit fuse is reinstalled and BPP switch is disconnected. Turn ignition on. Connect a jumper wire between BPP PWR feed circuit and BPP output circuit at BPP switch harness connector. (Scheme 43)- (Scheme 45). Using scan tool, select BPP/BOO PID from PID/DATA MONITOR & RECORD menu. If PID reading indicates ON, replace BPP switch. Clear DTCs and retest. If PID reading still indicates OFF, remove jumper wire and go to next step.
10) Check BPP Output Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure resistance of BPP output circuit between BPP switch 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, repair open in BPP output circuit between PCM and BPP switch. Clear DTCs and retest.
11) Confirm PCM Fault Turn ignition on. Using scan tool, access BPP/BOO PID from PID/DATA MONITOR & RECORD menu. While observing PID, firmly apply and release brake pedal. If PID reading cycles between ON and OFF, no concern is indicated at this time. Clear DTCs and retest. If PID reading does not cycle between ON and OFF, replace PCM. Clear DTCs and retest.
12) Check For Intermittent Open Or Short Circuit Turn ignition off. Ensure BPP switch is disconnected. Turn ignition on. Connect a jumper wire between BPP PWR feed circuit and BPP output circuit at BPP switch harness connector. Using scan tool, access BPP/BOO PID from PID/DATA MONITOR & RECORD menu. Ensure BPP/BOO PID reading on scan tool indicates ON and brakelights are also on. While observing BPP/BOO PID, wiggle and bend small sections of wiring harness starting at BPP switch connector and working toward PCM. If no fault is indicated (PID reading does not change to OFF), leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If fault is indicated (PID reading changes to OFF), isolate fault in wiring harness and repair as necessary. Clear DTCs and retest.
13) Check For Intermittent Short To Voltage Remove BPP PWR feed circuit fuse from central junction box (Econoline, Excursion and F250-750 with hydraulic brakes), or battery junction box (F650-750 with air brakes). Central junction box is located behind lower left side of instrument panel. Battery junction box is located on left front of engine compartment. Confirm BPP/BOO PID reading on scan tool indicates OFF and brakelights are also off. While observing 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. Clear DTCs and retest. If no fault is indicated, fault is intermittent and cannot be duplicated at this time. Clear DTCs and retest.

TEST FE: IDLE VALIDATION SWITCH

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

Detection & Management Any detected malfunction of IVS will illuminate CHECK ENGINE light.

Scheme 46

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0220 2	FE1
P0221 2	FE1
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected. () For vehilces with an Electronic Throttle Control see FAULT CODE SETTING CONDITION .

()

FAULT CODE SETTING CONDITION

1) KOER DTC P0220 Or P0221: Check IVS PID DTC P0220 indicates a malfunction has occurred in IVS circuit. DTC P0221 indicates a performance concern has occurred in IVS circuit. Possible causes are: Faulty Accelerator Pedal Assembly Open Circuit Short To Voltage In IVS Circuit Faulty PCM 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 & RECORD menu. With accelerator pedal released, IVS PID should read OFF. If IVS PID reading indicates ON, go to step 7). If IVS PID reading indicates OFF, go to next step.
2) Check IVS Transition Voltage Observe AP (voltage) and IVS (state) PID reading and slowly apply accelerator pedal. If IVS PID does not cycle from OFF to ON at.4-1.6 volts, go to next step. If IVS PID reading cycles from OFF to ON at.4-1.6 volts, clear DTCs and retest. If DTC resets, replace PCM.
3) Check IVS Observe IVS PID reading while slowly applying accelerator pedal fully. If IVS PID reading cycles to ON at any time during pedal travel, replace accelerator pedal assembly. Clear DTCs and retest. If IVS PID does not cycle to ON at any time during pedal travel, go to next step.
4) Check IVS Resistance Turn ignition off. Disconnect IVS connector. (Scheme 24) Inspect IVS connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Apply accelerator pedal fully. Using DVOM, 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. Clear DTCs and retest.
5) Check IVS Power Feed Circuit Turn ignition on. Using DVOM, check for battery voltage between chassis ground and Red/Light Green wire (Econoline) or Violet wire (F650-750) at IVS harness connector terminal No. 2. (Scheme 46) If battery voltage is present, go to next step. If battery voltage is not present, replace IVS PWR fuse or repair open circuit between central junction box and IVS.
6) Check IVS SIG RTN Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of SIG RTN circuit (Red/Orange wire on Econoline or Red/Light Green wire on F650-750) between IVS harness connector and test pin No. 10 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in SIG RTN circuit between PCM and IVS. Clear DTCs and retest.
7) Check SIG RTN Circuit For Short To Voltage Disconnect IVS connector. (Scheme 24) If IVS PID indicates OFF, replace accelerator pedal assembly. Clear DTCs and retest. If IVS PID indicates ON, repair short to voltage in SIG RTN circuit (Red/Orange wire on Econoline or Red/Light Green wire on F650-750) between PCM and IVS. Clear DTCs and retest.

TEST FF: PARKING BRAKE APPLIED SWITCH

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 47

Scheme 47: Diagnostic Aids

Scheme 48

Scheme 49

1) KOER DTC P1536: Perform BRAKE Warning Light Bulb Check DTC P1536 indicates that PCM does not detect a PBA state change during KOER ON-DEMAND SELF-TEST. Possible causes are: Low Brake Fluid Short To Ground Or Voltage Open Circuit Faulty Powertrain Control Module (PCM) Start engine and observe BRAKE warning light (bulb check). If BRAKE light illuminates, turn ignition off and go to next step. If BRAKE light does not illuminate, repair wiring in bulb circuit(s) as necessary. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. After repair is completed, perform bulb check again to confirm repair.
2) Check For Brake System Concern Ensure parking brake is fully released. Turn ignition on. Check BRAKE warning light. If BRAKE light is illuminated, a fault exists in brake system. Check and repair brake system as necessary. See appropriate DISC & DRUM article in BRAKES. If BRAKE light is off, go to next step.
3) Check PBA PID Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. Apply and release parking brake pedal fully several times, while observing PBA PID reading. If PBA PID reading indicates ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If PBA PID reading does not indicate ON only, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to step 6).
4) Check PBA Switch Failed Closed While observing PBA PID, disconnect PBA switch. Switch is located on top of parking brake pedal. If PBA PID reading changes from ON to OFF, replace PBA switch. Clear DTCs and retest. If PBA PID does not change from ON to OFF, go to next step.
5) Check For Short To Ground Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Ensure PBA switch is disconnected. Using DVOM, measure resistance between chassis ground and specified PBA signal circuit at test pin No. 5 at breakout box. See «PBA SIGNAL CIRCUIT WIRE IDENTIFICATION»(ref-139800-S28795613322002061200000) table. (Scheme 47)- (Scheme 49). If resistance is less than 10 k/ohms, repair short to ground in PBA signal circuit between PBA switch and PCM, Generic Electronic Module (GEM), or instrument cluster. If resistance is 10 k/ohms or more, check for short to ground at terminal No. 5 at PCM connector. Repair as necessary, reconnect all connectors and go to step 9). PBA SIGNAL CIRCUIT WIRE IDENTIFICATION Application Wire Color Econoline Violet/White Excursion & F250-550 Light Green/Red F650-750 Tan/Red
6) Check PBA PID While observing PBA PID, apply and release parking brake pedal fully several times. If PBA PID reading indicates OFF only, turn ignition off and go to next step. If PBA PID reading cycles between OFF and ON, fault may be intermittent. Leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to step 10).
7) Check PBA Switch For Failed Open Disconnect PBA switch. Switch is located on top of parking brake pedal. Connect a jumper wire between chassis ground and specified PBA signal circuit at PBA switch harness connector. See «PBA SIGNAL CIRCUIT WIRE IDENTIFICATION»(ref-139800-S28795613322002061200000) table. (Scheme 47)- (Scheme 49). Turn ignition on. Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. If PBA PID reading indicates ON, replace PBA switch. Clear DTCs and retest. If PBA PID reading indicates OFF, go to next step.
8) Check PBA Signal Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of PBA signal circuit between PBA switch harness connector and test pin No. 5 at breakout box. If resistance is 5 ohms or more, repair open in PBA signal circuit. Clear DTCs and retest. If resistance is less than 5 ohms, PBA signal circuit is okay. Reconnect all connectors, clear DTCs and retest. Go to next step to confirm repair.
9) Confirm PCM Fault Turn ignition on. Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. While observing PBA PID reading, apply and release parking brake pedal fully. If PBA PID cycles between ON and OFF, no concern is indicated at this time. If PBA PID does not cycle between ON and OFF, replace PCM. Clear DTCs and retest.
10) Check For Intermittent Short To Ground Disconnect PBA switch. PBA PID reading should indicate OFF. While observing PBA PID, wiggle and bend small sections of wiring harness working from PBA switch toward PCM. If fault is indicated (PBA PID changes to ON), isolate short to ground and repair as necessary. Clear DTCs and retest. If no fault is indicated, go to next step.
11) Check For Intermittent Open Connect jumper wire between chassis ground and PBA switch harness connector. PBA PID should now indicate ON. While observing PBA PID reading, wiggle and bend small sections of wiring harness working from PBA switch toward PCM. If fault is indicated (PBA PID changes to OFF), isolate open circuit and repair as necessary. Clear DTCs and retest. If no fault is indicated, no concern is indicated at this time. Clear DTCs and retest.

TEST FG: SPEED CONTROL COMMAND SWITCH

WARNING

Deactivate air bag system before working around steering column. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT.

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

Speed Control Switches
Speed Control Command Switch (SCCS) Wiring Harness Circuits
Powertrain Control Module (PCM)

The speed control function is integrated in PCM. Speed control command switches are momentary switches which are located on face of steering wheel. They consist of one ON-OFF toggle switch and one 3-position SET/ACCEL, COAST and RESUME switch. These switches when depressed, select one of several resistance values to PCM to select speed control functions.

DTC Descriptions

P0565 Speed control ON malfunction. Open or short circuit, switch failure, PCM failure or failed to activate switch during KOER SWITCH TEST.
P0566 Speed control OFF malfunction. Open or short circuit, switch failure, PCM failure or failed to activate switch during KOER SWITCH TEST.
P0567 Speed control RESUME malfunction. Open or short circuit, switch failure, PCM failure or failed to activate switch during KOER SWITCH TEST.
P0568 Speed control SET malfunction. Open or short circuit, switch failure, PCM failure or failed to activate switch during KOER SWITCH TEST.
P0569 Speed control COAST malfunction. Open or short circuit, switch failure, PCM failure or failed to activate switch during KOER SWITCH TEST.

Scheme 50

Scheme 51

Scheme 52

1) DTC P0565, P0566, P0567, P0568 Or P0569: Check SCCS PID 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 are: Switch Not Depressed During Test Faulty Speed Control Switch SCCS Circuit Open, Shorted To Ground Or Power Open Or Short In SC GND Circuit Open In Power Supply Circuit Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access SCCS PID from PID/DATA MONITOR & RECORD menu. DO NOT depress any switches. If SCCS PID voltage is 10 volts, go to step 5). If SCCS PID voltage is zero volt, go to step 8). If SCCS PID voltage is 6.58-6.78 volts, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step.
2) ON Switch 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) (Econoline, Excursion and F250-550), or step 12) (F650-750).
3) OFF Switch Function Check Depress speed control OFF switch. If SCCS PID voltage is zero volts, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If SCCS PID voltage is not zero volts, go to step 17).
4) Command Switches Function Using scan tool, access SCCS M PID. Monitor SCCS M PID voltages while depressing speed control RESUME, COAST and SET/ACCEL switches one at a time. Compare PID voltages to specifications. See «SCCS M PID SPECIFICATIONS»(ref-139800-S18768306002002050900000) table. If all SCCS M PID voltage readings are within plus or minus.2 volt of specification, repeat «KOER SWITCH SELF-TEST»(ref-139800-S12315474462002050900000) under QUICK TEST. If DTC is still present, replace PCM. Clear DTCs and retest. If any SCCS PID voltage reading is not within plus or minus.2 volt of specification, replace speed control switch assembly. Clear DTCs and retest. SCCS M PID SPECIFICATIONS Switch Volts COAST.68 SET/ACCEL 2.74 RESUME 4.66
5) Check Command Switch For Short To Power Remove horn pad or driver-side air bag module, if equipped. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch connector. Turn ignition on. Using scan tool, access SCCS PID from PID/DATA MONITOR & RECORD menu. Recheck SCCS PID voltage. If SCCS PID voltage is 6.58-6.78 volts, replace speed control switch assembly. Clear DTCs and retest. If SCCS PID voltage is still 10 volts, leave ignition on, scan tool in PID/DATA MONITOR & RECORD mode and go to next step.
6) Check Clockspring For Short To Power Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. If SCCS PID voltage is 6.58-6.78 volts, replace clockspring. Clear DTCs and retest. If SCCS PID voltage is still 10 volts, go to next step.
7) Check Signal Circuit For Short To Power Turn ignition off. Ensure steering column and speed control switch connectors are disconnected. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 61 at breakout box. If SCCS PID voltage is zero volts, replace PCM. Clear DTCs and retest. If SCCS PID voltage is still 10 volts, locate and repair short to voltage in Light Blue/Black wire between PCM and clockspring-to-steering column 6-pin connector. Clear DTCs and retest.
8) Check Command Switch For Short To Ground Remove horn pad or driver-side air bag module, if equipped. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch connector. Turn ignition on. Using scan tool, access SCCS PID from PID/DATA MONITOR & RECORD menu. Recheck SCCS PID voltage. If SCCS PID voltage is 6.58-6.78 volts, replace speed control switch assembly. Clear DTCs and retest. If SCCS PID voltage is still zero volt, go to next step.
9) Check Clockspring For Short To Ground Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. If SCCS PID voltage is 6.58-6.78 volts, replace clockspring. Clear DTCs and retest. If SCCS PID voltage is still zero volt, go to next step.
10) Check Signal Circuit For Short To Ground Turn ignition off. Ensure clockspring-to-steering column 6-pin connector is disconnected. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 61 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If each resistance is more than 10 k/ohms, replace PCM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short to ground in Light Blue/Black wire. Clear DTCs and retest.
11) Check Fuse Turn ignition off. On Econoline, remove and inspect fuse No. 27 (15-amp) from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuse No. 37 (15-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, if fuse is okay, reinstall fuse and go to next step. On all models, if fuse is blown, replace fuse. Clear DTCs and retest.
12) Check Power Circuit To Horn Switch On Econoline, remove HORN relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-750, remove HORN relay from central junction box. Central junction box is located behind lower left side of instrument panel. Remove horn pad or driver-side air bag module, if equipped. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch 5-pin connector. Using DVOM, measure resistance of Dark Blue wire between terminal "C" at clockspring side of 5-pin connector and HORN relay cavity No. 86. (Scheme 50)- (Scheme 52). If resistance is less than 75 ohms, go to next step. If resistance is 75 ohms or more, go to step 16).
13) Check Speed Control Switch Ensure ignition is off. Depress speed control ON switch. Using DVOM, measure resistance between terminal "A" and "C" at speed control switch connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace speed control switch assembly. Clear DTCs and retest.
14) Check Circuit No. 151 For Open Turn ignition off. Disconnect clockspring-to-steering column 6-pin connector. Connector is located below steering column. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Light Blue/Black wire between test pin No. 61 at breakout box and terminal No. 6 at clockspring-to-steering column 6-pin vehicle harness connector. (Scheme 50)- (Scheme 52). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Blue/Black wire. Clear DTCs and retest.
15) Check Clockspring For Open Circuit Check clockspring internal circuit. Using DVOM, measure resistance between terminal "C" at clockspring side of speed control switch 5-pin connector and terminal No. 5 at clockspring-to-steering column 6-pin connector. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, replace clockspring assembly. Clear DTCs and retest.
16) Check Clockspring For Open Circuit Check clockspring internal circuit. Using DVOM, measure resistance between terminal "C" at clockspring side of speed control switch 5-pin connector and terminal No. 5 at clockspring-to-steering column 6-pin connector. (Scheme 50)- (Scheme 52). If resistance is less than 5 ohms, check for the following: Open in Dark Blue wire between HORN relay and clockspring 6-pin connector (all models). Open power feed circuit (Yellow/Light Blue wire) to HORN relay cavity No. 30 (Econoline and F650-750). Faulty HORN relay (all models). Faulty central junction box circuit between HORN relay and fuse No. 37 (Excursion and F250-550). Repair as necessary. Clear DTCs and retest. If resistance is 5 ohms or more, replace clockspring assembly. Clear DTCs and retest.
17) Check Ground At Switch Remove horn pad or driver-side air bag module, if equipped. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Disconnect speed control switch 5-pin harness connector. Turn ignition on. Using DVOM, check for battery voltage between terminal "B" and "C" at clockspring side of speed control switch connector. (Scheme 50)- (Scheme 52). If battery voltage is not present, go to next step. If battery voltage is present, replace speed control switch assembly. Clear DTCs and retest.
18) Check Clockspring For Open Circuit Check clockspring internal circuit. Using DVOM, measure resistance between terminal "B" at clockspring side of speed control switch 5-pin connector and terminal No. 3 at clockspring-to-steering column 6-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace clockspring assembly. Clear DTCs and retest.
19) Check Signal Circuit For Open Turn ignition off. Ensure clockspring-to-steering column 6-pin connector is disconnected. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Gray/Red wire between terminal No. 3 at clockspring-to-steering column 6-pin harness connector and test pin No. 40 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in Gray/Red wire between PCM and clockspring harness connector. Clear DTCs and retest.

TEST FH: 4x4 LOW (EXCURSION & PICKUP)

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

4x4 Low Range Switch
Wiring Harness Circuits For 4x4 Low Range Switch
Powertrain Control Module (PCM)

Low range indicator illuminates when vehicle is shifted to 4x4 low range gear. On Manual Shift On The Fly (MSOF) 4x4 systems, 4x4 low switch provides ground path to complete 4x4L indicator circuit. On Electronic Shift On The Fly (ESOF) 4x4 systems, 4x4 module provides ground path to complete 4x4L indicator circuit. Status of 4x4 low range circuit is sent to PCM by instrument cluster through Standard Corporate Protocol (SCP) communications. There is no circuit from 4x4 low circuits to PCM.

Scheme 53

1) DTC P1729 Or P1781: Perform Switch Functional Check DTC P1729 indicates that PCM detected a 4x4 low switch error. DTC P1781 indicates PCM detected a 4x4L circuit out of self-test range. Possible cause are: 4x4L Circuit Open Or Shorted To Ground Faulty 4x4 Low Switch Or 4x4 Module Faulty Instrument Cluster Faulty PCM Turn ignition on. Observe 4x4L indicator while shifting 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) Check 4x4L Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access 4x4L PID from PID/DATA MONITOR & RECORD menu. Observe 4x4L PID while switching to and from 4x4L. If 4x4L PID agrees with lever position, go to next step. If 4x4L PID does not agree with lever position, diagnose 4x4L circuits and instrument cluster. Go to appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT and repair as necessary. If instrument cluster and related circuits are okay, replace PCM. Clear DTCs and retest.
3) Check For Intermittent While observing 4x4L PID, wiggle and bend all wiring harness circuits for 4x4L. If 4x4L PID switched between ON or OFF states at any time, isolate fault and repair as necessary. Clear DTCs and retest. If 4x4L PID does not switch between ON or OFF states, no concern is indicated at this time. Clear DTCs and retest.
4) Check Voltage At Switch Or Module On models with Manual Shift On The Fly (MSOF), disconnect 4x4 low range switch 2-pin connector. Switch is located on front of transfer case. On models equipped with Electronic Shift On The Fly (ESOF), disconnect 4x4 module 22-pin harness connector C281b. Module is located behind glove box on right side of dash. Using DVOM, measure voltage between chassis ground and Brown/Yellow wire at 4x4 low range switch harness connector (MSOF), or terminal No. 8 at 4x4 module harness connector (ESOF). (Scheme 53) If voltage is more than 10.5 volts, replace 4x4 low range switch (MSOF), or diagnose 4x4L indicator fault (ESOF). See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If voltage is 10.5 volts or less, go to next step.
5) Check 4x4L Circuit For Short To Ground Ensure 4x4 low range switch (MSOF) or 4x4 module (ESOF) are disconnected. Turn ignition on. Observe 4x4L indicator. If 4x4L indicator remains illuminated with connector disconnected, repair short to ground in Brown/Yellow wire between instrument panel and 4x4 low range switch (MSOF), or 4x4 module (ESOF). If 4x4L indicator does not remain illuminated when connector is disconnected, check low voltage from instrument cluster concern. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If no problem is found with instrument cluster, replace PCM. Clear DTCs and retest.

