Engine Controls - Basic Diagnostic Procedures - Trucks - Except Diesel Ford Explorer Sport Trac I

INTRODUCTION

Note. References to Econoline include Cutaway and RV Cutaway. References to F250-550 include Cab & Chassis.

The following diagnostic steps will help prevent overlooking a simple problem. This is also where to begin diagnosis for a no-start condition. The first step in diagnosing any driveability problem is verifying the symptom(s) with a test drive under the conditions the problem reportedly occurred.

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

VISUAL INSPECTION

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

Compression

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

Exhaust System Backpressure

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

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

FUEL SYSTEMS

Note. For fuel system diagnosis on Natural Gas Vehicles (NGV), see TEST HA: NATURAL GAS FUEL CONTROL and TEST HB: NATURAL GAS FUEL DELIVERY SYSTEM in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article or TEST H: FUEL CONTROL in SELF-DIAGNOSTICS - EEC-V - BI-FUEL article.

PRELIMINARY CHECKS

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

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

FUEL SYSTEM PRESSURE RELEASE

Note. For fuel pressure release procedures on Bi-Fuel and Natural Gas Vehicles (NGV), see appropriate REMOVAL, OVERHAUL & INSTALLATION article.

Gasoline Engines

1. Remove fuel cap to release fuel tank pressure. Remove relief valve service port cap. Relief valve service port is located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B ), release fuel pressure from Schrader valve.
2. If fuel pressure gauge is not available, disconnect electrical connector to Inertia Fuel Shutoff (IFS) switch. For IFS switch location, see «INERTIA FUEL SHUTOFF SWITCH LOCATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel) table. Crank engine with IFS disconnected for 15 seconds to reduce system pressure.

Bi-Fuel & Natural Gas Vehicle Engines

1. 1) Check Fuel Pressure Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Install Natural Gas Fuel Rail Pressure Gauge Tool Kit (134-00114) to fuel rail Schrader valve. Using scan tool, access FRP PID (if available) from PID/DATA MONITOR & RECORD menu. With ignition switch turned to ON position, record FRP sensor PID or fuel pressure gauge reading. Start engine and allow to idle. Again record FRP sensor PID or fuel pressure gauge reading. Increase engine speed to 2500 RPM and maintain for one minute. Record FRP sensor PID or fuel pressure gauge reading. Compare measured fuel pressure to fuel pressure specification. See «FUEL PRESSURE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/specifications/#fuel-system-pressure-specifications) . If fuel pressure readings are within specification, turn ignition switch to OFF position and go to next step. If fuel pressure readings are not within specification, turn ignition switch to OFF position and go to TEST HB, step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article for fuel delivery system diagnosis.
2. 2) Check Fuel System For Pressure Stability With fuel pressure gauge installed, cycle ignition switch from OFF to ON position 2 times to pressurize fuel system (DO NOT start engine). Verify no external leaks are present. If fuel pressure does not remain within 10 psi (69 kPa) of highest fuel pressure reading after 2 minutes, go to TEST HB, step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article for fuel delivery system diagnosis. If fuel pressure remains within 10 psi (69 kPa) of highest fuel pressure reading after 2 minutes, go to next step.
3. 3) Check Fuel System For Pressure Stability With Ignition Switch Turned To ON Position Using scan tool, access FRP PID (if available) from PID/DATA MONITOR & RECORD menu. If FRP PID is not available, ensure natural gas fuel rail pressure gauge tool kit is installed onto fuel rail Schrader valve. Cycle ignition switch from OFF to ON (DO NOT start engine). Monitor fuel pressure reading. If fuel pressure does not remain within 10 psi (69 kPa) of highest fuel pressure reading after 10 seconds, check for leaking fuel injectors or fuel pressure regulator. If fuel pressure remains within 10 psi (69 kPa) of highest fuel pressure reading after 10 seconds, fuel system is mechanically okay.