TEST FJ: INJECTOR DRIVER MODULE FEEDBACK

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

Injector Driver Module (IDM)
Wiring Harness Circuit (EF)
Powertrain Control Module (PCM)

IDM provides EF output signal to PCM to confirm that proper timing/duration of Fuel Delivery Command Signal (FDCS) was received. Additionally, EF signal is used to send diagnostics of IDM and electrical circuits of injectors to PCM.

Scheme 54

Scheme 55

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P1316 1	FJ9	FJ9
P1668	FJ1	FJ1
P1670		FJ1
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P1668 Or P1670: Repeat KOEO Self-Test DTC P1668 indicates a PCM-IDM diagnostic communication error. DTC P1670 indicates electronic feedback signal not detected. Possible causes are: Faulty IDM Open Or Grounded Circuit Faulty PCM Repeat KOEO ON-DEMAND SELF-TEST and retrieve Continuous Memory DTCs. Proceed as follows: If DTC P1668 is present, go to next step. If DTCs P1663 and P1667 are set together with or without DTC P1668, go to step 6). If DTC P1298 is also present, replace IDM. Clear DTCs and retest. If DTC P1667 is also present, go to TEST KA, step 1). If DTC P1663 is also present, go to TEST KF, step 1). If DTC P1662 is also present, go to TEST NC, step 1). If DTC P1670 is present without any other DTCs, go to step 10).
2) Check EF Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance of EF circuit (Gray/White wire) between test pin No. 48 at breakout box and terminal No. 4 at IDM harness connector. (Scheme 55) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/White wire between PCM and IDM. Clear DTCs and retest.
3) Check EF Circuit For Short To Ground Turn ignition off. Using DVOM, measure resistance between negative battery terminal and test pin No. 48 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Gray/White wire between PCM and IDM. Clear DTCs and retest.
4) Check EF Circuit For Short To Power Turn ignition on. Using DVOM, measure voltage between negative battery terminal and test pin No. 48 at breakout box. If voltage is present, repair short to voltage in Gray/White wire between PCM and IDM. Clear DTCs and retest. If no voltage is present, go to next step.
5) Check SIG RTN Circuit For Open Turn ignition off. Using DVOM, measure resistance of SIG RTN circuit (Gray/Red wire) between test pin No. 91 at breakout box and terminal No. 2 at IDM harness connector. (Scheme 55) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Red wire between PCM and IDM. Clear DTCs and retest.
6) Check IDM Power If not already performed, disconnect PCM 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 Rotunda Breakout Box (014-00950) and connect PCM to breakout box. Disconnect IDM 40-pin connector, if not already disconnected. IDM is located in left side of engine compartment. Turn ignition on. Using DVOM, check for battery voltage between negative battery terminal and IDM harness connector terminal No. 14 (Dark Green/Light Green wire). (Scheme 55) If battery voltage is present, go to next step. If battery voltage is not present, go to TEST NC, step 6).
7) Check IDM Ground For Open Turn ignition off. Using DVOM, measure resistance of Black/White wire (Econoline), or Black/Pink wire (Excursion and F250-750) between chassis ground and terminal No. 26 at IDM 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 ground circuit (Black/White wire on Econoline, or Black/Pink wire on Excursion and F250-750).
8) Measure EF Circuit Frequency Ensure PCM is connected to breakout box. Reconnect IDM connector. Perform the following: Connect scan tool to Data Link Connector (DLC). Connect test probe between scan tool common and test pin No. 77 (ground) at breakout box. Connect second test probe between scan tool signal and test pin No. 48 (EF line) at breakout box. Select VEHICLE and ENGINE. Select DIGITAL MEASUREMENT SYSTEM. Change level to 4 VOLT DC Press link button to choose a PID. Select PID/DATA MONITOR Select RPM PID and press START. Start engine and allow it to idle. Using scan tool, measure frequency at specified engine speed. See «IDM FREQUENCY SPECIFICATIONS»(ref-139800-S24947932652002050900000) table. If frequency does not closely match corresponding RPM, replace IDM. Clear DTCs and retest. If frequency closely matches corresponding RPM, replace PCM. Clear DTCs and retest. IDM FREQUENCY SPECIFICATIONS Engine Speed (RPM) Frequency (Hz) 1000 66 2000 133 3000 200
9) KOEO & Continuous Memory DTC P1316: Repeat KOEO Self-Test DTC P1316 indicates Injector Driver Module (IDM) DTCs are stored in IDM. Injector faults are stored in 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 IDM. IDM DTCs are cleared by using CLEAR ALL command from RETRIEVE/CLEAR CONTINUOUS DTCs menu on scan tool. Possible causes are: Injector(s) Or Circuit(s) Open Or Shorted IDM Enable Circuit Open Or Short In EF Circuit Open Or Short In FDCS Circuit Faulty IDM Relay Faulty IDM Open Or Grounded Circuit Faulty PCM Repeat KOEO ON-DEMAND SELF-TEST. If IDM or any other DTCs are present, perform appropriate test and repair as necessary. Clear DTCs and retest. If no DTCs are present, go to next step.
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 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of EF circuit (Gray/White wire) between test pin No. 48 at breakout box and terminal No. 4 at IDM harness connector. (Scheme 55) Also, measure resistance of FDCS circuit (Brown/Orange wire) between test pin No. 95 at breakout box and terminal No. 17 at IDM harness connector. Wiggle and bend small sections of wiring harness starting at IDM harness connector and working toward PCM. If both resistances remain less than 5 ohms during wiggle test, go to next step. If either resistance changes to 5 ohms or more during wiggle test, repair open in Gray/White wire or Brown/Orange wire between PCM and IDM. Clear DTCs and retest.
11) Check For Intermittent Short To Ground Using DVOM, measure resistance between negative battery terminal and test pins No. 48 and 95 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM harness connector and working toward PCM. If both resistances remain more than 10 k/ohms during wiggle test, go to next step. If either resistance changes to 10 k/ohms or less during wiggle test, repair short to ground in Gray/White wire or Brown/Orange wire. Clear DTCs and retest.
12) Check For Intermittent Short To Voltage Turn ignition on. Using DVOM, measure voltage between negative battery terminal and test pins No. 48 and 95 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM harness connector and working toward PCM. If no voltage is indicated while performing wiggle test, go to next step. If any voltage is indicated while performing wiggle test, repair short to voltage in Gray/White wire or Brown/Orange wire. Clear DTCs and retest.
13) Verify DTC P1316 &/Or DTC P1670 Reconnect all disconnected components and connectors. Clear DTCs. Turn ignition off, then start engine. Road test vehicle. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000). Retrieve Continuous Memory DTCs. If DTC P1316 and/or P1670 is present in Continuous Memory without any KOEO DTCs, go to next step. If DTC P1316 and/or P1670 is present in Continuous Memory with other KOEO DTCs, service KOEO DTCs. Perform appropriate system test and repair as necessary. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). Clear DTCs and retest.
14) Attempt To Generate IDM DTCs Turn ignition off. Disconnect one valve cover connector. Start engine to generate IDM DTCs. Perform «KOEO INJECTOR ELECTRICAL SELF-TEST»(ref-139800-S15778450502002050900000) and «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If IDM DTCs are present, replace PCM. Clear DTCs and retest. If no IDM DTCs are present, replace IDM. Clear DTCs and retest.

TEST FK: FUEL PUMP MONITOR CONTROL (ECONOLINE, EXCURSION & F250-550)

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

Fuel Pump Relay
Inertia Fuel Shutoff (IFS) Switch
Warning Light
Wiring Harness Circuits (FPC & FPM)
PCM

Fuel Pump Control (FPC) circuit from PCM is used to energize fuel pump relay. With ignition on, fuel pump relay is energized for 20 seconds and whenever engine RPM is detected. Fuel Pump Monitor (FPM) circuit is downstream of Inertia Fuel Shutoff (IFS) switch and is used by PCM to monitor voltage going to fuel pump.

Scheme 56

Scheme 57

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0230	FK1		FK16
P0231 1	FK5		FK18
	P0232	FK11	FK20
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO DTC P0230: Check Fuel Pump Relay PWR Fuse DTC P0230 indicates PCM has detected a fuel pump relay driver circuit failure. Possible causes are: Blown Fuse Faulty Fuel Pump Relay Open FPC Circuit Faulty PCM On Excursion and F250-550, go directly to next step. On Econoline, remove and inspect fuse No. 8 (30-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. If fuse is okay, reinstall fuse and go to next step. If fuse is blown, replace fuse. Clear DTCs and retest.
2) Check Power To Fuel Pump Relay Coil On Econoline, remove fuel pump relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuel pump relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, turn ignition on. Using DVOM, measure voltage between chassis ground and fuel pump relay cavity No. 85 (Econoline), or cavity No. 1 (Excursion and F250-550) in battery junction box. (Scheme 56)or (Scheme 57). If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check for open in Red/Light Green wire between fuse No. 8 and fuel pump relay (Econoline), or check for open circuit in central junction box between PCM PWR relay and fuel pump relay (Excursion and F250-550). Repair circuit or replace central junction box as necessary. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
3) Check Relay Trigger Circuit Ensure fuel pump relay is removed. Using DVOM, measure resistance between chassis ground and fuel pump relay cavity No. 86 (Econoline), or cavity No. 2 (Excursion and F250-550). (Scheme 56)or (Scheme 57). Turn ignition on. If resistance is less than 100 ohms within 20 seconds of turning ignition on, replace fuel pump relay. Clear DTCs and retest. If resistance is 100 ohms or more at all times, go to next step.
4) Check For Open FPC Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of FPC circuit (Light Blue/Orange wire) between test pin No. 94 at breakout box and fuel pump relay cavity No. 86 (Econoline), or cavity No. 2 (Excursion and F250-550). (Scheme 56)or (Scheme 57). If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Light Blue/Orange wire between PCM and fuel pump relay. Clear DTCs and retest.
5) KOEO DTC P0231: Check FPM Circuit To IFS Switch If DTC P0230 is also present, go to step 1). DTC P0231 indicates fuel pump relay driver failed on and was not detected on FPM circuit when fuel pump was commanded on by PCM. Possible causes are: Faulty Inertia Fuel Shutoff (IFS) Switch Blown Fuel Pump Fuse Open Fuel Pump Control (FPC) Or Fuel Pump Monitor (FPM) Circuit Faulty Fuel Pump Relay Disconnect IFS switch connector. IFS switch is located behind right kick panel. Turn ignition on. Using DVOM, measure voltage between chassis ground and Dark Green/Yellow wire at IFS switch harness connector. (Scheme 56)or (Scheme 57). If voltage is more than 10.5 volts within 20 seconds of turning ignition on, go to next step. If voltage is 10.5 volts or less at all times, go to step 8).
6) Check IFS Switch Reconnect IFS switch connector. Using DVOM, measure voltage between chassis ground and Pink/Black wire at IFS switch harness connector. If battery voltage is present, go to next step. If battery voltage is not present, reset or replace inertia switch.
7) Check For Open FPM Circuit Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Disconnect IFS switch connector. Using DVOM, measure resistance of FPM circuit (Pink/Black wire) between IFS switch harness connector and test pin No. 40 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Pink/Black wire between PCM and IFS switch. Clear DTCs and retest.
8) Check Fuel Pump Fuse Turn ignition off. On Econoline, remove and inspect fuse No. 17 (30-amp) from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuse No. 40 (20-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, if fuse is okay, reinstall fuse and go to next step. If fuse is blown, replace fuse. Clear DTCs and retest.
9) Check For Power To Fuel Pump Relay Remove fuel pump relay from battery junction box (Econoline) or central junction box (Excursion and F250-550). Turn ignition on. Using DVOM, measure voltage between chassis ground and fuel pump relay cavity No. 30 (Econoline), or cavity No. 3 (Excursion and F250-550). (Scheme 56)or (Scheme 57). If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check for open in Yellow wire between fuse No. 17 and fuel pump relay (Econoline), or check for open circuit in central junction box between fuse No. 40 and fuel pump relay (Excursion and F250-550). Repair circuit or replace central junction box as necessary. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
10) Check IFS Switch Power Circuit Turn ignition off. Disconnect IFS switch connector. IFS switch is located behind right kick panel. Using DVOM, measure resistance of Dark Green/Yellow wire between IFS switch harness connector and fuel pump relay cavity No. 87 (Econoline), or cavity No. 5 (Excursion and F250-550). If resistance is less than 5 ohms, replace fuel pump relay. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in Dark Green/Yellow wire between IFS switch and fuel pump relay. Clear DTCs and retest.
11) KOEO DTC P0232: Repeat KOEO Self-Test DTC P0232 indicates fuel pump relay driver failed off and voltage was detected on FPM circuit when fuel pump was commanded off. Possible causes are: Short To Voltage In IFS Switch Power Circuit Short To Voltage In FPM Or Fuel Pump Power Circuit Short To Ground In FPC Circuit Faulty Fuel Pump Relay Faulty PCM On Excursion and F250-550, go to next step. On Econoline, remove fuse No. 8 (30-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000). If DTC P0232 is present, reinstall fuse and go to next step. If DTC P0232 is not present, go to step 15).
12) Check Fuel Pump Relay For Internal Short On Econoline, remove fuel pump relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuel pump relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0232 is present, go to next step. If DTC P0232 is not present, replace fuel pump relay. Clear DTCs and retest.
13) Check For Short To Voltage In IFS PWR Circuit Disconnect IFS switch connector. IFS switch is located behind right kick panel. Repeat KOEO ON-DEMAND SELF-TEST. If DTC P0232 is present, go to next step. If DTC P0232 is not present, repair short to voltage in Dark Green/Yellow wire between IFS switch and fuel pump relay. Clear DTCs and retest.
14) Check For Short To Voltage In FPM Circuit Or Fuel Pump PWR Feed Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. If voltage is more than 10.5 volts, repair short to voltage in fuel pump PWR feed or fuel pump monitor circuit. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest. If voltage is 10.5 volts or less, replace PCM (Econoline), or go to next step (Excursion and F250-550). Clear DTCs and retest.
15) Check FPC Circuit For Short To Ground Turn ignition off. Remove fuel pump relay if not already removed. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 94 at breakout box. If resistance is less than 10 k/ohms, repair short to ground in Light Blue/Orange wire between PCM and fuel pump relay. Clear DTCs and retest. If resistance is 10 k/ohms or more, replace PCM. Clear DTCs and retest.
16) Continuous Memory DTC P0230: Repeat KOEO Self-Test DTC P0230 indicates PCM has detected a fuel pump relay driver circuit failure. Possible causes are: Blown Fuse Faulty Fuel Pump Relay Open Or Intermittent FPC Circuit Fault Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P0230 is present, go to step 1). If DTC P0230 is not present, go to next step.
17) Check For Intermittent Fault Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0230 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0230 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.
18) Continuous Memory DTC P0231: Repeat KOEO Self-Test DTC P0231 indicates fuel pump relay driver failed on and was not detected on FPM circuit when fuel pump was commanded on by PCM. Possible causes are: Open Inertia Fuel Shutoff (IFS) Switch Blown Fuel Pump PWR Fuse Open FPC Or FPM Circuit Faulty Fuel Pump Relay If Continuous Memory DTC P0230 is also present, go to step 16). Ensure IFS switch had not been reset without clearing DTCs. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0231 is present, go to step 5). If KOEO P0231 is not present, go to next step.
19) Check For Intermittent Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0231 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0231 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.
20) Continuous Memory DTC P0232: Repeat KOEO Self-Test DTC P0232 indicates fuel pump relay driver failed off and voltage was detected on FPM circuit when fuel pump was commanded off. Possible causes are: Short To Voltage In Fuel Pump PWR Circuits Shorted Fuel Pump Relay Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If KOEO DTC P0232 is present, go to step 11). If KOEO DTC P0232 is not present, go to next step.
21) Check For Intermittent Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0232 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0232 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.

TEST H: AUXILIARY POWERTRAIN CONTROL SYSTEM

Note. Functions may not be available if operator has deprogrammed them.

Perform this test only when directed by a symptom 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 only intended to diagnose the following components and circuits

Wiring Harness Circuits (VPWR, GND, BUS (+), BUS (-) & Hi-Mount Brakelight)
APCM

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Application & Circuit		(1) Terminal No. (Wire Color)
Econoline
BUS (+)		1 (Tan/Orange)
BUS (-)		3 (Pink/Light Blue)
GND		2 (Black)
PWR		4 (Red/Light Green)
F250-550
BUS (+)		2 (Tan/Orange)
BUS (-)		4 (Pink/Light Blue)
GND		1 (Black)
PWR		3 (Red/Yellow)
F650-750
BUS (+)		2 (Tan/Orange)
BUS (-)		1 (Pink/Light Blue)
GND		3 (Black)
PWR		4 (Red/Yellow)
(1) (Scheme 59)- (Scheme 61).

(1)	(Scheme 59)- (Scheme 61).

APCM CIRCUIT WIRE COLOR IDENTIFICATION

1) Verify Operation Procedure Ensure vehicle has proper calibration. Refer to auxiliary powertrain control manual provided with system to verify correct operating procedures and entry conditions. If entry conditions are met and proper calibration is installed, go to next step. If entry conditions are not met and proper calibration is not installed, correct operating procedure or correct calibration level as necessary. Clear error codes and DTCs and retest. If system still does not operate, go to next step.
2) Check For DTCs Ensure auxiliary powertrain control system is off. Using scan tool, perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000), «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) and «KOER SWITCH SELF-TEST»(ref-139800-S12315474462002050900000) under QUICK TEST. Retrieve DTCs. If any DTCs are present, service DTCs as necessary. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). If no DTCs are present, go to next step.
3) Check For KEY ON Power Turn ignition off. Disconnect APCM connector. Connector is located behind left side of instrument panel, near steering column. Turn ignition on. Using DVOM, check for battery voltage between chassis ground and specified APCM PWR circuit at APCM harness connector. See «APCM CIRCUIT WIRE COLOR IDENTIFICATION»(ref-139800-S31390751142002061700000) table. (Scheme 59)- (Scheme 61). If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in Red/Light Green wire between ignition switch and APCM Econoline), or remove and inspect APCM PWR circuit fuse located in central junction box (F250-750). Central junction box is located behind lower left side of instrument panel. If fuse is blown, replace fuse and check for short to ground in Red/Yellow wire. If fuse is okay, repair open in Red/Yellow wire between central junction box and APCM. Clear codes and retest.
4) Check GND Circuit Turn ignition off. Using DVOM, measure resistance between chassis ground and specified GND terminal at APCM harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black wire between APCM and ground. Clear codes and retest.
5) Check For Open In BUS (-) Circuit Using DVOM, measure resistance of BUS (-) circuit between specified terminal at APCM harness connector and terminal No. 10 at Data Link Connector (DLC). See «APCM CIRCUIT WIRE COLOR IDENTIFICATION»(ref-139800-S31390751142002061700000) table. (Scheme 59)- (Scheme 61). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in BUS (-) circuit. Clear codes and retest.
6) Check For Open In BUS (+) Circuit Using DVOM, measure resistance of BUS (+) circuit between specified terminal at APCM harness connector and terminal No. 2 at DLC. If resistance is less than 5 ohms, replace APCM. Clear codes and retest. If resistance is 5 ohms or more, locate and repair open in BUS (+) circuit. Clear codes and retest.
7) APCM Inoperative With Hazard Flashers (Except Cutaway) Turn ignition off. Apply service brake pedal. If hi-mount brakelight illuminates, go to TEST FD, step 1). If hi-mount brakelight does not illuminate, go to next step.
8) Check Hi-Mount Brakelight Remove and inspect hi-mount brakelight bulb. Bench test bulb by applying battery voltage to one side and ground to the other. Replace bulb as necessary and retest system operation. Clear codes and retest. If bulb is okay, go to next step.
9) Check GND Circuit Using DVOM, measure resistance of Black wire between chassis 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. Clear codes and retest.
10) Check For PWR Circuit To Brakelight Bulb Turn ignition off. Apply service brake pedal. Using non-powered test light, probe between chassis ground and Light Green wire at hi-mount brakelight bulb socket. If battery voltage is present, check for loose connection in bulb socket. Repair as necessary. Clear codes and retest. If battery voltage is not present, repair open in Light Green wire. Clear codes and retest.
11) APCM Inoperative With Hazard Flashers (Cutaway) Disconnect brake resistor, located on left "B" pillar. Using DVOM, measure resistance of Black wire between resistor connector and chassis ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black wire. Clear codes and retest.
12) Check Power Circuit To Brake Resistor Apply service brake pedal. Using non-powered test light, probe between Light Green wire at brake resistor connector and chassis ground. If test light illuminates, go to next step. If test light does not illuminate, repair open in Light Green wire. Clear codes and retest.
13) Check Brake Resistor Using a DVOM, measure resistance across brake resistor. If resistance is 130-150 ohms, reconnect resistor and go to TEST FD, step 1). If resistance is not 130-150 ohms, replace resistor. Clear codes and retest.

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

Injector Driver Module (IDM)
Wiring Harness Circuits (CID & SIG RTN)
Powertrain Control Module (PCM)

The CID output from PCM provides information to IDM so that injector current can be supplied to correct injector.

Scheme 62

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P1218	KA9	KA9
P1219	KA12	KA12
P1298	KA1	KA1
P1667	KA1

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P1298 & P1667: Repeat KOEO Self-Test DTCs P1298 Or P1667 indicates that PCM has detected a failure on CID circuit. Possible causes are: Faulty Injector Driver Module (IDM) Open Or Grounded Circuit Faulty Powertrain Control Module (PCM) Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. Proceed as follows: If only DTC P1667 is present, go to next step. If DTCs P1667 and P1298 are present, replace 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, step 1).
2) Check Voltage On CID Circuit Disconnect PCM 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 Rotunda Breakout Box (014-00950). Connect PCM connector to breakout box. Turn ignition on. Using DVOM, measure voltage between test pin No. 96 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 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 4 volts, go to step 5).
3) Perform Output State Check Attach scan tool to Data Link Connector (DLC). Turn ignition on. Perform «KOEO OUTPUT STATE SELF-TEST»(ref-139800-S18640610012002051000000) under QUICK TEST. Toggle outputs ON and OFF by applying and releasing accelerator pedal. Using DVOM, measure voltage between test pin No. 96 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If voltage does not toggle between.5-.7 volt and battery voltage, replace PCM. Clear DTCs and retest. If voltage toggles between.5-.7 volt and battery voltage, fault is intermittent. Go to step 8).
4) Check CID Circuit For Open Turn ignition off. Disconnect PCM from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance of Yellow/Light Blue wire between test pin No. 96 at breakout box and terminal No. 16 at IDM connector. (Scheme 55) If resistance is less than 5 ohms, go to step 6). If resistance is 5 ohms or more, repair open in Yellow/Light Blue wire between PCM and IDM. Clear DTCs and retest.
5) Check CID Circuit For Short To Power Turn ignition off. Disconnect PCM from breakout box. Turn ignition on. Using DVOM, check for voltage between negative battery terminal and test pin No. 96 at breakout box. If voltage is present, locate and repair short to voltage in Yellow/Light Blue wire. Clear DTCs and retest. If voltage is not present, go to step 7).
6) Check CID Circuit For Short To Ground Turn ignition off. Using DVOM, measure resistance between test pin No. 96 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, repair short to ground in Yellow/Light Blue wire. Clear DTCs and retest.
7) Check PCM Output State Function Disconnect IDM connector if not done previously. Connect PCM connector to breakout box. Turn ignition on. Perform «KOEO OUTPUT STATE SELF-TEST»(ref-139800-S18640610012002051000000) under QUICK TEST. Using DVOM, measure voltage between test pin No. 96 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box while depressing and releasing accelerator pedal. If voltage does not toggle between.5-.7 volt and zero volt, replace PCM. Clear DTCs and retest. If voltage toggles between.5-.7 volt and zero volt, replace IDM. Clear DTCs and retest.
8) Check For Intermittent Turn ignition off. Reconnect all connectors. Clear DTCs. Cycle ignition off, then on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1667 resets, replace PCM. Clear DTCs and retest. If DTC P1667 does not reset, no concern is indicated at this time. Clear DTCs and retest.
9) KOEO & Continuous Memory DTC P1218: Repeat KOEO Self-Test DTC P1218 indicates that PCM has detected CID circuit stuck high. Possible causes are: CID Circuit Open Or Shorted To Power Faulty Injector Driver Module (IDM) Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. 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 are present, replace IDM. If DTC P1218 and P1662 are present, go to TEST NC, step 1).
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 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Yellow/Light Blue wire between terminal No. 16 at IDM connector and test pin No. 96 at breakout box. (Scheme 55) Resistance should be less than 5 ohms. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. If resistance changes to more than 5 ohms at anytime, locate and repair open circuit in Yellow/Light Blue wire. Clear DTCs and retest. If resistance stays at less than 5 ohms at all times, go to next step.
11) Check CID Circuit For Intermittent Short To Power Turn ignition on. Using DVOM, check for voltage between chassis ground and test pin No. 96 at breakout box. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. If any voltage is indicated, locate and repair short to voltage in Yellow/Light Blue wire in wiring harness. Clear DTCs and retest. If no voltage is indicated, reconnect PCM and IDM. Road test vehicle. If DTC resets, replace IDM. Clear DTCs and retest.
12) KOEO & Continuous Memory DTC P1219: Repeat KOEO Self-Test DTC P1219 indicates that PCM has detected CID circuit stuck low. Possible causes are: CID Circuit Shorted To Ground Faulty Injector Driver Module (IDM) Turn ignition on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. 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 are present, replace IDM. Clear DTCs and retest. If DTC P1219 and P1662 are present, go to TEST NC, step 1).
13) Check CID Circuit For Intermittent Short To Ground Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 96 and pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. Resistance should be more than 10 k/ohms. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. If resistance changes to 10 k/ohms or less at anytime, locate and repair short to ground in Yellow/Light Blue wire. Clear DTCs and retest. If resistance stays at more than 10 k/ohms at all times, reconnect PCM and IDM. Road test vehicle. If DTC resets, replace IDM. Clear DTCs and retest.

TEST KB: EXHAUST BACKPRESSURE REGULATOR

Diagnostic Procedures

Note. Exhaust Back Pressure Regulator (EPR) is not used on F650-750.

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

Exhaust Backpressure Regulator (EPR)
Wiring Harness Circuits (PWR GND & EPR Signal)
Powertrain Control Module (PCM)

Valve position is controlled by switching output signal circuit to 12 volts inside PCM. ON/OFF time is dependent upon exhaust backpressure.

Output Functions EPR is a variable position valve that controls exhaust backpressure during cold ambient temperatures to increase cab heat and decrease amount of time needed to defrost windshield. PCM uses measured exhaust backpressure, intake air temperature and engine load to determine desired exhaust backpressure.
Detection & Management An open or shorted to ground control circuit can be detected by an on-demand output circuit check performed during KOEO ON-DEMAND SELF-TEST. An exhaust backpressure step test, in which PCM commands and then measures specific preprogrammed pressures, is performed during KOEO ON-DEMAND SELF-TEST. If PCM detects an Exhaust Back Pressure (EBP) or Intake Air Temperature (IAT) sensor fault, it will disable exhaust backpressure regulator.

Scheme 63

1) KOEO DTC P0475: Check EBR PWR GND Circuit For Open DTC P0475 indicates exhaust pressure control valve malfunction. Possible causes are: Faulty EPR Solenoid EPR PWR GND Circuit Open EPR Circuit Open, Or Shorted To Ground Or Power Faulty PCM Disconnect EPR connector. EPR is located in turbocharger mounting pedestal on top left rear of engine. (Scheme 19)or (Scheme 20). Turn ignition off. Using DVOM, measure resistance between chassis ground and Black/White wire at EPR harness connector. (Scheme 63) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black/White wire between chassis ground and EPR. Clear DTCs and retest.
2) Check EPR Coil Using DVOM, 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. Clear DTCs and retest.
3) Check EPR Circuit For Short To Power Disconnect PCM 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. While shaking wiring harness, measure voltage between chassis ground and Gray/Red wire at EPR harness connector. If battery voltage is not present, go to next step. If battery voltage is present, repair short to voltage in Gray/Red wire between PCM and EPR. Clear DTCs and retest.
4) Check EPR Circuit For Short To Ground While shaking wiring harness, measure resistance between chassis ground and Gray/Red wire at EPR harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Gray/Red wire. Clear DTCs and retest.
5) Check EPR Circuit For Open Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. While shaking wiring harness, measure resistance between Gray/Red wire at EPR 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. Clear DTCs and retest.
6) Perform Output State Check Reconnect PCM connector. Attach scan tool to Data Link Connector (DLC). Turn ignition on. Using DVOM, measure between chassis ground and Gray/Red wire at EPR harness connector. Perform «KOEO OUTPUT STATE SELF-TEST»(ref-139800-S18640610012002051000000) under QUICK TEST. If voltage does not toggle between 12 volts and zero volt, replace PCM. Clear DTCs and retest. If voltage toggles between 12 volts and zero volt, reconnect all components. No fault is indicated at this time. Clear DTCs and retest.
7) KOER & Continuous Memory DTC P0476: Check EPR Mechanical Operation DTC P0476 indicates PCM detected poor exhaust pressure control valve performance malfunction during KOER ON-DEMAND SELF-TEST. Possible causes are: Stuck Or Damaged Turbocharger Wastegate Valve (Butterfly) Misadjusted Or Damaged Linkage Restricted Exhaust Exhaust Leaks Faulty EPR Faulty Exhaust Backpressure (EBP) Sensor Faulty PCM Visually inspect turbocharger wastegate valve tang. (Scheme 27) 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 retest.
8) Check For Exhaust Restriction Unplug EOT sensor to cause EBP valve to stay open. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. Start engine and allow it to idle. Briefly accelerate engine speed to Wide Open Throttle (WOT) while monitoring EBP PID. If EBP PID is more than 25 psi (172 kPa), go to next step. If EBP PID reading is 25 psi (172 kPa) or less, go to step 10).
9) EBP Operation Test Inspect exhaust system for damage. Observe EBP valve operation while repeating «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If EBP valve cycles and then opens completely (tang against stop), check EBP adjustment. If EBP valve does not cycle and then open completely, go to next step.
10) Check Electrical System Ensure EBP and associated wiring harness and connectors are okay. Repair as necessary. If wiring and connectors are okay, go to next step.
11) EBP Sensor Check Turn ignition on. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. Start engine and record EBP PID value. While observing scan tool, briefly accelerate engine speed several times. If EBP PID reading increases 4 psi or more with each acceleration, go to next step. If EBP PID reading increases less than 4 psi with each acceleration, replace EBP sensor. Clear DTCs and retest. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20).
12) Check For Exhaust Leaks Inspect turbo pipe, crossover pipe and exhaust manifolds for leaks. Repair as necessary. Clear DTCs and retest. If no exhaust leaks are found, go to next step.
13) Check EBP During KOER Self-Test Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Install ICP/EBP Adapter Cable (D94T-50-A) between EBP sensor and sensor harness connector. Start engine. Using DVOM, measure voltage between signal circuit and signal ground at ICP/EBP adapter cable. Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If voltage increases 1.5-2.5 volts and then decreases as test ends, replace PCM. Clear DTCs and retest. If voltage does not increase 1.5-2.5 volts and then decreases as test ends, go to next step.
14) EPR Visual Inspection Observe EPR valve linkage while performing «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If linkage moves during test, check EPR linkage adjustment. See «WASTEGATE CONTROL SOLENOID ADJUSTMENT»(ref-142317-S32592077652002072900000) under AIR INDUCTION in REMOVAL, OVERHAUL & INSTALLATION - ECONOLINE, EXCURSION & F250-550 PICKUP - DIESEL article. Adjust as necessary and retest. If linkage does not move during test, replace EPR valve. Clear DTCs and retest.

TEST KC: GLOW PLUG SYSTEM (FEDERAL EMISSIONS)

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

Glow Plug Relay
Harness Circuits (GP/RELAY Coil)
PCM

Note. WAIT TO START indicator ON time is independent from glow plug relay ON time (1-10 seconds).

Output Functions Glow plug relay controls current flow to glow plugs. Glow plug relay ON time is controlled by PCM and is a function of engine oil temperature, barometric pressure and battery voltage. Glow plug ON time normally varies between 10-120 seconds. Glow plug ON time is dependent on oil temperature and altitude. Glow plug relay comes on between 1-120 seconds and does not come on at all if oil temperature is above 86°F (30°C) for Econoline, or 131°F (55°C) for Excursion and F250-750. Using scan tool, you can run OUTPUT STATE SELF TEST, which will cycle glow plug relay on for 5 seconds, the first time only, that accelerator pedal is pressed. OUTPUT STATE SELF TEST does not set DTCs.
Detection & Management An open or shorted to ground glow plug relay or WAIT TO START indicator circuit can be detected during KOEO ON-DEMAND SELF-TEST. On all vehicles with Federal emissions, glow plug and glow plug harness concerns cannot be detected by PCM.

Scheme 64

Scheme 65

Scheme 66

WARNING

Red-striped wires carry 115 volts DC. Severe electrical shock may be received. DO NOT pierce engine electrical wires or damage to harness may occur.

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0380	KC1		KC1

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P0380: Repeat KOEO Self-Test Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. Retrieve DTCs. If KOEO DTC P0380 is present, go to next step. If KOEO DTC P0380 is not present, go to step 7).
2) DTC P0380: Check PWR Circuit To Glow Plug Relay DTC P0380 indicates that PCM detects a glow plug relay control circuit malfunction. Possible causes are: Short To Voltage Blown Fuse Faulty Glow Plug Relay PWR Circuit To Glow Plug Relay Open, Or Shorted To Ground Or Power Faulty PCM Turn ignition on. Using DVOM, measure voltage between chassis ground and Red wire at glow plug relay. Glow plug relay is located on top of engine. (Scheme 19)or (Scheme 20). If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in PWR circuit to glow plug relay. On Excursion and F250-550, check PWR circuit fuse No. 22 (20-amp) from PCM relay to glow plug relay. If fuse is blown, check PWR circuit for short to ground. On all models, repair as necessary. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
3) Check Glow Plug Relay Resistance Turn ignition off. Disconnect Violet/Orange wire at glow plug relay. Using DVOM, measure resistance between terminal for Violet/Orange wire and terminal for Red wire at glow plug relay. On all models, if resistance is 1-8 ohms, go to next step. If resistance is not 1-8 ohms, replace glow plug relay. Clear DTCs and retest.
4) Check For Short To Power Turn ignition off. Ensure Violet/Orange wire is disconnected from glow plug relay. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 101 at breakout box. If voltage is 10.5 volts or less, go to next step. If voltage is more than 10.5 volts, repair short to voltage in Violet/Orange wire between PCM and glow plug relay. Clear DTCs and retest.
5) Check For Short To Ground Turn ignition off. Using DVOM, measure resistance between chassis ground and disconnected Violet/Orange wire. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Violet/Orange wire between PCM and glow plug relay. Clear DTCs and retest.
6) Check For Open Circuit Using DVOM, measure resistance between disconnected Purple/Orange wire and test pin No. 101 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Purple/Orange wire. Clear DTCs and retest.
7) Check Glow Plug Relay "On" Time Turn ignition on. Using scan tool, access EOT and GPCTM PIDs from PID/DATA MONITOR & RECORD menu. Verify EOT PID value is less than 86°F (30°C) on Econoline, or less than 131°F (55°C) on Excursion and F250-750. On all models, measure voltage between chassis ground and glow plug relay terminal No. 87 (Brown wire on Econoline and F650-750, or White wire on F250-550). See «WIRING DIAGRAMS»(ref-139134) article. If voltage is present for the time indicated on GPCTM PID, go to next step. If voltage is not present for the time indicated on GPCTM PID, replace glow plug relay. Clear DTCs and retest.
8) Check For Intermittent Fault Clear DTCs. Wiggle and bend small sections of wiring harness starting at glow plug relay and working toward PCM. PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous DTC P0380 is present, locate and repair intermittent circuit fault in wiring harness. If Continuous DTC P0380 is not present, fault cannot be duplicated at this time and testing is complete.
9) Check Glow Plugs Turn ignition off. Disconnect glow plug/injector connectors at both valve cover gaskets. Using DVOM and Glow Plug Adapter (134-00132), measure resistance between chassis ground and each glow plug connector. See «WIRING DIAGRAMS»(ref-139134) article. If resistance is.1-2.0 ohms, go to next step. If resistance is not.1-2.0 ohms, remove valve cover and inspect harness for opens and shorts. If harness is okay, replace appropriate glow plug.
10) Check Glow Plug Connectors Using DVOM, measure resistance between each glow plug contact in engine harness and the 2 brown wires on glow plug relay. If resistance is 0-2.0 ohms, inspect inside of air filter-to-turbocharger air duct. If dirt or abrasives are present, engine may be damaged or worn. See 7.3L V8 TURBO DIESEL article in ENGINES for engine testing and repair procedures. If resistance is not 0-2.0 ohms, replace engine wiring harness.

TEST KD: GLOW PLUG LIGHT

WARNING

Red-striped wires carry 115 volts DC. Severe electrical shock may be received. DO NOT pierce engine electrical wires or damage to harness may occur.

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 only intended to diagnose the following components and circuits

Glow Plug Light (GPL) Or WAIT TO START Light
Instrument Cluster
PCM

Econoline & F650-750 Glow Plug WAIT TO START Lamp is used to indicate to operator when glow plugs have been on long enough to crank and start engine. It is controlled by PCM. WAIT TO START lamp ON time is a function of engine oil temperature, barometric pressure and battery voltage. ON time normally varies between 1-10 seconds.
Excursion & F250-550 Glow Plug Indicator Light (GPL) is used to indicate to operator when glow plugs have been on long enough to crank and start engine. GPL ON time is a function of engine oil temperature, barometric pressure and battery voltage. ON time normally varies between 1-10 seconds. Command to illuminate indicator is sent from PCM to instrument cluster through Standard Corporate Protocol (SCP) communications. PCM sends cluster an electronic SCP message for indicator function. Failure check is performed by instrument cluster and pass/fail information is sent back to PCM for setting of failed GPL, DTC P0381. DTC P0381 is an OBD-II code for California emission vehicles only and will illuminate CHECK ENGINE light.
Detection & Management An open or shorted to ground glow plug relay or WAIT TO START lamp circuit can be detected during KOEO ON-DEMAND SELF TEST. Glow plug and glow plug harness problems cannot be detected by PCM.

Scheme 67

Scheme 68

Scheme 69

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0381	KD3		KD3

FAULT CODE SETTING CONDITION

WARNING

Red-striped wires carry 115 volts DC. Severe electrical shock may be received. DO NOT pierce engine electrical wires or damage to harness may occur.