1. 1) Fuel System Visual Inspection Visually inspect fuel system, including fuel lines, connections, injectors and electrical connections. Ensure Inertia Fuel Shutoff (IFS) switch is not tripped. Check condition of battery and fuses. Ensure fuel level in tank is sufficient.
2. 2) Check Fuel Pressure Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel__fuel-system-pressure-release) . Install fuel pressure gauge. Using scan tool, access OUTPUT TEST MODE. For additional information, see OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article. Command fuel pump ON and run fuel pump to obtain maximum fuel pressure. Record fuel pressure. Compare measured fuel pressure to fuel pressure specification. See «FUEL PRESSURE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/specifications/#fuel-system-pressure-specifications) . If fuel pressure is within specification, go to next step. If fuel system pressure is not within specification, go to TEST HC, step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article for fuel delivery system diagnosis.
3. 3) Check Fuel Pressure Leakdown With fuel pressure gauge still installed, cycle ignition switch on and off several times. Record fuel pressure. After one minute with ignition off, fuel pressure should remain within 5 psi (34 kPa) of maximum fuel pressure. If fuel pressure remains within specification, system is capable of maintaining fuel pressure. If fuel pressure does not remain within specification, check for leaking fuel injectors or fuel pressure regulator.

Fuel Injector Resistance

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

INDIVIDUAL INJECTOR RESISTANCE

Fuel Injector Check

Start engine and allow to idle. If engine will not start, crank engine for 10 seconds. Using a stethoscope, listen for clicking sound at each injector. If clicking sound is heard, fuel injector is operating. If clicking sound is not heard, see TEST HD: MISFIRE DETECTION MONITOR under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

INERTIA FUEL SHUTOFF SWITCH

1. In event of a collision, electrical contacts in inertia switch open, automatically shutting off fuel pump. Fuel pump shuts off even if engine does not stop running. Engine will stop due to lack of fuel.
2. Engine cannot be restarted until inertia switch is manually reset. To reset inertia switch, depress button on switch. See «INERTIA FUEL SHUTOFF SWITCH LOCATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel) table.

INERTIA FUEL SHUTOFF SWITCH LOCATIONS

Note. If vehicle is a no-start, see NO START/NORMAL CRANK under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - GASOLINE & NGV article, or TEST A: NO-START under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

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

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

EDIS (DISTRIBUTORLESS) IGNITION SYSTEM

Note. Blackwood, Econoline & Pickup 4.6L, 5.4L and 6.8L, Escape 3.0L, Expedition 4.6L and 5.4L, Excursion 5.4L and 6.8L, Explorer and Mountaineer 4.6L, and Navigator 5.4L 4V use Coil On Plug (COP). COP faults should set a DTC. For additional COP testing, see TEST JF: INTEGRATED IGNITION COIL ON PLUG FAILURE in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

Note. For circuit identification, see appropriate wiring diagram in WIRING DIAGRAMS article.

Spark Check

Always perform self-diagnostic QUICK TEST to check for ignition-related fault codes, and repair as necessary. See QUICK TEST in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article. If no fault codes are retrieved, check for proper spark at each cylinder, go to TEST JB, step 17) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article. If spark is not present, go to TEST A: NO-START in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

IGNITION COIL RESISTANCE

Note. Resistance values are not provided by manufacturer. For integrated ignition coil testing, see TEST JE: INTEGRATED IGNITION COIL FAILURE in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article. For integrated ignition Coil On Plug (COP) testing, see TEST JF: INTEGRATED IGNITION COIL ON PLUG FAILURE in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

IDLE SPEED & IGNITION TIMING

Note. Idle speed and ignition timing are not adjustable. If idle speed is incorrect, see TEST HU: AIR INTAKE SYSTEM and TEST KE: IDLE AIR CONTROL VALVE in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

IDLE MIXTURE ADJUSTMENT

Idle mixture is not adjustable. If idle mixture is incorrect, see TEST H: FUEL CONTROL in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

IGNITION TIMING

Note. On all models with distributorless electronic ignition, manufacturer does not recommend checking ignition timing, as faulty readings are common and timing is not adjustable.

BASE IGNITION TIMING

THROTTLE POSITION SENSOR ADJUSTMENT

Throttle Position (TP) sensor is not adjustable. If testing is necessary, see TEST DH: THROTTLE POSITION SENSOR in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.

SUMMARY

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

See also:
• FUEL PRESSURE SPECIFICATIONS
• INERTIA FUEL SHUTOFF SWITCH LOCATIONS
• FUEL SYSTEM PRESSURE RELEASE