1) DTC P0381: Check GPL Operation DTC P0381 indicates PCM has detected a glow plug indicator circuit malfunction. Possible causes are: Faulty Glow Plug Indicator Faulty Instrument Cluster Faulty PCM Turn ignition on and observe GPL. If GPL illuminates for 1-10 seconds then turns off, clear DTCs and retest. If DTC P0381 resets, diagnose instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If GPL does not illuminate for 1-10 seconds then turn off, go to next step.
2) Repeat KOEO Self-Test Cycle ignition off, then on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. Retrieve DTCs. If KOEO DTC P0381 is present, diagnose instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If KOEO DTC P0381 is not present, fault is intermittent. Restore vehicle.
3) KOEO & Continuous Memory DTC P0381: Check WAIT TO START Indicator Operation DTC P0381 indicates PCM has detected a WAIT TO START indicator circuit malfunction. Possible causes are: Faulty WAIT TO START Indicator Open Or Short To Ground in WTSL Signal Circuit Open Or Short To Ground in WTSL PWR Circuit Blown WAIT TO START Indicator Fuse Faulty PCM Start engine and observe WAIT TO START light. If light remains on after engine start-up, go to next step. If light goes off after engine start-up, go to step 5).
4) Check WTSL Signal Circuit For Short To Ground Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Turn ignition on. If WAIT TO START light remains illuminated, repair short to ground in WTSL signal circuit (Black/Pink wire) between PCM and instrument cluster. See «WIRING DIAGRAMS»(ref-139134) article. If WAIT TO START light does not illuminate, replace PCM. Clear DTCs and retest.
5) Check For Intermittent DTC P0381 Turn ignition on. Observe WAIT TO START light. Wait 5 seconds, then turn ignition off. If WAIT TO START light does not illuminate at all, go to next step. If WAIT TO START light illuminates for at least one second, concern is intermittent. Go to step 11).
6) Check WAIT TO START Light PWR Fuse Turn ignition off. Remove and inspect fuse No. 2 (Econoline) or fuse No. 29 (F650-750) from central junction box. Central junction box is located behind lower left side of instrument panel. If fuse is okay, reinstall fuse and go to next step. If fuse is blown, leave fuse removed and go to step 8).
7) Check WAIT TO START Light Bulb Remove and inspect WAIT TO START bulb. If bulb is okay, go to step 9). If bulb is bad, replace bulb. Clear DTCs and retest.
8) Check WTSL PWR Circuit For Short To Ground Remove WAIT TO START bulb. Using DVOM, measure resistance between chassis ground and WTSL PWR circuit (Red/Yellow wire) at WAIT TO START bulb socket. If resistance is more than 10 k/ohms, circuit is okay. Replace fuse. Clear DTCs and retest. If resistance is 10 k/ohms or less, locate and repair short to ground in Red/Yellow wire. Replace fuse, clear DTCs and retest.
9) Check WTSL PWR Circuit For Open Access instrument cluster connectors. Remove WAIT TO START light. Turn ignition on. On Econoline, check for battery voltage between chassis ground and terminal No. 11 (Red/Yellow wire) at instrument cluster White 16-pin connector. On F650-750, check for battery voltage between chassis ground and terminal No. 12 (Red/Yellow wire) at instrument cluster 12-pin connector. (Scheme 67)or (Scheme 69). On all models, if battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in WTSL PWR circuit (Red/Yellow wire) between fuse in central junction box and instrument cluster connector.
10) Check WTSL Signal Circuit For Open Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of WTSL signal circuit (Black/Pink wire) between test pin No. 70 at breakout box and instrument cluster Black 12-pin connector terminal No. 11 (Econoline), or terminal No. 2 (F650-750). If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in Black/Pink wire between PCM and instrument cluster connector.
11) Continuous Memory DTC P0381: Clear DTCs & Road Test Clear DTCs. Road test vehicle. Retrieve Continuous Memory DTCs. If Continuous Memory DTC P0381 is present, go to next step. If Continuous Memory DTC P0381 is not present, DTC was not cleared after a previous repair. Testing is complete.
12) Check For WAIT TO START Light Flicker If WAIT TO START light came on or flickered on and off during road test in step 11), locate and repair intermittent short to ground in Black/Pink wire between WAIT TO START light and PCM. Clear DTCs and retest. If WAIT TO START light did not come on or flicker on and off during road test, go to next step.
13) Check For Intermittent Open Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Connect jumper wire between chassis ground and test pin No. 70 at breakout box. WAIT TO START light should be illuminated. Observe WAIT TO START light and tap on instrument panel. Wiggle and bend small sections of wiring harness starting at engine compartment 76-pin bulkhead connector and working toward PCM. If WAIT TO START light flickers off and on, locate and repair intermittent open circuit in wiring harness. Clear DTCs and retest. If WAIT TO START light does not flicker off and on, intermittent open or short cannot be located at this time. Replace PCM and retest.

TEST KE: INJECTION PRESSURE REGULATOR

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

Injection Pressure Regulator (IPR)
Injection Control Pressure (ICP) Sensor
Powertrain Control Module (PCM)
Wiring harness circuit (IPR)

Output Functions Injection Pressure Regulator (IPR) is a variable position valve that controls injection control pressure. PCM uses many input variables to determine desired injection control pressure. Battery voltage is supplied to IPR when ignition is on. Valve position is controlled by switching output signal circuit to ground inside PCM. ON/OFF time is modulated from 0-50 percent, dependent upon desired injection control pressure.
Detection & Management An open or shorted to ground control circuit can be detected during KOEO ON-DEMAND SELF-TEST. When starter is engaged and engine fails to start, IPR command will increase toward its maximum until engine starts. Normal range for IPR at idle is between 8-16 percent. A range above 16 percent indicates high effort to achieve idle. A range below 8 percent indicates low effort to achieve idle. PCM is capable of detecting whether desired injection control pressure is equal to measured injection control pressure while engine is running. If measured injection control pressure does not reasonably compare to desired injection control pressure, PCM ignores measured ICP sensor signal and attempts to control engine with desired value. If problem is in sensor circuit, this strategy causes little performance deterioration. If problem is in control circuit, engine performance will probably still be unsatisfactory. An injection control pressure step test, in which PCM commands and then measures specific preprogrammed pressures is performed during KOER ON-DEMAND SELF-TEST.

Scheme 70

Scheme 71

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1209			KE15
P1211 1	KE15	KE7	KE15
P1282 1		KE5	KE5
P1283	KE1
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO DTC P1283: Check Power Feed Circuit DTC P1283 indicates high or low resistance in IPR circuit. Possible causes are: Mechanically Stuck IPR IPR Circuit Open, Or Shorted To Ground Or Power Loose Or Poor Harness Connection Faulty IPR Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. On Econoline and F650-750, remove PCM PWR relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove PCM PWR relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, measure resistance of Red wire between IPR harness connector and PCM PWR relay cavity No. 87. (Scheme 70)or (Scheme 71). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, check for open in IPR PWR circuit. On Excursion and F250-550, check fuse No. 22 (20-amp) located in central junction box. If fuse is okay, check for open in IPR PWR circuit (Red wire) between IPR and battery junction box (Econoline and F650-750), or central junction box (Excursion and F250-550). Repair circuit as necessary. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
2) Check IPR Coil Resistance Using DVOM, measure resistance between IPR terminals. If resistance is 5-20 ohms, go to next step. If resistance is not 5-20 ohms, replace IPR. Clear DTCs and retest.
3) Check IPR Control Circuit For Short To Ground Or Voltage Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 83 and test pins No. 25, 51, 71, 76 (Econoline), 77, 97 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground or short to voltage in IPR control circuit (Yellow/Red wire between PCM and IPR. Clear DTCs and retest.
4) Check IPR Control Circuit Resistance Using DVOM, measure resistance of Yellow/Red wire between test pin No. 83 at breakout box and IPR harness connector. (Scheme 70)or (Scheme 71). If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Red/Yellow wire. Clear DTCs and retest.
5) KOER & Continuous Memory DTC P1282: Attempt To Start Engine DTC P1282 indicates injection control pressure was more than 3675 psi for 1.5 seconds (possible grounded IPR control circuit). If electronic concern with IPR or ICP is not found, see INJECTION CONTROL PRESSURE TESTS under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL. Possible causes are: Intermittent Short To Ground In IPR Control Circuit Mechanically Stuck IPR Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. Attempt to start engine. If engine does not start, go to next step. If engine starts, replace IPR. Clear DTCs and retest.
6) Check For Intermittent Short To Ground Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 83 at breakout box. Resistance should be more than 10 k/ohms. Wiggle and bend small sections of wiring harness starting at IPR connector and working toward PCM. A fault is indicated when resistance changes to 10 k/ohms or less. If fault is indicated, isolate intermittent short to ground and repair as necessary. Clear DTCs and retest. If no fault is indicated, clear DTCs and repeat «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If DTC resets, replace PCM. Clear DTCs and retest.
7) KOER DTC P1211: Check Engine Oil Quality & Viscosity, & Fuel Grade DTC P1211 indicates that injection control pressure was more than or less than commanded desired pressure during self-test. Possible causes are: Incorrect Oil Or Viscosity Poor Oil Quality Gel Fuel Or No Fuel Low Fuel Pressure Faulty IPR Valve High Pressure Oil System Leak Faulty High Pressure Oil Pump Faulty PCM Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil or fuel as necessary. Clear DTCs and retest. Ensure DTC does not reset. If oil and fuel are okay, go to next step.
8) Check Fuel Pressure Measure fuel pressure at regulator block. Measure fuel pressure with engine idling and while driving vehicle at Wide Open Throttle (WOT) with a full load. Fuel pressure should be 45 psi (310 kPa) at idle and 45-80 psi (310-552 kPa) while driving vehicle at WOT 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. Clear DTCs and retest.
9) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm) of top of reservoir, go to next step. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and retest.
10) ICP Sensor Check Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD 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. Clear DTCs and retest.
11) Oil Aeration Check Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine. Raise engine speed to Wide Open Throttle (WOT) for 3 minutes. If ICP PID reading increases to more than 1800 psi, change engine oil and repeat test. Clear DTCs and retest. If ICP PID reading does not increase to more than 1800 psi, go to next step.
12) Check ICP Sensor Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Install ICP/EBP Adapter Cable (D94T-50-A) between ICP sensor and sensor harness connector. Start engine. Using DVOM, measure voltage between ICP signal circuit and ground at ICP/EBP adapter cable. (Scheme 23) Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If voltage increases to more than 3 volts and then decreases to about one volt during ICP portion of KOER self-test, replace PCM. Clear DTCs and retest. If voltage does not increase to more than 3 volts and then decrease to about one volt during ICP portion of KOER self-test, go to next step.
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, access and monitor IPR PID from PID/DATA MONITOR & RECORD menu. 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, install onto 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. Clear DTCs and retest. If both IPR PID readings are within 2 percent of each other, replace IPR. Clear DTCs and retest. If DTC P1211 is still present, go to next step.
14) Oil System Pressure Test Check for pressurized oil leaks. See TEST 10A: INJECTION CONTROL PRESSURE TESTS (OIL AERATION/POOR IDLE) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. Clear DTCs and retest. If no leaks are found, replace high pressure oil pump. Clear DTCs and retest.
15) KOEO & Continuous Memory DTC P1209 Or P1211: DTC P1209 indicates injector control pressure system fault. If DTC P1211 is set during normal engine operation, it indicates engine is operating in open loop control and injection control pressure is more than or less than desired pressure. If DTC P1211 is set during KOER ON-DEMAND SELF-TEST, it indicates ICP system failed step test and could not maintain commanded pressure. Possible causes are: Incorrect Oil Or Viscosity Poor Oil Quality Gel Fuel Or No Fuel Low Fuel Pressure Faulty IPR Valve High Pressure Oil System Leak Faulty High Pressure Oil Pump Faulty PCM Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil or fuel as necessary. Clear DTCs and retest. If oil and fuel are okay, go to next step.
16) Check Fuel Pressure Measure fuel pressure at regulator block. Measure fuel pressure with engine idling and while driving vehicle at Wide Open Throttle (WOT) with a full load. Fuel pressure should be 45 psi (310 kPa) at idle and 45-80 psi (310-552 kPa) while driving vehicle at WOT 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. Clear DTCs and retest.
17) Perform KOER On-Demand Self-Test Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. If DTC P1211 is present, go to step 9). If DTC P1211 is not present, go to next step.
18) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm) of top of reservoir, go to next step. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and retest.
19) ICP Sensor Check Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. If ICP PID reading indicates zero psi, go to next step. If ICP PID reading does not indicate zero psi, replace ICP sensor. Clear DTCs and retest.
20) Oil Aeration Check Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine. Raise engine speed to Wide Open Throttle (WOT) for 3 minutes. If ICP PID reading increases to more than 1800 psi, change engine oil and repeat test. Clear DTCs and retest. If ICP PID reading does not increase to more than 1800 psi, go to next step.
21) Check IPR Duty Cycle Under Load Using scan tool, access IPR PID from PID/DATA MONITOR & RECORD menu. Road test vehicle with engine at Wide Open Throttle (WOT) and with full load condition. If IPR PID value increases to 65 percent, replace IPR valve. Clear DTCs and retest. If IPR PID value does not increase to 65 percent, no concern is indicated at this time. Clear DTCs and retest.

TEST KF: FUEL DELIVERY COMMAND SIGNAL

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

Injector Driver Module
Wiring Harness Circuit (FDCS)
Powertrain Control Module (PCM)

Scheme 72

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1663	KF1

FAULT CODE SETTING CONDITION

1) KOEO DTC P1663: Repeat KOEO Self-Test DTC P1663 indicates that PCM has detected a failure on Fuel Delivery Command Signal (FDCS) circuit. Possible causes are: Faulty Injector Driver Module (IDM) FDCS Circuit Open Or Shorted To Ground Faulty PCM Repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST and retrieve Continuous Memory DTCs. Proceed as follows: If DTC P1663 is present, go to next step. If DTCs P1663 and P1667 are set together with or without DTC P1668, go to TEST FJ, step 6). If DTC P1298 is also present, replace IDM. Clear DTCs and retest. If DTC P1667 is also present, go to TEST KA, step 1). If DTC P1662 is also present, go to TEST NC, step 1).
2) Check Voltage On FDCS Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950) and connect PCM connector to breakout box. Turn ignition on. Using DVOM, measure voltage between test pin No. 95 (FDCS) and GND circuit test pins No. 25, 51, 76 (Econoline), 91 and 103 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 4 volts, go to step 5).
3) Perform Output State Check Turn ignition on. Perform «KOEO OUTPUT STATE SELF-TEST»(ref-139800-S18640610012002051000000) under QUICK TEST. Toggle outputs ON and OFF by applying and releasing accelerator pedal. Using DVOM, measure voltage between test pin No. 95 (FDCS) and GND circuit test pins No. 25, 51, 76 (Econoline), 91 and 103 at breakout box. If voltage does not toggle between.5-.7 volt and battery voltage, replace PCM. Clear DTCs and retest. If voltage toggles between.5-.7 volt and battery voltage, fault is intermittent. Go to step 8).
4) Check FDCS Circuit For Open Turn ignition off. Disconnect PCM connector from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance of FDCS circuit (Brown/Orange wire) between test pin No. 95 at breakout box and terminal No. 17 at IDM harness connector. (Scheme 55)and (Scheme 72). If resistance is less than 5 ohms, go to step 6). If resistance is 5 ohms or more, repair open in Brown/Orange wire between PCM and IDM. Clear DTCs and retest.
5) Check FDCS Circuit For Short To Power Turn ignition off. Disconnect PCM connector from breakout box. Turn ignition on. Using DVOM, measure voltage between test pin No. 95 (FDCS) and GND circuit test pins No. 25, 51, 76 (Econoline), 91 and 103 at breakout box. If battery voltage is not present, go to step 7). If battery voltage is present, locate and repair short to voltage in Brown/Orange wire between PCM connector and IDM connector. Clear DTCs and retest.
6) Check FDCS Circuit For Short To Ground Turn ignition off. Using DVOM, measure resistance between test pin No. 95 and pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Brown/Orange wire between PCM connector and IDM connector. Clear DTCs and retest.
7) Check PCM Output State Function Turn ignition off. Connect PCM to breakout box. Ensure IDM is disconnected. Turn ignition on. Perform «KOEO OUTPUT STATE SELF-TEST»(ref-139800-S18640610012002051000000) under QUICK TEST. Toggle outputs ON and OFF by applying and releasing accelerator pedal. Using DVOM, measure voltage between test pin No. 95 and pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If voltages does not toggle between.5-.7 volt and zero volt, replace PCM. Clear DTCs and retest. If voltage toggles between.5-.7 volt and zero volt, replace IDM. Clear DTCs and retest.
8) Check For Intermittent Turn ignition off and reconnect all components. Turn ignition on. Clear DTCs. Cycle ignition off, then on. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. IF DTC P1663 is present, replace PCM. Clear DTCs and retest. If DTC P1663 is not present, no concern is indicated at this time.

TEST KG: TACHOMETER (EXCURSION & F250-750)

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

Wiring Harness Circuits (VPWR, GND & TACH Signal)
Tachometer

Excursion & F250-550 Tachometer is controlled by instrument cluster. Instrument cluster receives engine speed information (RPM) from PCM through Standard Corporate Protocol (SCP) communications network. (Scheme 73)
F650-750 Tachometer is controlled by TAC output circuit on PCM. (Scheme 74)

Scheme 73

Scheme 74

1) Tachometer Inoperative: Check Tachometer PWR Fuse Remove and inspect fuse No. 29 (10-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. If fuse is okay, reinstall fuse and go to next step. If fuse is blown, locate and repair short to ground in Tachometer PWR circuit (Red/Yellow wire) between central junction box and instrument cluster. Replace fuse and retest system.
2) Check Tachometer Ground Circuit Turn ignition off. Access connectors behind instrument cluster. Disconnect instrument cluster Black 12-pin connector C220a and inspect for damaged pins, corrosion and loose wires. Repair connector as necessary. Using DVOM, measure resistance between chassis ground and terminal No. 12 (Black wire) at instrument cluster Black harness connector. (Scheme 74) 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 between instrument cluster and ground G201 located at center of dash, below instrument panel. Restore vehicle and check system for normal operation.
3) Check PWR Circuit To Tachometer Disconnect instrument cluster White 12-pin connector C220c and inspect for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between chassis ground and terminal No. 12 (Red/Yellow wire) at instrument cluster harness connector. (Scheme 74) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, locate and repair open in PWR circuit (Red/Yellow wire) between instrument cluster and tachometer PWR fuse No. 29 in central junction box.
4) Check Tach Signal Circuit To Instrument Cluster Connect scan tool to Data Link Connector (DLC). Connect a jumper wire between instrument cluster Black 12-pin harness connector terminal No. 12 (Black wire) and COM port at scan tool. Connect another jumper wire between instrument cluster White 16-pin harness connector terminal No. 12 (White/Pink wire) and SIG port at scan tool. Start engine and allow it to idle. Using 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 access PIDs. Select PID/DATA MONITOR. Select RPM PID. Press START. Observe RPM PID reading at specified engine speed. See «RPM PID FREQUENCY SPECIFICATIONS»(ref-139800-S09113306502002050900000) 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 and retest system. If frequency is not as specified, go to next step. RPM PID FREQUENCY SPECIFICATIONS RPM Hz 650 33-53 1500 90-110 2500 160-180
5) Check For Open In TACH Signal Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of TACH signal circuit (White/Pink wire) between instrument cluster White 16-pin harness connector terminal No. 12 and test pin No. 19 at breakout box. (Scheme 74) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in White/Pink wire between PCM and instrument cluster and retest system.
6) Check For Short To Ground In TACH Signal Circuit Using DVOM, measure resistance between chassis ground and instrument cluster White 16-pin harness connector terminal No. 12 (White/Pink wire). (Scheme 74) If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in White/Pink wire between PCM and instrument cluster and retest system.
7) Check For Short To Voltage In TACH Signal Circuit Turn ignition on. Using DVOM, measure voltage between chassis ground and instrument cluster White 16-pin harness connector terminal No. 12 (White/Pink wire). If voltage is more than 10.5 volts, locate and repair short to voltage in White/Pink wire between PCM and instrument cluster. Retest system. If voltage is 10.5 volts or less, replace PCM and retest system.
8) Perform Tachometer Active Command Using Scan Tool If any other gauge or indicator on instrument panel is faulty, diagnose instrument cluster concern before proceeding. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Turn ignition on. Perform «QUICK TEST»(ref-139800-S19570345092002050900000) procedures to ensure all electronic engine control systems are working properly and DTCs are not present. If DTCs are present, service appropriate DTC. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). If no DTCs are present, use scan tool and access Instrument Cluster Tachometer Active Command. Select tachometer, press "Trigger" and scroll in increments of 10 percent. Monitor vehicles tachometer reading. Tachometer should increase in increments of approximately 600 RPM for each 10 percent change. If tachometer reading does not increase as specified, go to next step. If tachometer reading does increase as specified, replace PCM.
9) Check For Correct Instrument Cluster Operation Disconnect all instrument cluster connectors. Check connectors and inspect for damaged pins, corrosion and loose wires. Reconnect all instrument cluster connectors and make sure they seat correctly. Operate system and verify concern is still present. If concern is still present, replace instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Test system for normal operation. If concern is no longer present, concern was intermittent and system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Retest system.

TEST KH: WASTEGATE CONTROL SOLENOID (EXCURSION & F250-550)

Perform this test only when directed by QUICK TEST or if no DTCs are present and you are directed here from TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article. This test is only intended to diagnose the following components and circuits

Wiring Harness Circuits (VPWR & WGC Signal)
Wastegate Control (WGC) Solenoid
WGC Actuator
Powertrain Control Module (PCM)

Note. Wastegate Control (WGC) solenoid is not used on F650-750.

A wastegated turbo is designed to reach maximum boost sooner than a conventional turbo, but overboosting will cause damage to turbo. PCM will control boost pressure by sending a duty cycle to WGC solenoid to maximize boosting performance, no more than 16.5 psi (113.8 kPa). When pressure is supplied on Red hose going to actuator (solenoid NOT energized), valve will open, dumping boost. When low or no pressure is on Red hose going to actuator (solenoid energized), valve will stay closed.

Scheme 75

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1249			KH6

FAULT CODE SETTING CONDITION

1) Boost Pressure Test Connect scan tool to Data Link Connector (DLC). Turn A/C off. Using scan tool, access and monitor Manifold Gauge Pressure (MGP) PID from PID/DATA MONITOR & RECORD menu. Road test vehicle. Observe PID reading while performing several accelerations from 1500-3000 RPM to determine turbo boost. Test works best by road testing vehicle up a hill or with vehicle fully loaded. With accelerator at wide open throttle, note highest boost reading while accelerating through 2500-3000 RPM range. MGP PID reading will level out after 3000 RPM and should be 16 psi (110 kPa) or more. If MGP PID reading is more than minimum specification, go to next step. If MGP PID reading is less than minimum specification, return to RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article to complete diagnosis.
2) KOEO & Continuous Memory DTC P1690: Check For Power To WGC Solenoid DTC P1690 indicates PCM has detected a failure on WGC circuit. Possible causes are: Blown Fuse VPWR Circuit Open WGC Circuit Open Or Shorted To Ground Faulty WGC Solenoid Faulty PCM Turn ignition off. Disconnect WGC solenoid. Solenoid is located on turbocharger wastegate. Turn ignition on. Using DVOM, measure voltage between chassis ground and WGC solenoid harness connector terminal No. 2 (Red/Light Green wire). (Scheme 75) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check for open in VPWR circuit. Check fuse No. 64 (30-amp) in central junction box. If fuse is blown, check for short to ground in VPWR circuit. Repair circuit and replace fuse as necessary. If fuse is okay, repair open in Red/Light Green wire between central junction box and WGC solenoid. Clear DTCs and retest.
3) Check WGC Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of White/Red wire between terminal No. 1 at WGC solenoid harness connector and test pin No. 47 at breakout box. (Scheme 75) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in White/Red wire between PCM and WGC solenoid. Clear DTCs and retest.
4) Check WGC Circuit For Short To Ground Using DVOM, measure resistance between chassis ground and WGC solenoid harness connector terminal No. 1 (White/Red wire). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in White/Red wire between PCM and WGC solenoid. Clear DTCs and retest.
5) Check WGC Solenoid Using DVOM, measure resistance between WGC solenoid terminals. If resistance is 50 ohms or more, replace WGC solenoid. Clear DTCs and retest. If resistance is less than 50 ohms, replace PCM. Clear DTCs and retest.
6) Continuous Memory DTC P1249: Repeat KOEO Self-Test DTC P1249 indicates wastegate steady state failure. Possible causes are: Short To Ground Plugged WGC Vacuum Hose Or Port Faulty WGC Solenoid Faulty WGC Actuator Faulty PCM Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1690 is present, go to step 2). If DTC P1690 is not present, go to next step.
7) Check WGC Vacuum Hose Disconnect Red hose from WGC actuator. (Scheme 75) Connect a vacuum pump to end of disconnected Red hose. Apply vacuum. If vacuum does not hold, go to step 9). If vacuum holds, leave vacuum applied and go to next step.
8) Check Intake Port 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 retest. If hose still holds vacuum, replace plugged WGC hose. Clear DTCs and retest.
9) Check Intercooler Port Disconnect Red hose from charge air cooler housing. Connect vacuum pump to intake port and apply vacuum. If port does not hold vacuum, go to next step. If port holds vacuum, clean plugged charge air cooler housing hose port. Clear DTCs and retest.
10) Check WGC Actuator Connect vacuum pump to WGC actuator. Apply vacuum. If actuator does not hold vacuum, actuator diaphragm is faulty. Replace actuator. Clear DTCs and retest. If actuator holds vacuum, check for sticking WGC actuator linkage. Repair or replace as necessary. Clear DTCs and retest.

TEST KJ: KICKDOWN SOLENOID RELAY (ALLISON AT545)

Note. Kickdown Solenoid Relay is also referred to as downshift solenoid relay or shift control modulator relay.

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

Wiring Harness Circuits (ASM, ASMM, B+ & VPWR)
Blown Battery Junction Box Fuse No. 10 (15-Amp)
Downshift Solenoid
Downshift Solenoid Relay
Powertrain Control Module (PCM)

Note. Kickdown Solenoid Relay is used on F650-750 with an Allison AT545 automatic transmission only.

On F650-750, PCM controls a relay which provides kickdown necessary for Wide Open Throttle (WOT) downshifts. Downshift solenoid relay is powered through VPWR circuit. When PCM sends a signal to downshift solenoid relay control (ASM) circuit, it causes downshift solenoid relay to switch voltage from battery junction box fuse No. 10 (15-Amp) to positive side of transmission mounted downshift solenoid. PCM monitors switched side of relay through terminal No. 40 for diagnostics.

Scheme 76

1) KOEO & Continuous Memory DTC P1902: Check VPWR Circuit For Open DTC P1902 indicates PCM detected kickdown solenoid relay control circuit failure. Possible causes are: VPWR Circuit To Downshift Relay Open Downshift Relay Control Circuit Open Faulty Downshift Relay Faulty PCM Turn ignition off. Remove downshift solenoid relay from battery junction box. Battery junction box is located in left rear corner of engine compartment. Turn ignition on. Using DVOM, measure voltage between chassis ground and downshift solenoid relay cavity No. 1 (White/Light Blue wire). (Scheme 76) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit (White/Light Blue wire) between battery junction box and downshift solenoid relay. Retest system.
2) Check PCM Control Circuit Turn ignition off. Reinstall downshift solenoid relay. Disconnect PCM connector. Connect a jumper wire between chassis ground and PCM harness connector terminal No. 94 (Orange/Yellow wire). Turn ignition on, then off. If an audible click is heard from downshift solenoid relay when ignition is on, replace PCM. Retest system. If an audible click is not heard from downshift solenoid relay, go to next step.
3) Check Downshift Solenoid Relay Control Circuit For Open Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between downshift solenoid relay cavity No. 2 (Orange/Yellow wire) and test pin No. 94 at breakout box. (Scheme 76) If resistance is less than 5 ohms, replace downshift solenoid relay. Retest system. If resistance is 5 ohms or more, repair open in Orange/Yellow wire between PCM and downshift solenoid relay. Retest system.
4) KOEO DTC P1903: Check Fuse DTC P1903 indicates downshift solenoid circuit low voltage. Downshift solenoid relay was commanded ON by PCM and a low voltage was present at B+ terminal of downshift solenoid. Possible causes are: Blown Fuse Open Circuit In Battery Junction Box B+ Circuit To Downshift Relay Open B+ Circuit To PCM Or Downshift Solenoid Open Faulty PCM Remove and inspect downshift solenoid relay B+ fuse No. 10 (15-amp) located in battery junction box. Battery junction box is located in left rear corner of engine compartment. If fuse is okay, go to next step. If fuse is blown, replace fuse. Retest system.
5) Check Downshift Solenoid Relay B+ Circuit For Voltage Turn ignition off. Remove downshift solenoid relay from battery junction box. Turn ignition on. Using DVOM, measure voltage between chassis ground and downshift solenoid relay cavity No. 3 (White/Violet wire). (Scheme 76) If voltage is more than 10.5 volts, go to step 7). If voltage is 10.5 volts or less, go to next step.
6) Check Downshift Solenoid Relay B+ Circuit For Open Using DVOM, measure resistance of White/Violet wire between output side of downshift solenoid relay B+ circuit fuse No. 10 and downshift solenoid relay cavity No. 3. If resistance is less than 5 ohms, check battery feed circuit to fuse No. 10. Repair circuit or replace battery junction box as necessary. See appropriate POWER DISTRIBUTION article in WIRING DIAGRAMS. If resistance is 5 ohms or more, repair open in B+ circuit (White/Violet wire). Retest system.
7) Check Downshift Relay ASSM Circuit To PCM Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Connect a jumper wire between downshift relay cavities No. 3 (White/Violet wire) and No. 5 (Black/Yellow wire). (Scheme 76) Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. Observe DVOM voltage reading and listen for an audible "click" from downshift solenoid while ignition is cycled on, then off. Proceed as follows: If voltage is 10.5 volts or more and downshift solenoid does not "click" when ignition is cycled on, go to next step. If voltage is 10.5 volts or more and downshift solenoid "clicks" when ignition is cycled on, replace PCM. Retest system. If voltage is less than 10.5 volts and downshift solenoid "clicks" when ignition is cycled on, repair open in Black/Yellow wire between splice S139 and PCM. Splice S139 is located on left side of engine compartment. Retest system.
8) Check Downshift Solenoid Relay Output Circuit To Downshift Solenoid Using DVOM, measure resistance of Black/Yellow wire between downshift relay cavity No. 5 and downshift solenoid harness connector. If resistance is less than 5 ohms, check for automatic transmission concern. See «4R100 DIAGNOSIS»(ref-140948) article in AUTOMATIC TRANSMISSIONS for further diagnostic and repair procedures. If resistance is 5 ohms or more, repair open in Black/Yellow wire between downshift solenoid and splice S139. Splice S139 is located on left side of engine compartment. Retest system.
9) KOEO & Continuous Memory DTC P1904: Check Downshift Solenoid Relay Resistance DTC P1904 indicates downshift solenoid circuit high voltage. Downshift solenoid relay was commanded OFF by PCM and a high voltage was present at B+ terminal of downshift solenoid. Possible causes are: Downshift Solenoid Relay Control Circuit Shorted To Ground B+ Circuit To PCM & Downshift Solenoid Shorted To PWR Faulty Downshift Solenoid Relay Faulty PCM Turn ignition off. Remove downshift solenoid relay from battery junction box. Using DVOM, measure resistance between downshift solenoid relay terminals No. 3 and 5. If resistance is less than 5 ohms, replace downshift solenoid relay. Retest system. If resistance is 5 ohms or more, leave downshift solenoid removed and go to next step.
10) Check Downshift Solenoid Relay Control Circuit For Short To Ground Ensure ignition is off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 94 at breakout box. (Scheme 76) If resistance is less than 10 k/ohms, repair short to ground in downshift solenoid relay control circuit (Orange/Yellow wire). If resistance is 10 k/ohms or more, go to next step.
11) Check Downshift Solenoid B+ Circuit For Short To Power Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. If voltage is more than 10.5 volts, repair short to voltage in Black/Yellow wire. If voltage is 10.5 volts or less, replace PCM. Retest system.

TEST KL: MANIFOLD INTAKE AIR HEATER

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

Wiring Harness Circuits (B+, MIAH, MIAHM & VPWR)
Manifold Intake Air Heater (MIAH)
MIAH Relay
Powertrain Control Module (PCM)

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

Ambient Temperature Must Be Less Than 32°F (0°C)
Engine Oil Temperature Must Be Less Than 131°F (55°C)
Vehicle Power (IVPWR) Must Be 11.8-15.0 Volts
Parking Brake Must Be Applied On M/T Models
Gearshift Lever Must Be In Park Or Neutral On A/T Models
Glow Plugs Must Be Off

Note. MIAH is not available on F650-750 models.

Scheme 77

1) KOEO, KOER & Continuous Memory DTC P0640: Check Power Feed To Relay Coil DTC P0640 indicates MIAH relay coil circuit fault. Possible causes are: Open VPWR Circuit To MIAH Relay Open MIAH Control Circuit To MIAH Relay Faulty MIAH Relay Faulty PCM Turn ignition on. Using DVOM, measure voltage between chassis ground and MIAH relay VPWR terminal (Red wire). (Scheme 77) MIAH relay is located on top of engine. (Scheme 19) 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 between MIAH relay and central junction box. Clear DTCs and retest.
2) Isolate Relay Turn ignition off. Disconnect MIAH control circuit (Violet wire) from MIAH relay terminal. Connect a jumper wire between chassis ground and MIAH control circuit terminal at MIAH relay. Cycle ignition on, then off and listen for an audible "click" from MIAH relay. If relay "clicks", go to next step. If relay did not "click", replace MIAH relay. Clear DTCs and retest.
3) Isolate PCM Disconnect PCM 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. Using DVOM, measure resistance of Violet wire between MIAH relay control circuit and test pin No. 98 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Violet wire between PCM and MIAH relay. Clear DTCs and retest.
4) KOER & Continuous Memory DTC P0541 & P0542: Check B+ Circuit To MIAH Relay DTC P0541 indicates MIAH monitor circuit low fault. DTC P0542 indicates MIAH monitor circuit high fault. Possible causes are: B+ Circuit To MIAH Relay Open MIAH Monitor Circuit Open Faulty MIAH Relay Faulty PCM Turn ignition on. Using DVOM, measure voltage between chassis ground and B+ circuit terminal (Black/Orange wire) at MIAH relay. (Scheme 77) MIAH relay is located on top of engine. (Scheme 19) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in Black/Orange wire between MIAH relay and battery fusible links. Clear DTCs and retest.
5) Isolate Relay Contacts Turn ignition off. Connect jumper wire between MIAHM circuit (Red/Yellow wire) and B+ (Black/Orange wire) circuit at MIAH relay terminals. Clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000). If DTC is still present, go to next step. If DTC is no longer present, replace MIAH relay. Clear DTCs and retest.
6) Check MIAH Monitor Circuit For Open Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of MIAHM circuit (Red/Yellow wire) between test pin No. 3 at breakout box and MIAH relay. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Red/Yellow wire between PCM and MIAH relay. Clear DTCs and retest.
7) KOEO DTC P0542: Isolate Relay DTC P0542 indicates MIAH monitor circuit high fault. Possible causes are: MIAH Circuit Shorted To Ground MIAHM Circuit Shorted To PWR Faulty MIAH Relay Faulty PCM Turn ignition off. Disconnect MIAHM circuit (Red/Yellow wire) from MIAH relay terminal. MIAH relay is located on top of engine. (Scheme 19) Turn ignition on. Using DVOM, measure voltage between chassis ground and MIAHM circuit terminal No. 87 at MIAH relay. (Scheme 77) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, leave MIAHM circuit disconnected and go to step 10).
8) Check MIAH Relay Control Circuit Turn ignition off. Disconnect MIAH control circuit (Violet wire) from MIAH relay terminal No. 86. Using DVOM, measure resistance between chassis ground and MIAH circuit (Violet wire) at relay harness. If resistance is 10 k/ohms or less, go to next step. If resistance is more than 10 k/ohms, MIAH relay contacts are stuck closed. Replace MIAH relay. Clear DTCs and retest.
9) Check PCM Control Circuit Ensure ignition is off. Disconnect PCM 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. Using DVOM, measure resistance between chassis ground and MIAH circuit (Violet wire) at relay harness. If resistance is 10 k/ohms or less, repair short to ground in Violet wire between MIAH relay. If resistance is more than 10 k/ohms, check for short to ground at terminal No. 92 at PCM connector. Repair as necessary. If no short to ground is found, replace PCM. Clear DTCs and retest.
10) Check MIAH Monitor Circuit For Short To PWR Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis 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 between PCM and MIAH relay. Clear DTCs and retest. If voltage is 10.5 volts or less, check for short to voltage at terminal No. 3 at PCM connector. Repair as necessary. If no short to voltage is found, replace PCM. Clear DTCs and retest.

TEST MA: CONTINUOUS MEMORY FAILURE

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

Wiring Harness Circuit (KAPWR)
Powertrain Control Module (PCM)

Note. Installing a breakout box or disconnecting battery terminals will interrupt Keep Alive Power (KAPWR) to PCM, causing DTC P0603 to be stored in Continuous Memory.

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0603	MA1		MA1

FAULT CODE SETTING CONDITION

1) Confirm KOEO & Continuous Memory DTC P0603: Repeat Self-Test DTC P0603 indicates a PCM Keep Alive Memory (KAM) error. Possible causes are: Battery Or PCM Has Been Disconnected Battery Cables Loose Or Poor Connection Battery Discharged Keep Alive Power (KAPWR) Circuit Open Blown KAPWR Fuse Faulty PCM Clear DTCs. Cycle ignition off, then on. Repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If Continuous Memory DTC P0603 is still present, go to next step. If Continuous Memory DTC P0603 is not present, no concern is indicated at this time. Service any other DTCs that are present. If no other DTCs are present, testing is complete.
2) Check Fuse On Econoline, check fuse No. 4 (10-amp) in battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, check fuse No. 36 (10-amp) in central junction box. On F650-750, check fuse No. 13 (20-amp) in central junction box. On Excursion and F250-750, central junction box is located behind lower left side of instrument panel. On all models, if fuse is okay, go to next step. If fuse is blown, check for short to ground in Yellow wire (Econoline), Red/White wire (Excursion and F250-550) or Light Blue/Pink wire (F650-750) between blown fuse and PCM. See «WIRING DIAGRAMS»(ref-139134) article. Repair wiring as necessary and replace fuse. Clear DTCs and retest.
3) Check Voltage To PCM Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure voltage between chassis ground and test pin No. 55 at breakout box. If battery voltage is not present, locate and repair open in Yellow wire (Econoline), Red/White wire (Excursion and F250-550) or Light Blue/Pink wire (F650-750) between fuse and PCM. See «WIRING DIAGRAMS»(ref-139134) article. Repair wiring as necessary and replace fuse. Clear DTCs and retest. If battery voltage is present, reconnect all connectors. Clear DTCs and repeat «QUICK TEST»(ref-139800-S19570345092002050900000) . If DTC P0603 resets, replace PCM. Clear DTCs and retest.

TEST MB: OBD-II READINESS CODE

1) Continuous Memory DTC P1000: Repeat Self-Test DTC P1000 indicates operating conditions have not been satisfied for all OBD-II monitors to be run. Possible causes are: Drive Conditions Not Satisfied Keep Alive Memory (KAM) Cleared Faulty PCM Perform all SELF-TESTS and check for DTCs. If any DTCs other than P1000 are present, perform appropriate system test and repair as necessary. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) . If DTC P1000 is only DTC present, go to next step.
2) Perform Drive Cycle Perform drive cycle. See «DRIVE CYCLE PROCEDURE»(ref-139800-S08224181432002050900000) under ADDITIONAL SYSTEM FUNCTIONS. If DTC P1000 is now cleared, no concern is indicated at this time. If DTC P1000 is still present, go to next step.
3) Verify Certain Operating Conditions Have Been Satisfied Ensure the following conditions are met: Using scan tool, access EOT, VPWR and GPC PIDs from PID/DATA MONITOR & RECORD 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 Excursion and F250-750, VPWR value must be 11.5-14.0 volts until GPC PID value is zero percent. Using scan tool, monitor MFDES PID reading with engine speed (RPM) under full load. MFDES PID reading must be more than 37 milligrams/stroke for 12 seconds or more with engine speed at more than 2300 RPM. Using scan tool, monitor MFDES PID reading with engine at normal operating temperature and at idle. MFDES PID value must be less than 12 milligrams/stroke for 12 seconds or more. With all conditions met in this step, if DTC P1000 is cleared, no concern is indicated at this time. If DTC P1000 is still present, determine DTC clearing fault. Perform all engine performance diagnostic procedures. See ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article.

TEST MC: PCM 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.

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0606	MD1		MD1

FAULT CODE SETTING CONDITION

1) KOEO DTC P0606: Inactive Background Fault DTC P0606 indicates an internal failure of PCM. If any other DTCs are present, service all other DTCs before continuing with this test. If DTC P0606 is still present after servicing other DTCs, replace PCM. Clear DTCs and retest. If DTC P0606 is not present, no concern is indicated at this time.

TEST MD: PCM ROM FAILURE

This DTC indicates that an internal failure has occurred in PCM.

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0107	MD1		MD1

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P0605: Internal PCM ROM Failure DTC P0605 indicates that an internal ROM failure has occurred in PCM. Repeat «QUICK TEST»(ref-139800-S19570345092002050900000) . If DTC P0605 is set, replace PCM. Clear DTCs and retest. If DTC P0605 is not set, no concern is indicated at this time.

The Powertrain Control Module (PCM) reset occurs when PCM momentarily "reboots" or is turned off and on while engine running. If condition occurs a single time, engine will momentarily stumble and PCM will go through a normal key on cycle, including turning WAIT TO START light and glow plugs on. It will also attempt to validate accelerator pedal position. If accelerator pedal is not at idle position when fault occurs, pedal authority will not be allowed by PCM until accelerator pedal is released and engine speed returns to idle. This pinpoint test is intended to diagnose following

Powertrain Control Module (PCM)
Injector Driver Module (IDM)
AP, BARO, CMP, EBP, ETC, ICP & MAP Sensors
Under Valve Cover (UVC) Gasket, Chassis & Engine Harnesses

Note. Perform this pinpoint test only after TESTS 5, 6 and 7 under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES have been performed. This will determine if PCM has detected any fault conditions that can cause a PCM reset.

1) Check Vehicle Battery Power Circuit Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950) and connect PCM to breakout box. Turn ignition on. Using DVOM, measure voltage between PCM power test pins No. 55, 71 and 97 and PCM ground test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are more than 10.5 volts and within one volt of each other, go to next step. If any resistance is 10.5 volts or less or not within one volt of each other, go to TEST A, step 1).
2) Check VREF Voltage Using DVOM, 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) Check VREF & SIG RTN Circuits Turn ignition off. Disconnect suspect sensor connector. (Scheme 19)or (Scheme 20). Disconnect PCM from breakout box. Using DVOM, measure resistance between test pin No. 90 at breakout box and VREF circuit terminal at suspect sensor harness connector. (Scheme 18) Using DVOM, measure resistance between test pin No. 91 at breakout box and SIG RTN circuit terminal at suspect sensor harness connector. If both resistances are less than 5 ohms, no concern is indicated at this time. Fault may be intermittent. Retest system. If either resistance is 5 ohms or more, locate and repair open in VREF or SIG RTN circuit. Retest system.
4) Check For Excess Voltage On VREF Circuit Disconnect PCM connector from breakout box. Turn ignition on. Using DVOM, measure voltage between negative battery terminal and test pin No. 90 at breakout box. If voltage is less than.5 volt, replace PCM. Retest system. If voltage is.5 volt or more, locate and repair short to voltage. Retest system.
5) Check SIG RTN Circuit Turn ignition off. Using DVOM, measure resistance between test pin No. 91 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, replace PCM. Retest system.
6) Check For Shorted Accelerator Pedal/Electronic Throttle Control (AP/ETC) Sensor Disconnect AP/ETC sensor connector. Sensor is located above accelerator pedal. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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/ETC sensor. Retest system.
7) Check For Shorted Camshaft Position (CMP) Sensor Turn ignition off. Disconnect CMP sensor connector. Sensor is located right on front of engine, above crankshaft pulley. (Scheme 19)or (Scheme 20). Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Injection Control Pressure (ICP) Sensor Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top center of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Exhaust Backpressure (EBP) Sensor Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. (Scheme 19)or (Scheme 20). Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check For Shorted Manifold Absolute Pressure (MAP) Sensor Turn ignition off. Disconnect MAP sensor connector. MAP sensor is mounted to cowl in engine compartment. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, 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) Check VREF Circuit For Short To Ground Disconnect PCM connector from breakout box. Ensure all 3-wire sensors are still disconnected. Using DVOM, measure resistance between test pin No. 90 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace PCM and perform «QUICK TEST»(ref-139800-S19570345092002050900000). If any resistance is 10 k/ohms or less, go to next step.
12) Check PCM & Vehicle Harness Connectors Ensure ignition is off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Inspect IDM, PCM and harness connectors for damaged, loose or pushed out terminals, or loose or poorly crimped wires. Remove valve covers. Inspect under valve cover connectors and harnesses for damage. If any connectors or terminals are damaged, repair as necessary. Retest system. If all connectors and terminals are okay, go to next step.
13) Check High Side Circuit For Short To Ground Disconnect both valve cover connectors on bank with fault. Using DVOM, measure resistance between suspect high side circuit at IDM connector and negative battery terminal. (Scheme 78) If resistance is more than 10 k/ohms, fault may be intermittent. Go to next step. If resistance is 10 k/ohms or less, repair short to ground. Retest system.
14) Check Injector Circuit For Short To Ground Using DVOM, measure resistance between chassis ground and suspect high side circuit at IDM connector. Wiggle and bend small sections of wiring harness starting at harness closest to suspect injector harness connector and work toward IDM. A fault is indicated when resistance changes to 10 k/ohms or less. If fault is indicated, isolate intermittent short to ground and repair as necessary. Retest system. If no fault is indicated, ensure no circuit issues are present. Repair circuits as necessary and retest system. If concern still exists, replace IDM and retest system.

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.

High Side Drive Outputs (Right & Left Bank) High side driver output function is to distribute energy to correct bank based on Cylinder Identification (CID) and provide regulated current to unit injectors, based on Fuel Delivery Command Signal (FDCS) from Injector Driver Module (IDM) internal 115-volt supply. Injection timing and duration is commanded by PCM in FDCS.
Low Side Drive Outputs Low side drive outputs control sequencing (firing order) of engine, based on CID and FDCS inputs.
Detection & Management Turn ignition on. Record IDM DTCs stored in KOEO ON-DEMAND SELF TEST and KOEO INJECTOR ELECTRICAL SELF TEST. Using scan tool, access RETRIEVE/CLEAR CONTINUOUS DTCs from scan tool menu to clear IDM trouble codes from memory. Record any DTCs displayed. Press CLEAR ALL button on scan tool. IDM DTCs are now cleared from memory. Repeat KOEO ON-DEMAND SELF-TEST and KOEO INJECTOR ELECTRICAL SELF-TEST. Any IDM DTCs that reappear are IDM hard faults. If no IDM DTCs reappear, then fault is intermittent. 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. A KOEO INJECTOR ELECTRICAL SELF-TEST allows operator to enable all injector solenoids while engine is off to verify operation. IDM DTCs will not be transmitted if Electronic Feedback (EF) line is not functioning. However, engine will not shut down due to a non-functional EF line. If a low side short to ground condition is determined by IDM, this condition will be transmitted to PCM via EF signal. PCM will enable CHECK ENGINE light and command minimum fuel to affected bank.

Scheme 78

Scheme 79

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P0261 1	NA1		NA1
P0262	NA6		NA6
P0263		NA25
P0264 1	NA1		NA1
P0265	NA6		NA6
P0266		NA25
P0267 1	NA1		NA1
P0268	NA6		NA6
P0269		NA25
P0270 1	NA1		NA1
P0271	NA6		NA6
P0272		NA25
P0273 1	NA1		NA1
P0274	NA6		NA6
P0275		NA25
P0276 1	NA1		NA1
P0277	NA6		NA6
P0278		NA25
P0279 1	NA1		NA1
P0280	NA6		NA6
P0281		NA25
P0282 1	NA1		NA1
P0283	NA6		NA6
P0284		NA25
P0301 1			NA25
P0302 1			NA25
P0303 1			NA25
P0304 1			NA25
P0305 1			NA25
P0306 1			NA25
P0307 1			NA25
P0308 1			NA25
P1261	NA6		NA6
P1262	NA6		NA6
P1263	NA6		NA6
P1264	NA6		NA6
P1265	NA6		NA6
P1266	NA6		NA6
P1267	NA6		NA6
P1268	NA6		NA6
P1271	NA11		NA11
P1272	NA11		NA11
P1273	NA11		NA11
P1274	NA11		NA11
P1275	NA11		NA11
P1276	NA11		NA11
P1277	NA11		NA11
P1278	NA11		NA11
P1291	NA16		NA16
P1292	NA16		NA16
P1293	NA16		NA16
P1294	NA16		NA16
P1295 1	NA30		NA30
P1296 1	NA30		NA30
P1297	NA27		NA27
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P0261, P0264, P0267, P0270, P0273, P0276, P0279 Or P0282 These DTCs indicate a low side short to ground between IDM and injector. Possible causes are: Low Side Circuit Shorted To Ground UVC Harness Shorted To Ground Faulty IDM Faulty Injector For DTC and related injector circuit and cylinder bank identification, refer to table in illustration. (Scheme 78) Turn ignition off. Disconnect suspect injector circuit valve cover gasket connector. Using DVOM, measure resistance between negative battery terminal and suspect low side circuit terminal at valve cover gasket harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, go to step 4).
2) Check Injector Circuit For Short To Ground Install Glow Plug Injector Adapter (014-00935) to valve cover gasket injector connector. Using DVOM, measure resistance between chassis ground and suspect injector circuit at glow plug injector adapter. If resistance is more than 10 k/ohms, fault may be intermittent. Go to step 5). If resistance is 10 k/ohms or less, go to next step.
3) Check Under Valve Cover Wiring Harness For Short To Ground Remove valve cover. Disconnect suspect injector connector. Inspect Under Valve Cover (UVC) wiring harness for a short to ground. Replace wiring harness as necessary. Clear DTCs and retest. If wiring harness is okay, replace injector. Clear DTCs and retest.
4) Check For Short To Ground In Low Side Circuit From IDM Disconnect IDM 40-pin connector. (Scheme 55) IDM is located in left side of engine compartment. Using DVOM, measure resistance of suspect injector circuit between IDM harness connector terminal, and all other circuits of IDM connector and chassis ground. If all resistances are more than 10 k/ohms, replace IDM. Clear DTCs and retest. If any resistance is 10 k/ohms or less, locate and repair short in affected circuit between valve cover injector harness connector and IDM harness connector. Clear DTCs and retest.
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. Using DVOM, measure resistance between chassis ground and suspect injector low side circuit terminal at IDM harness connector. Wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to less than 10 k/ohms at any time, isolate fault and repair short to ground in affected circuit. Clear DTCs and retest. If resistance does not change to less than 10 k/ohms, an internal failure in IDM exists. Replace IDM, clear DTCs and retest.
6) KOEO & Continuous Memory DTC P0262, P0265, P0268, P0271, P0274, P0277, P0280, P0283 Or P1261-P1268 These DTCs indicate low side circuit is shorted to power, or is shorted to high side circuit between IDM and fuel injector. Possible causes are: Low Side Circuit Shorted To Power Low Side Circuit Shorted To High Side Circuit Low Side Circuit Shorted In Gasket Harness Low Side Circuit Shorted In Under Valve Cover (UVC) Harness Faulty IDM Faulty Injector For DTC and related injector circuit and cylinder bank identification, refer to table in illustration. (Scheme 78) Turn ignition on. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect suspect injector valve cover gasket harness connector. Disconnect remaining injector connector on same cylinder bank. Using DVOM, measure resistance between low side circuit terminal at suspect injector valve cover gasket harness connector, positive battery terminal, and high side circuit terminal at suspect injector valve cover gasket harness connector. If both resistances are more than 10 k/ohms, go to next step. If either resistance is 10 k/ohms or less, locate and repair short to voltage in suspect circuit between IDM and valve cover gasket harness connector. Clear DTCs and retest.
7) Check Under Valve Cover Wiring Harness For Short Install Glow Plug Injector Adapter (014-00935) to suspect injector valve cover gasket connector. Using DVOM, 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) Check For Short Under Valve Cover Remove valve cover. Disconnect suspect injector connector. Using DVOM, measure resistance of both high and low side circuits between glow plug injector adapter and suspect injector harness connector. (Scheme 78)If both resistances are more than 10 k/ohms, replace injector. Clear DTCs and retest. If either resistance is 10 k/ohms or less, go to next step.
9) Check For Short Between Low Side & High Side Circuits Remove Under Valve Cover (UVC) wiring harness. Using DVOM, measure resistance between low side and high side circuits at valve cover gasket wiring harness. If resistance is less than 10 k/ohms, replace gasket wiring harness. Clear DTCs and retest. If resistance is 10 k/ohms or more, replace UVC wiring harness. Clear DTCs and retest.
10) Check For Intermittent Short To Voltage Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect all 4 injector valve cover gasket connectors. Using DVOM, measure resistance between suspect injector low side circuit terminal and at IDM harness connector, positive battery terminal, and high side circuit terminal at IDM harness connector. (Scheme 78) Wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to less than 10 k/ohms at any time, isolate short to voltage in affected circuits and repair as necessary. Clear DTCs and retest. If resistance does not change to less than 10 k/ohms, an internal failure in IDM exists. Replace IDM, clear DTCs and retest.
11) KOEO & Continuous Memory 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. Possible causes are: Open In Low Side Circuit Open In High Side Circuit Faulty IDM Faulty Injector For DTC and related injector circuit and cylinder bank identification, refer to table in illustration. (Scheme 78) Turn ignition off. Disconnect suspect injector valve cover gasket harness connector. Install Glow Plug Injector Adapter (014-00935) to injector valve cover gasket connector. Using DVOM, 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.
12) Check Injector For Open Remove valve cover. Disconnect suspect injector connector. Using DVOM, measure resistance of both the high side and low side circuits between injector connector and glow plug injector adapter. If both resistances are less than 5 ohms, replace injector. Clear DTCs and retest. If either resistance is 5 ohms or more, go to step 23).
13) Check Low Side Circuit For Open Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance of suspect low side circuit between injector valve cover gasket harness connector and IDM harness 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. Clear DTCs and retest.
14) Check High Side Circuit For Open Using DVOM, measure resistance of suspect high side circuit between injector valve cover gasket harness connector and IDM harness 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. Clear DTCs and retest.
15) Check Injector Circuit For Intermittent Open Ensure IDM is disconnected. Reconnect all other connectors. Using DVOM, measure resistance between suspect low side and high side circuits at IDM harness connector. (Scheme 78) 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 open in affected circuit and repair as necessary. Clear DTCs and retest. If resistance does not change to more than 5 ohms, replace IDM. Clear DTCs and retest.
16) KOEO & Continuous Memory DTC P1291 Or P1292: Check For Short In High Side Circuit These DTCs indicate a short to ground or short to voltage in high side circuit between Injector Driver Module (IDM) and fuel injector. Possible causes are: High Side Circuit Shorted To Ground High Side Circuit Shorted To Power Faulty IDM For DTC and related injector circuit and cylinder bank identification, refer to table in illustration. (Scheme 78) Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance between negative battery terminal and suspect high side circuit terminal at IDM harness connector. If resistance is more than 10 k/ohms, go to step 18). If resistance is 10 k/ohms or less, go to next step.
17) Check High Side Circuit For Short To Ground Disconnect both injector valve cover gasket harness connectors at cylinder bank with DTC. Using DVOM, measure resistance between negative battery terminal and suspect high side circuit terminal at IDM harness connector. If resistance is more than 10 k/ohms, go to step 2). If resistance is 10 k/ohms or less, locate and repair short to ground in high side circuit between IDM harness connector and injector valve cover gasket harness connector. Clear DTCs and retest.
18) Check High Side Circuit For Short To Power Turn ignition on. Using DVOM, measure resistance between suspect high side circuit terminal at IDM harness connector, positive battery terminal, and other high side circuit terminal at IDM harness connector. If both resistances are more than 10 k/ohms, fault may be intermittent. Go to next step. If either resistance is 10 k/ohms or less, repair short to power in affected high side circuit. Clear DTCs and retest.
19) Check High Side Circuit For Intermittent Short To Power Ensure IDM is disconnected and ignition is on. Using DVOM, measure resistance between suspect high side circuit terminal at IDM harness connector, positive battery terminal, and other high side circuit terminal at IDM harness connector. Wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to less than 10 k/ohms at anytime, isolate short to power and repair as necessary. Clear DTCs and retest. If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs and retest.
20) KOEO & Continuous Memory DTC P1293 & P1294: Check High Side Circuit For Voltage These DTCs indicate an open in high side circuit between IDM and fuel injector. Possible causes are: Faulty Injector High Side Circuit Open In Gasket Harness High Side Circuit Open In Under Valve Cover (UVC) Harness For DTC and related injector circuit and cylinder bank identification, refer to table in illustration. (Scheme 78) Turn ignition off. Disconnect both injector valve cover gasket harness connectors at cylinder bank with DTC. Turn ignition on. Using DVOM, measure voltage of suspect high side circuit between chassis ground and terminal "E" at injector valve cover gasket harness connector. If voltage is more than one volt, go to next step. If voltage is one volt or less, go to step 24).
21) Check Injector Resistance Turn ignition off. Install Glow Plug Injector Adapter (014-00935) to suspect injector valve cover gasket connector. Using DVOM, 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) Check For Open In Wiring Harness Remove valve cover. Disconnect suspect injector harness connector. Using DVOM, measure resistance between suspect injector harness connector and valve cover gasket connector. If resistance is less than 5 ohms, replace injector. Clear DTCs and retest. If resistance is 5 ohms or more, go to next step.
23) Determine Wiring Fault Disconnect Under Valve Cover (UVC) wiring harness from connector at valve cover gasket. Using DVOM, measure resistance across each terminal in valve cover gasket connector. If all resistances are less than 5 ohms, connector is okay. Replace UVC wiring harness. Clear DTCs and retest. If any resistance is 5 ohms or more, an open circuit exists in connector. Replace valve cover gasket. Clear DTCs and retest.
24) Check High Side Circuit For Open Turn ignition off. Disconnect IDM 40-pin connector. IDM is located on left side of engine compartment. Ensure both injector valve cover gasket connectors are disconnected at cylinder bank with DTC. Using DVOM, measure resistance of suspect high side circuit between IDM harness connector and terminal "E" at both suspect injector connectors. If both resistances are less than 5 ohms, fault may be intermittent. Go to step 15). If either resistance is 5 ohms or more, locate and repair open in affected high side circuit. Clear DTCs and retest.
25) KOER & Continuous Memory DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281, P0284 Or P0301-P0308: Cylinder Non-Contributing These DTCs indicate a cylinder is not contributing equally during KOER CYLINDER CONTRIBUTION SELF-TEST. If any Continuous Memory or KOER Cylinder Contribution Self-Test DTCs listed in «CYLINDER CONTRIBUTION CODE IDENTIFICATION»(ref-139800-S25495019572002062700000) table are retrieved, this SYSTEM TEST must be performed to diagnose fault. CYLINDER CONTRIBUTION CODE 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 a Continuous Memory DTC. Retrieve DTCs. Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000), «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-139800-S26331301612002050900000) and «RETRIEVE/CLEAR CONTINUOUS MEMORY DTCS»(ref-139800-S16760289892002050900000) under QUICK TEST. If any DTCs are present, service DTCs as necessary. If no DTCs are present, go to next step.
26) Cylinder Non-Contributing Possible causes are: Broken Compression Rings Faulty Injector Assembly Leaking Or Bent Valve Bent Push Rod Broken Rocker Arm Bolts Bent Connecting Rod Perform Tests 8A, 8B, 8C, 8D, 9, 10A, 10B, 11, 11A, 11B, and 12 under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If any concerns are found, repair as necessary. If no concerns are found, check engine mechanical condition. Repair as necessary. If engine mechanical condition is okay, replace injector assembly. Clear DTCs and retest.
27) KOEO & Continuous Memory DTC P1297: Check Injector High Side Circuit For Short DTC P1297 indicates a short between injector high side circuits. Possible causes are: High Side Circuits Shorted Together Faulty Injector Driver Module (IDM) Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance between both high side circuit terminals No. 23 (Pink/Yellow wire) and No. 24 (Orange wire) at IDM harness connector. (Scheme 55)and (Scheme 78). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short between high side circuits. Clear DTCs and retest.
28) Check For Intermittent Short Between High Side Circuits Turn ignition off. Using DVOM, measure resistance between both high side circuit terminals No. 23 (Pink/Yellow wire) and No. 24 (Orange wire) at IDM harness connector. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward injector valve cover gasket connectors. If resistance changes to less than 10 k/ohms at anytime, isolate short between high side circuits and repair as necessary. Clear DTCs and retest. If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs and retest.
29) Check For Low IDM Power Start engine and run without a load at Wide Open Throttle (WOT). Engine speed should be 3300 RPM (2500 RPM for F650-750). If engine reaches specified engine speed (RPM), go to RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article. If engine does not reach specified engine speed (RPM), ensure injector wiring circuits are okay. If circuits are okay, replace IDM. Retest system.
30) KOEO & Continuous Memory DTC P1295 Or P1926: Check For Short To Ground DTC P1295 indicates that more than one fault exists on right cylinder bank. DTC P1296 indicates that more than one fault exists on left cylinder bank. A short and open on both low side and high side circuits can exist on cylinder bank with DTC. Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance between chassis ground and each injector circuit terminal one at a time at IDM harness connector. (Scheme 78) If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, perform the following: If low side circuit short to ground was found, go to step 1) to isolate short, then return to this step. If high side circuit short to ground was found, go to step 16) to isolate short, then return to this step.
31) Check For Short To Battery Voltage Turn ignition on. Using DVOM, measure voltage between negative battery terminal and each injector circuit terminal one at a time at IDM harness connector. If all measurements are zero volt, go to next step. If any measurement is zero volt, perform the following: If low side circuit short to voltage was found, go to step 6) to isolate short, then return to this step. If high side circuit short to voltage was found, go to step 16) to isolate short, then return to this step.
32) Check For High Side Circuit Shorted Together Turn ignition off. Using DVOM, measure resistance between both high side circuit terminals No. 23 (Pink/Yellow wire) and No. 24 (Orange wire) at IDM harness connector. (Scheme 55)and (Scheme 78). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short between high side circuits. Clear DTCs and retest.
33) Check High Side & Low Side Circuits For Open Disconnect all 4 injector valve cover gasket harness connectors. Using DVOM, measure resistance of each injector high side and low side circuits between valve cover gasket harness connector and IDM harness connector. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open in suspect circuit. Clear DTCs and retest.
34) Check High Side & Low Side Circuits For Open Under Valve Cover Install Glow Plug Injector Adapter (014-00935) to injector valve cover gasket connector. Using DVOM, measure resistance between high side and low side of each injector circuit at glow plug injector adapter. (Scheme 78) If any resistance is more than 5 ohms, go to step 12). If all resistances are 5 ohms or less, reconnect all connectors. Clear DTCs and repeat «KOEO INJECTOR ELECTRICAL SELF-TEST»(ref-139800-S15778450502002050900000) and «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1295 or P1296 reset, replace IDM. Clear DTCs and retest.

TEST NB: CHECK ENGINE LIGHT

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

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

CHECK ENGINE Light Circuit
Instrument Cluster
Powertrain Control Module (PCM)

Scheme 80

Scheme 81

Scheme 82

Econoline & F650-750 CHECK ENGINE light is intended to alert driver of certain concerns in closed loop system. CHECK ENGINE light output is turned on when strategy detects a concern in certain input and output circuits. CHECK ENGINE light will remain on as long as concern is present. Regulations governing this light also require that DTCs be displayed by flashing of this light.
Excursion & F250-550 CHECK ENGINE light is used to indicate to operator when certain faults have been detected by PCM. When certain faults are detected, command to illuminate indicator is sent from PCM to instrument cluster through Standard Corporate Protocol (SCP) communications. With ignition on, indicator is commanded on as a prove-out function of indicator. CHECK ENGINE light is illuminated when strategy detects a concern in certain PCM input and output circuits. CHECK ENGINE light will remain on when a fault is present, and for OBD-II applications, CHECK ENGINE light follows guidelines for OBD-II fault detection.
CHECK ENGINE Light Functionality CHECK ENGINE light is located in instrument cluster and is Amber colored. CHECK ENGINE light functions in one of 3 modes: 1) Bulb Check With ignition on light is turned on for a short duration as a bulb check. If this does not occur, check wiring, bulb, and associated fuse. 2) Detection Of Certain Concerns CHECK ENGINE light is used to indicate that one of certain concerns has been detected by PCM or IDM. Only those concerns which result in a change in power output available from engine will cause light to be illuminated. An example of such concerns is: injector low side circuit shorted to ground, PCM will turn off 4 cylinders to prevent engine damage. 3) Accelerator Pedal Sensor Out Of Range PCM will allow engine to idle only.

1) CHECK ENGINE Light Fault Turn ignition on. If any KOEO or Continuous Memory DTCs exist, service them before proceeding. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). If CHECK ENGINE light is always illuminated, go to appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT to diagnose CHECK ENGINE light always on. If CHECK ENGINE light is not always on, go to next step.
2) Check ENGINE Light Never On Disconnect MAP sensor to force CHECK ENGINE light to illuminate. Cycle key on and off 2 times waiting at least 10 seconds between cycles. If CHECK ENGINE light illuminates, system is functioning correctly. Retest system. If CHECK ENGINE light does not illuminate, go to TEST N under SYSTEM TESTS in ANALOG INSTRUMENT PANELS - EXCURSION & F250-550 article in ACCESSORIES & EQUIPMENT to diagnose instrument cluster. Retest system.
3) CHECK ENGINE Light Fault Turn ignition on. If any KOEO or Continuous Memory DTCs exist, service them before proceeding. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000). If CHECK ENGINE light is always illuminated, go to next step. If CHECK ENGINE light is not always on, go to step 5).
4) CHECK ENGINE Light Always On: Check Circuit No. 658 (Pink/Light Green Wire) For Short To Ground Turn ignition off. Disconnect PCM 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. Turn ignition on. If CHECK ENGINE light is illuminated, repair short to ground in circuit No. 658 (Pink/Light Green wire) between PCM and instrument cluster. (Scheme 80)or (Scheme 81). Clear DTCs and retest. If CHECK ENGINE light is off, replace PCM. Clear DTCs and retest.
5) CHECK ENGINE Light Never On Turn ignition off. Disconnect MAP sensor connector and inspect for damaged pins, corrosion and loose wires. MAP sensor is located in rear of engine compartment, mounted on cowl. Repair connector as necessary. Start engine and allow to idle. If CHECK ENGINE light is illuminated, system is operating correctly. Clear DTCs and retest. If CHECK ENGINE light is not illuminated, reconnect MAP sensor and go to next step.
6) Check Ignition Feed Circuit Turn ignition on. Using DVOM, measure voltage between chassis ground and input side of fuse No. 2 (Econoline) or fuse No. 29 (F650-750) at central junction box. Central junction box is located behind lower left side of instrument panel. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in power circuit (Red/Light Green wire on Econoline or Dark Blue/Light Green wire on F650-750) between ignition switch and appropriate fuse in central junction box. If power circuit is okay, replace defective ignition switch. Clear DTCs and retest.
7) Check Fuse Remove and inspect CHECK ENGINE light PWR fuse No. 2 (Econoline) or fuse No. 29 (F650-750) from central junction box. If fuse is okay, go to next step. If fuse is blown, locate and repair short to ground in Red/Yellow wire between central junction box and instrument cluster. Replace fuse. Clear DTCs and retest.
8) Check PWR Feed Circuit To CHECK ENGINE Light For Open Ensure CHECK ENGINE light PWR fuse No. 2 (Econoline) or fuse No. 29 (F650-750) is removed. Remove CHECK ENGINE light bulb. Using DVOM, measure resistance of Red/Yellow wire between output side of CHECK ENGINE light PWR fuse at central junction box and power side of CHECK ENGINE light bulb socket. If resistance is less than 5 ohms, PWR feed circuit to CHECK ENGINE light is okay. Go to next step. If resistance is 5 ohms or more, locate and repair open in Red/Yellow wire. Clear DTCs and retest.
9) Inspect CHECK ENGINE Light Bulb Check CHECK ENGINE light bulb. If bulb is okay, go to next step. If bulb is bad, replace bulb. Clear DTCs and retest.
10) Check Signal Circuit To CHECK ENGINE Light For Open Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of CHECK ENGINE light signal circuit (Pink/Light Green wire) between CHECK ENGINE light bulb socket and test pin No. 2 at breakout box. If resistance is less than 5 ohms, signal circuit is okay. Replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in signal circuit (Pink/Light Green wire). Reconnect all components, clear DTCs and retest.

TEST NC: INJECTOR DRIVER MODULE ENABLE

WARNING

Injector Driver Module (IDM) supplies 115 DC volts to all fuel injectors. DO NOT pierce injector wiring harness, severe electrical shock may occur.

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

Injector Driver Module (IDM) Relay
Powertrain Control Module (PCM)
Wiring Harness Circuit (IDM-EN)

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1662	NC1

FAULT CODE SETTING CONDITION

1) KOEO DTC P1662: Check VPWR Circuit To IDM Relay For Open DTC P1662 indicates that PCM has detected an IDM-EN circuit malfunction. Possible causes are: Faulty IDM Relay Open IDM-EN Or VPWR Circuit To IDM Relay Blown IDM VPWR Fuse Faulty PCM Remove IDM relay from wiring harness near IDM on left front fender well (F650-750), or from battery junction box (all others). see scheme 79- see scheme 81. Battery junction box is located on left front of engine compartment. Turn ignition on. On Econoline, measure voltage between chassis ground and cavity No. 85 (Red/Light Green wire) at IDM relay in battery junction box. On Excursion and F250-550, measure voltage between chassis ground and cavity No. 86 (Red wire) at IDM relay in battery junction box. On F650-750, measure voltage between chassis ground and cavity No. 85 (White/Light Blue wire) at IDM relay in wiring harness. see scheme 82, see scheme 83 or see scheme 84. On all models, if battery voltage is present, go to next step. If battery voltage is not present, check for blown IDM VPWR fuse, or for open circuit in Red/Light Green wire (Econoline), Red wire (Excursion and F250-550), or White/Light Blue wire (F650-750) to IDM relay. Repair wiring as necessary. Clear DTCs and retest.
2) Check IDM-EN Circuit For Short To Ground Turn ignition off. On Econoline and F650-750, measure resistance between chassis ground and cavity No. 86 (White/Black wire) at IDM relay. On Excursion and F250-550, measure resistance between chassis ground and cavity No. 85 (White/Black wire) at IDM relay. On all models, if resistance is more than 10 k/ohms, go to step 4). If resistance is 10 k/ohms or less, go to next step.
3) Check PCM Internal IDM-EN Circuit For Short To Ground Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 80 at breakout box. If resistance is more than 10 k/ohms, replace PCM. Clear DTCs and retest. If resistance is 10 k/ohms or less, locate and repair short to ground in White/Black wire between PCM and IDM relay. Clear DTCs and retest.
4) Verify PCM Is Enabling IDM Relay Turn ignition off. On Econoline and F650-750, measure resistance between chassis ground and cavity No. 86 (White/Black wire) at IDM relay. On Excursion and F250-550, measure resistance between chassis ground and cavity No. 85 (White/Black wire) at IDM relay. On all models, note resistance reading. While observing DVOM, turn ignition on. If resistance changes to less than 5 ohms, replace IDM relay. Clear DTCs and retest. If resistance does not change to less than 5 ohms, go to next step.
5) Check For Open Circuit Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of White/Black wire between test pin No. 80 at breakout box and cavity No. 86 (Econoline and F650-750), or No. 85 (Excursion and F250-550) at IDM relay. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in White/Black wire between PCM and IDM relay. Clear DTCs and retest.
6) DTC P1663 & P1667 Present Along With/Without P1668: Check For DTC P1662 Ensure PCM and IDM are connected. Turn ignition on. Repeat «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. If DTC P1662 is present, go to step 1). If DTC P1662 is not present, go to next step.
7) Check IDM PWR Feed Fuse Remove and inspect fuse No. 11 (Econoline) or fuse No. 118 (F650-750) from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove and inspect fuse No. 53 from central junction box. Central junction box is located behind lower left side of instrument panel. see scheme 79- see scheme 84. On all models, if fuse is okay, go to next step. If fuse is blown, check for short to ground in B+ circuit between IDM and appropriate junction box. Repair circuit as necessary and replace fuse. Clear DTCs and retest.
8) Check B+ Circuit To IDM Relay For Open Remove IDM relay from wiring harness on left front fender well (F650-750), or from engine compartment battery junction box (all others). On Econoline, measure resistance of Yellow wire between output side of fuse No. 11 and cavity No. 30 at IDM relay. On Excursion and F250-550, measure resistance between output side of fuse No. 53 and cavity No. 30 at IDM relay. On F650-750, measure resistance of Dark Green/Light Green wire between output side of fuse No. 119 and cavity No. 30 at IDM relay. see scheme 82, see scheme 83 or see scheme 84. On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open B+ circuit or replace central junction box as necessary. Clear DTCs and retest.
9) Check B+ Circuit To IDM For Open Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Using DVOM, measure resistance of Dark Green/Light Green wire between cavity No. 87 at IDM relay and terminal No. 14 at IDM harness connector. (Scheme 55)and see scheme 82, see scheme 83 or see scheme 84. If resistance is less than 5 ohms, leave IDM disconnected and go to next step. If resistance is 5 ohms or more, repair open in Dark Green/Light Green wire between IDM and IDM relay. Clear DTCs and retest.
10) IDM Relay Check Reinstall IDM relay. Ensure fuse No. 11 (Econoline), fuse No. 118 (F650-750) or fuse No. 53 (Excursion and F250-550) is removed. Turn ignition on. Using DVOM, measure resistance of Dark Green/Light Green wire between terminal No. 14 at IDM harness connector and output side of fuse No. 11 (Econoline), fuse No. 118 (F650-750) or fuse No. 53 (Excursion and F250-550). On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace IDM relay. Clear DTCs and retest.
11) Check IDM Ground Circuit For Open Using DVOM, measure resistance between battery negative terminal and terminal No. 26 (Black/White wire on Econoline or Black/Pink wire on Excursion and F250-750) at IDM harness connector. If resistance is less than 5 ohms, replace IDM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Black/White wire (Econoline) or Black/Pink wire (Excursion and F250-750). Clear DTCs and retest.

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

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

Standard Corporate Protocol (SCP) Communication Wiring Harness Circuits; BUS (+) & BUS (-)
Wiring Harness Circuits (Chassis Ground, PWR GND & B+)
Powertrain Control Module (PCM)

Scheme 83

Scheme 84

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	KOER	Continuous Memory
P1502	QA1	QA1	QA1

FAULT CODE SETTING CONDITION

1) KOEO, KOER & Continuous Memory DTC P1502: Verify Self-Test Method Used DTC P1502 indicates APCM was functioning during self-test. Verify that correct procedure was used to activate KOEO and KOER ON-DEMAND SELF-TEST for scan tool. See «QUICK TEST»(ref-139800-S19570345092002050900000) under SELF-DIAGNOSTIC SYSTEM. Verify 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) 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, step 1).
3) Check B+ Circuit At DLC For Open Turn ignition off. Inspect DLC for damaged pins, corrosion and loose wires. Repair as necessary. Using DVOM, measure resistance between positive battery terminal and terminal No. 16 (Light Green/Red wire on Econoline, Light Blue/White wire on Excursion and F250-550, or Red/Yellow wire on F650-750) at DLC. (Scheme 83)or (Scheme 84). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in B+ circuit between central junction box and DLC. Clear DTCs and retest.
4) Check CHASSIS GROUND Circuit At DLC For Open Turn ignition off. Using DVOM, measure resistance between chassis ground and terminal No. 4 (Black/Light Blue wire on Econoline and F650-750, or Black wire on Excursion and F250-550) at DLC. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in CHASSIS GROUND circuit between DLC and ground point. See appropriate GROUND DISTRIBUTION article in WIRING DIAGRAMS. Clear DTCs and retest.
5) Check PWR GND Circuit At DLC For Open Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between terminal No. 5 (Black/White wire) at DLC and test pins No. 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, locate and repair open in PWR GND circuit. Clear DTCs and retest.
6) Check BUS (-) Circuit At DLC For Open Using DVOM, measure resistance between terminal No. 10 (Pink/Light Blue wire) at DLC 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, repair open in Pink/Light Blue wire between DLC and PCM. Clear DTCs and retest.
7) Check BUS (-) Circuit At DLC For Short To Ground Using DVOM, measure resistance between chassis ground and test pin No. 15 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in BUS (-) circuit (Pink/Light Blue wire). Clear DTCs and retest.
8) Check BUS (-) Circuit At DLC For Short To Voltage Turn ignition on. Using DVOM, measure voltage between test pin No. 15 and test pins No. 51, 76 (Econoline), 77 or 103 at breakout box. If voltage is one volt or less, go to next step. If voltage is more than one volt, locate and repair short to voltage in BUS (-) circuit (Pink/Light Blue wire). Clear DTCs and retest.
9) Check BUS (+) Circuit At DLC For Open Turn ignition off. Using DVOM, measure resistance between terminal No. 2 (Tan/Orange wire) at DLC 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, repair open in BUS (+) circuit (Tan/Orange wire) between PCM and DLC. Clear DTCs and retest.
10) Check BUS (+) Circuit At DLC For Short To Voltage Turn ignition on. Using DVOM, measure voltage between terminal No. 16 (Tan/Orange wire) at DLC and test pins No. 51, 76 (Econoline), 77 or 103 at breakout box. If voltage is one volt or less, go to next step. If voltage is more than one volt, repair short to voltage in BUS (+) circuit (Tan/Orange wire). Clear DTCs and retest.
11) Check For BUS (-) & BUS (+) Circuits Shorted Together Turn ignition off. Using DVOM, measure resistance between test pins No. 15 and 16 at breakout box. If resistance is more than 10 k/ohms, clear DTCs and retest. If DTC P1502 is still present or self-test aborts, replace PCM. Clear DTCs and retest. If resistance is 10 k/ohms or less, repair short between BUS (-) and BUS (+) circuits. Clear DTCs and retest.

TEST QB: GLOW PLUG SYSTEM (CALIFORNIA EMISSIONS)

This test is for models with California emissions only. Perform this test when directed by QUICK TEST or SYMPTOM DIAGNOSIS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article. The glow plug system is composed of solid state Glow Plug Control Module (GPCM), glow plugs and associated wiring. Glow plug "on" time is controlled by Powertrain Control Module (PCM) and is a function of engine oil temperature, barometric pressure and battery voltage. WAIT TO START light "on" time is independent from GPCM glow plug "on" time. PCM enables GPCM, which drives individual glow plugs. Glow plug "on" time varies between 1-120 seconds. In addition to PCM control, GPCM internally limits glow plug operation to 180 seconds regardless of PCM commanded "on" time. Power to glow plugs is provided though GPCM solid state drivers directly from battery. Failures detected by GPCM are passed to PCM using a serial communication signal. This test is only intended to diagnose the following components and circuits

Glow Plugs
GPCM
Under Valve Cover (UVC) Wiring Harness
Engine & Chassis Wiring Harness
PCM

CAUTION

GPCM connectors are not interchangeable. If connectors are mismatched, a DTC will be generated. Ensure Green harness connector is plugged into Green GPCM connector, and Black harness connector is plugged into Black GPCM connector. Black stripe on GPCM housing should align with Black harness connector.

WARNING

DO NOT perform voltage checks with engine running. Injector Driver Module (IDM) supplies 115 DC volts to all fuel injectors. DO NOT pierce injector wiring harness, severe electrical shock may occur.

Glow Plug Test Setup & Procedure - Key On/Engine Off (KOEO) test is performed in order to test and retrieve DTCs stored in PCM memory. Glow plugs are not operated during this test. Glow Plug Monitor Self Test is a functional Key On/Engine Running (KOER) self-test of PCM performed on-demand with engine running and A/C off. PCM will activate GPCM, which monitors glow plugs. Accelerator pedal may be used to increase engine speed to increase battery voltage, if needed. A fault must be present at time of testing for test to detect a fault. Faults will be sent to PCM on diagnostic line and then output to scan tool.

Scheme 85

CAUTION

When disconnecting Green and Black connectors at GPCM it is suggested that GPCM be unbolted from mounting bracket first and then connectors disconnected. This will allow for easier disconnect and will help prevent damage to connector terminals.

1) Check For KOEO & Continuous Memory DTC P0671-P0678: Repeat KOER Self-Test These DTCs are set upon detection of a failed glow plug No. 1-8 respectively (P0671 = glow plug No. 1, P0672 = glow plug No. 2, etc.). DTC will also be set if an open, shorted to ground, or shorted to power condition occurs anywhere in the circuit. Possible causes are: Open Or Shorted Glow Plug Circuit Faulty Connector Faulty GPCM Faulty Glow Plug Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. Retrieve DTCs. If any glow plug DTCs (P0671-P0678) are present, go to next step. If no glow plug DTCs are present, go to step 6).
2) Check For Faulty Glow Plug Circuit Turn ignition off. Disconnect GPCM connectors and inspect for damaged pins, corrosion and loose wires. GPCM is located on top of engine. (Scheme 19)or (Scheme 20). Repair connectors as necessary. Using DVOM, measure resistance between chassis ground and suspect glow plug terminal at GPCM harness connector. See «GLOW PLUG DIAGNOSTIC TROUBLE CODE IDENTIFICATION»(ref-139800-S36137590082002050900000) table to identify suspect glow plug. If resistance is more than 5 ohms, go to next step. If resistance is 5 ohms or less, replace suspect glow plug. Clear DTCs and retest. If DTC is still present, replace GPCM. GLOW PLUG DIAGNOSTIC TROUBLE CODE IDENTIFICATION DTC Glow Plug No. P0671 1 P0672 2 P0673 3 P0674 4 P0675 5 P0676 6 P0677 7 P0678 8
3) Check Glow Plug Circuit For Open Disconnect 9-pin connector at valve cover gasket that corresponds to DTC. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Using DVOM, measure resistance of suspect circuit between appropriate terminal at valve cover gasket harness connector and appropriate terminal at GPCM harness connector. (Scheme 85) If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in affected circuit between valve cover gasket and GPCM. Clear DTCs and retest.
4) Check Glow Plug Circuit Under Valve Cover For Open Remove appropriate valve cover to access Under Valve Cover (UVC) wiring harness. Disconnect suspect glow plug connector. Using DVOM, measure resistance of circuit between terminal at disconnected glow plug harness connector and appropriate terminal at UVC harness connector. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace UVC wiring harness. Clear DTCs and retest.
5) Check Glow Plug Resistance Using DVOM, measure resistance between chassis ground and suspect glow plug terminal. If resistance is more than 5 ohms, replace glow plug. Clear DTCs and retest. If resistance is 5 ohms or less, replace GPCM. Clear DTCs and retest.
6) Check For KOEO & Continuous Memory DTC P0670: Repeat KOEO Self-Test DTC P0670 is set when control circuit is open or shorted to ground or power. Possible causes are: Open, Or Short To Ground Or Power In Control Circuit Faulty GPCM Circuit Faulty PCM Circuit Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST. Retrieve DTCs. If DTC P0670 is present, go to next step. If DTC P0670 is not present, go to step 11).
7) Check Control Line For Open Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Disconnect GPCM connectors. GPCM is located on top of engine. (Scheme 19)or (Scheme 20). Inspect connectors for damaged pins, corrosion and loose wires. Repair connectors as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Violet/Orange wire between test pin No. 101 at breakout box and terminal No. 8 at GPCM Green harness connector. (Scheme 85) If resistance is 5 ohms or less, leave PCM and GPCM disconnected and go to next step. If resistance is more than 5 ohms, repair open in Violet/Orange wire between PCM and GPCM. Clear DTCs and retest.
8) Check Control Line For Short To Power Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 101 at breakout box. If voltage is 5 volt or less, go to next step. If voltage is more than 5 volt, repair short to voltage in Violet/Orange wire between PCM and GPCM. Clear DTCs and retest.
9) Check Control Circuit For Short To Ground Turn ignition off. Using DVOM, measure resistance between chassis ground and test pin No. 101 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Violet/Orange wire between PCM and GPCM. Clear DTCs and retest.
10) Check GPCM Function Ensure ignition is off. Reconnect PCM and GPCM connectors. Disconnect Engine Oil Temperature (EOT) sensor. This will maximize glow plug "on" time. EOT sensor is located on left side of engine. (Scheme 19)or (Scheme 20). Using DVOM, measure voltage between battery terminals. Turn ignition on. Note voltage reading within one minute of turning ignition on. NOTE: If voltage drops to less than 11 volts, recharge and test battery before continuing with this test. If battery voltage is okay, measure voltage between chassis ground and test pin No. 101 at breakout box with ignition on. Voltage should be less than one volt with glow plugs on. Wait at least 2 minutes for glow plug system to time out and note voltage reading. Voltage should be more than 10 volts with glow plugs off. If voltage readings are as specified, replace GPCM. Clear DTCs and retest. If voltage readings are not as specified, replace PCM. Clear DTCs and retest.
11) Check For KOER & Continuous Memory DTC P0683: Repeat KOER Self-Test DTC P0683 is set when PCM detects diagnostic line is open or shorted to ground or power. Possible causes are: Open, Or Short To Ground Or Power In Diagnostic Line Faulty GPCM Circuit Faulty PCM Circuit Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST. Retrieve Continuous Memory DTCs. If DTC P0670 is present with DTC P0683, repair DTC P0670 before continuing with this test. Go to step 6). If DTC P0683 is only DTC present, go to next step. If DTC P0683 is not present, no concern is indicated at this time. Test is complete.
12) Check Diagnostic Line For Open Turn ignition off. Disconnect PCM connector. PCM is located in left rear of engine compartment, near brake master cylinder. Disconnect GPCM connectors. GPCM is located on top of engine. (Scheme 19)or (Scheme 20). Inspect connectors for damaged pins, corrosion and loose wires. Repair connectors as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of White/Light Green wire between test pin No. 8 at breakout box and terminal No. 9 at GPCM Green harness connector. (Scheme 85) If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in White/Light Green wire between PCM and GPCM. Clear DTCs and retest.
13) Check Diagnostic Line For Short To Power Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 8 at breakout box. If voltage is 5 volt or less, go to next step. If voltage is more than 5 volt, repair short to voltage in White/Light Green wire between PCM and GPCM. Clear DTCs and retest.
14) Check Diagnostic Line For Short To Ground Turn ignition off. Reconnect PCM and GPCM connectors. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 8 at breakout box. If circuit is not shorted, voltage should pulse from zero volt to 12 volts. If voltage is zero volt, repair short to ground in White/Light Green wire between PCM and GPCM. Clear DTCs and retest. If voltage pulses, go to next step.
15) Check GPCM Diagnostic Line Turn ignition off. Ensure GPCM connector is connected, and PCM is connected to breakout box. Using scan tool, perform the following: Select VEHICLE and ENGINE. Select DIGITAL MEASUREMENT SYSTEM. Select FREQUENCY METER. Change level to 6 VOLT DC. Connect scan tool SIG INPUT probe to PCM breakout box terminal No. 8 (GPCM diagnostic line). NOTE: Typical frequency for diagnostic signal with all plugs functioning is maximum 7 Hz. Typical frequency for signal with one or more glow plugs failed is maximum 15 Hz. Disconnect Engine Oil Temperature (EOT) sensor. This will maximize glow plug "on" time. EOT sensor is located on left side of engine. (Scheme 19)or (Scheme 20). Using scan tool, access frequency meter. Turn ignition on. Wait about 5 seconds for frequency to stabilize. If frequency reading is 5-10 Hz, replace PCM. Clear DTCs and retest. If frequency reading is not 5-10 Hz, replace GPCM. Clear DTCs and retest.

TEST QC: ELECTRONIC THROTTLE CONTROL

Perform this test when directed by QUICK TEST. Electronic Throttle Control (ETC) sensor may also be referred to as a throttle pedal position sensor or an accelerator pedal position sensor. This test is only intended to diagnose the following components and circuits

ETC Sensor
Wiring Harness Circuits (VREF, SIG RTN & ETC SIG)
Powertrain Control Module (PCM)

Fault Detection & Management - Any detected malfunction of ETC will illuminate CHECK ENGINE light. ETC signal that is detected out of range (high or low) by PCM will cause engine to ignore ETC signal and will only allow engine to operate at low idle. If a disagreement in state of idle validation input and ETC sensor input is detected by PCM, engine will only be allowed to operate at low idle.

Note. ETC sensor was used on F650-750 starting in October 2002.

Scheme 86

Note. Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

Fault Code	KOEO	Continuous Memory
P0122 1	QC5	QC5
P0123 1	QC1	QC1
P0220 1		QC13
P0221 1		QC13
() For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.

()

FAULT CODE SETTING CONDITION

1) KOEO & Continuous Memory DTC P0123: Check ETC PID Reading DTC P0123 indicates ETC sensor circuit high input. Possible causes are: Damaged Accelerator Pedal Assembly ETC Sensor Not Installed Properly Faulty ETC Sensor Short To Power In Wiring Harness Faulty PCM Ensure scan tool is connected to DLC. Turn ignition on. Using scan tool, access ETC PID from PID/DATA MONITOR & RECORD menu. While observing scan tool, slowly depress accelerator pedal. If ETC PID reading changes to more than 4.5 volts, leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If ETC PID reading does not change to more than 4.5 volts, fault cannot be duplicated at this time. Clear DTCs and retest.
2) Induce Opposite Failure Disconnect ETC sensor connector. ETC sensor is mounted above accelerator pedal and has a 10-pin connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. If ETC PID reading changes from more than 4.5 volts to zero volt when connector is disconnected, circuit is okay. Replace accelerator pedal assembly. If ETC PID reading does not change from more than 4.5 volts to zero volt when connector is disconnected, leave ETC sensor disconnected and go to next step.
3) Check ETC Sensor Signal Wire Turn ignition on. Using DVOM, measure voltage between chassis ground and Gray/White wire at ETC sensor harness connector. (Scheme 86) If voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, replace PCM. Clear DTCs and retest.
4) Check For Short To Voltage Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 89 at breakout box. If voltage is present, locate and repair short to voltage in Gray/White wire between PCM and ETC sensor. Clear DTCs and retest. If voltage is not present, replace PCM. Clear DTCs and retest.
5) KOEO & Continuous Memory DTC P0122 DTC P0122 indicates ETC sensor circuit low input. Possible causes are: ETC Sensor Not Installed Properly Faulty ETC Sensor Open Or Grounded Circuit In Wiring Harness Faulty PCM Ensure scan tool is connected to DLC. Turn ignition on. Using scan tool, access ETC PID from PID/DATA MONITOR & RECORD menu. While observing ETC PID, slowly depress accelerator pedal. If ETC PID reading changes to less than.37 volt, leave scan tool in PID/DATA MONITOR & RECORD mode and go to next step. If ETC PID reading does not change to less than.37 volt, fault cannot be duplicated at this time. Test is complete. Clear DTCs and retest.
6) Induce Opposite Failure Disconnect ETC sensor connector. ETC sensor is mounted above accelerator pedal and has a 10-pin connector. Connect a jumper wire between VREF circuit (Brown/White wire) and ETC SIG circuit (Gray/White wire) at ETC sensor harness connector. (Scheme 86) If ETC PID reading changes to more than 4.5 volts with jumper connected, circuits are okay. Replace accelerator pedal assembly. Clear DTCs and retest. If voltage reading does not change to more than 4.5 volts with jumper connected, disconnect jumper wire and go to next step.
7) Check VREF Circuit Voltage Turn ignition on. Using DVOM, measure voltage between chassis ground and VREF circuit (Brown/White wire) at ETC sensor 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 Brown/White wire between PCM and ETC sensor. Clear DTCs and retest.
8) Check ETC GND Circuit Turn ignition off. Using DVOM, measure resistance between chassis ground and ETC GND circuit (Yellow/White wire) at ETC sensor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/White wire between PCM and ETC sensor. Clear DTCs and retest.
9) Check ETC Sensor Circuit Continuity Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of Gray/White wire between terminal No. 8 at ETC sensor harness connector and test pin No. 89 at breakout box. (Scheme 86) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/White wire between PCM and ETC sensor. Clear DTCs and retest.
10) Check ETC SIG Circuit For Short To Ground Turn ignition off. Ensure ETC sensor is disconnected. Using DVOM, measure resistance between test pin No. 89 and test pins No. 51, 77, 91 and 103 at breakout box. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in ETC SIG circuit (Gray/White wire). Clear DTCs and retest.
11) Check VREF Circuit Continuity Using DVOM, measure resistance of Brown/White wire between terminal No. 10 at ETC sensor 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, repair open in Brown/White wire between PCM and ETC sensor. Clear DTCs and retest.
12) Check ETC GND Circuit Continuity Using DVOM, measure resistance of Yellow/White wire between terminal No. 9 at ETC sensor harness connector and test pin No. 24 at breakout box. (Scheme 86) If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Yellow/White wire between PCM and ETC sensor. Clear DTCs and retest.
13) KOER & Continuous Memory DTC P0220 Or P0221 DTC P0220 indicates a malfunction has occurred in IVS circuit. DTC P0221 indicates a performance concern has occurred in IVS circuit. Possible causes are: Blown Fuse Faulty Accelerator Pedal Assembly Open In IGN PWR Feed Circuit To ECT Faulty ETC Sensor ETC Transition Out-Of-Range Faulty PCM Turn ignition off. Ensure scan tool is connected to DLC. Turn ignition on. Ensure accelerator pedal is released. Using scan tool, access ETC PID from PID/DATA MONITOR & RECORD menu. If ETC PID reading indicates ON, leave scan tool in PID/DATA MONITOR & RECORD mode and go to step 19). If ETC PID reading indicates OFF, go to next step.
14) Check ETC Transition Voltage Observe ETC (voltage) and ETC (state) PID reading and slowly depress accelerator pedal. If ETC PID reading switches to ON at.4-1.6 volts, clear DTCs and retest. If DTC resets, replace PCM. If ETC PID does not switch to ON at.4-1.6 volts, go to next step.
15) Check ETC Sensor Observe ETC PID reading and fully depress accelerator pedal. If ETC PID reading switches to ON at any time, replace accelerator pedal assembly. Clear DTCs and retest. If ETC PID does not switch to ON at any time, go to next step.
16) Check ETC Sensor Resistance Turn ignition off. Disconnect ETC sensor. ETC sensor is mounted above accelerator pedal and has a 10-pin connector. Inspect ETC sensor connector for damaged pins, corrosion and loose wires. Repair connector as necessary. With accelerator pedal depressed, measure resistance between IGN PWR circuit and IVS circuit at ETC sensor connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, ETC sensor is defective. Replace accelerator assembly. Clear DTCs and retest.
17) Check IGN PWR Circuit For Open Turn ignition on. Using DVOM, measure voltage between chassis ground and IGN PWR circuit at ETC sensor harness connector. (Scheme 86) If battery voltage is present, go to next step. If battery voltage is not present, replace fuse or repair open circuit between central junction box and ETC sensor. See «WIRING DIAGRAMS»(ref-139134) article. Clear DTCs and retest.
18) Check SIG RTN Circuit For Open Turn ignition off. Disconnect PCM 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 Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of IVS circuit (Red/Light Green wire) between terminal No. 7 at ETC sensor wiring harness and test pin No. 10 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Red/Light Green wire between PCM and ETC sensor. Clear DTCs and retest.
19) Check IVS Circuit For Short To Power Disconnect ETC sensor connector. ETC sensor is mounted above accelerator pedal and has a 10-pin connector. If ETC PID reading indicates OFF, replace accelerator pedal assembly. Clear DTCs and retest. If ETC PID indicates ON, locate and repair short to voltage in Red/Light Green wire between PCM and ETC sensor. Clear DTCs and retest.

Engine Controls - Self-Diagnostics - Eec-V - Diesel: Diagnosis Ford Excursion I

DIAGNOSTIC FORMATS

DIAGNOSTIC TROUBLE CODES

RETRIEVING DIAGNOSTIC TROUBLE CODES

Scheme 11

READING DIAGNOSTIC TROUBLE CODES

KOEO & KOER On-Demand Self-Test Codes

Diagnostic Aids

Generic Scan Tool

Performing Self-Test

KOER ON-DEMAND SELF-TEST

KOER SWITCH SELF-TEST

Performing CCT Self-Test

KOEO GLOW PLUG MONITOR SELF-TEST

Accessing OSR Test Mode (Generic Scan Tool)

Accessing OSR Test Mode (New Generation Star Tester)

Accessing PID Data Monitor (Generic Scan Tool)

Accessing PID Data Monitor - Pending Codes (Generic Scan Tool)

Accessing Freeze Frame PID Data (Generic Scan Tool)

Resetting OBD-II DTCs (Generic Scan Tool)

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS (ECONOLINE, EXCURSION & F250-550)

DIAGNOSTIC TROUBLE CODE DEFINITIONS (F650-750)

TEST A: VEHICLE BATTERY

Testing

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

TEST C: REFERENCE VOLTAGE

Scheme 18

Scheme 19

Scheme 20

TEST DA: INTAKE AIR TEMPERATURE SENSOR

Scheme 21

TEST DB: ENGINE OIL TEMPERATURE SENSOR

Scheme 22

TEST DC: INJECTION CONTROL PRESSURE SENSOR

Scheme 23

Scheme 24

Scheme 25

TEST DE: EXHAUST BACKPRESSURE SENSOR

Scheme 26

Scheme 27

Scheme 28

TEST DF: CAMSHAFT POSITION SENSOR

Scheme 29

TEST DG: BAROMETRIC PRESSURE SENSOR

TEST DH: MANIFOLD ABSOLUTE PRESSURE SENSOR

Scheme 30

TEST DI: MANIFOLD AIR TEMPERATURE SENSOR (EXCEPT ECONOLINE)

Scheme 31

TEST DJ: WATER IN FUEL SENSOR

Scheme 32

TEST DK: WATER IN FUEL INDICATOR LIGHT

TEST DL: VEHICLE SPEED SENSOR

Scheme 33

TEST FA: AIR CONDITIONING

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

TEST FC: CLUTCH PEDAL POSITION SWITCH/NEUTRAL START SWITCH

Scheme 41

Scheme 42

TEST FD: BRAKE PEDAL POSITION SWITCH

Scheme 43

Scheme 44

Scheme 45

TEST FE: IDLE VALIDATION SWITCH

Scheme 46

TEST FF: PARKING BRAKE APPLIED SWITCH

Scheme 47

Scheme 48

Scheme 49