Engine Controls - Tests W/codes - 7.3L Diesel - Eec-Iv: Diagnosis Ford Pickup F350

SELF-DIAGNOSTIC SYSTEM

Note. Diagnostics for 1995-96 7.3L direct injection diesel, are OBD-I standard with 4-digit Diagnostic Trouble Codes (DTCs).

If no DTCs or only pass codes (system functioning properly) are present during self-tests, proceed to H - TESTS W/O CODES - 7.3L DIESEL article for diagnosis by symptom.

DIAGNOSTIC FORMATS

QUICK TEST and PINPOINT TESTS are diagnostic formats used to test and service diesel EEC-IV system. QUICK TEST allows technician to identify problems and retrieve Diagnostic Trouble Codes (DTCs). PINPOINT TESTS check circuits, sensors and actuators.

Before starting any PINPOINT TEST, perform QUICK TEST to find appropriate pinpoint test to perform. If vehicle passes QUICK TEST and no driveability symptoms or intermittent faults exist, EEC-IV system is functioning properly at this time.

KOEO Injector Electrical Self-Test

KOEO injector electrical self-test determines if injector solenoids and valves are operating, by buzzing and providing DTCs and audible feedback. DTCs will be output and displayed in KOEO SELF TEST. All injectors will buzz together for approximately 2 seconds, then each injector will buzz for about one second in numerical order (1-8). (Scheme 328)

Scheme 328

KOER Cylinder Contribution Self-Test

KOER cylinder contribution self-test determines if all cylinders are contributing equally to engine performance. IDM will test cylinders in order (1-8). A non-contributing or low power cylinder will have little effect on idle quality during this test. DTCs will be displayed at end of test.

Diagnostic Aids

After each service or repair procedure has been completed, repeat QUICK TEST to ensure all EEC-IV systems work properly and DTCs are no longer present. To keep battery from going dead when performing QUICK TEST, disconnect glow plug relay. Relay is located on top, right side of engine. Ignore DTC 0380 while glow plug relay is disconnected.

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

1. «VISUAL CHECK»(ref-23600-S20642516142001010300000)
2. «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000)
3. «KEY ON ENGINE OFF (KOEO) SELF-TEST»(ref-23600-S10365652382001010300000)
4. «KEY ON ENGINE RUNNING (KOER) SELF-TEST»(ref-23600-S20126232932001010300000)
5. «RETRIEVE/CLEAR CONTINUOUS DTCS»(ref-23600-S14145481792001010300000)
6. «KOEO INJECTOR ELECTRICAL SELF-TEST (BUZZ TEST)»(ref-23600-S24396087592002012200000)
7. «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000)
8. «KOER SWITCH SELF-TEST»(ref-23600-S05518326102001010300000)
9. «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-23600-S17927227932001010300000)

KOEO SELF-TEST

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

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. Record DTCs and perform appropriate pinpoint test. See «DIAGNOSTIC TROUBLE CODE IDENTIFICATION»(ref-23600-S39286360782001010300000) .

KOER SELF-TEST

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

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO SELF-TEST.
7. Start engine and allow to idle.
8. Follow operating instructions from scan tool menu.
9. Record DTCs and perform appropriate pinpoint test. See «DIAGNOSTIC TROUBLE CODE IDENTIFICATION»(ref-23600-S39286360782001010300000) .

KOEO INJECTOR ELECTRICAL SELF-TEST (BUZZ TEST)

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

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO INJECTOR ELECTRICAL SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. After test, cycle ignition off before running other tests or driving vehicle.

Note. If unable to perform KOEO INJECTOR ELECTRICAL SELF-TEST (BUZZ TEST), no DTCs are present and engine does not start, disconnect IDM and check injector high or low side circuits for shorts or opens. Go to TEST AB, step 29) .

KOEO OUTPUT STATE SELF-TEST

Connect NGS Tester to DLC located under dash. Turn off all electrical accessories. If vehicle is equipped with an auxiliary powertrain control (RPM control), it must be turned off to perform self tests. Ensure VISUAL CHECK and VEHICLE PREPARATION & EQUIPMENT HOOKUP have been performed. Program scan tool using the following steps

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO OUTPUT STATE SELF TEST.
7. Follow special instructions from NGS Tester menu.
8. Apply and release accelerator pedal to cycle output state on relays, solenoids, WAIT TO START light, FDCS, EF, CID and TCIL.
9. After test, cycle ignition off before running other tests or driving vehicle.

KOER SWITCH SELF-TEST

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

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER SWITCH SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. 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.
10. After test, cycle ignition off before running other tests or driving vehicle.

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

1. Select VEHICLE & ENGINE SELECTION menu.
2. Select NEW VEHICLE, YEAR & MODEL.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CONTROL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER CYLINDER CONTRIBUTION SELF-TEST.
7. Turn ignition on.
8. Follow operating instructions from scan tool menu.
9. After test, cycle ignition off before running other tests or driving vehicle.

1. 1) DTC 0560, 0562 Or 0563: Check Battery Voltage Turn ignition on. Measure voltage across battery terminals. If voltage is more than 9.5 volts, go to step 12) (Econoline), or go to next step (Pickup). If voltage is 9.5 volts or less, service discharged battery.
2. 2) Check For Battery Voltage Measure voltage between negative battery terminal and output terminal (Yellow wire) of fuse No. 9 at power distribution center. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Yellow wire.
3. 3) Check Fuse Remove and inspect fuse No. 9 at power distribution center. If fuse is okay, go to next step. If fuse is blown, locate and repair short to ground and replace fuse.
4. 4) Check Circuit No. 37 Turn ignition off. Remove PCM relay from power distribution center. Measure resistance between non-powered side of No. 9 fuse holder and Yellow wire at PCM relay connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Yellow wire.
5. 5) Check Ignition Feed To Diode Remove diode from power distribution center. Turn ignition on. Measure voltage between negative battery terminal and ignition feed side of diode connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in Red/Light Green wire or replace defective ignition switch.
6. 6) Check Diode Turn ignition off. Using an ohmmeter, check diode continuity. Ensure continuity exists in one direction only. Replace diode as necessary. If diode is okay, go to next step.
7. 7) Check Black/Yellow Wire Measure resistance of Black/Yellow wire between PCM relay connector and non-powered side of diode connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Black/Yellow wire.
8. 8) Check Ground Circuit Turn ignition off. Measure resistance between negative battery terminal and circuit No. 57 (Black wire) at PCM relay connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Black wire.
9. 9) Check Circuit No. 361 Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Red wire between PCM relay connector and test pins No. 71 and 97 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Red wire between PCM relay and PCM connector.
10. 10) Check PWR GND Circuit Measure resistance between negative battery terminal and test pins No. 25, 51, 76, 77 and 103 at breakout box. If each reading is less than 5 ohms, go to next step.
11. 11) Check PCM Relay Install PCM relay. Turn ignition on. Measure resistance between non-powered side of fuse No. 9 (Yellow wire) and test pins No. 71 and 97 at breakout box. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, replace PCM relay.
12. 12) Check Voltage At PCM Relay Turn ignition off. Remove PCM relay from power distribution box. Measure voltage between PCM relay cavity (Yellow wire) and negative battery terminal. If battery voltage is present, go to step 5) . If battery voltage is not present, repair open in Yellow wire between PCM relay and starter relay.
13. 13) Check Circuit 16 (Red/Light Green Wire) Turn ignition off. Measure resistance between non-power side of diode connector (Red/Light Green wire) and PCM relay cavity. If resistance is less than 5 ohms, go to step 8) . If resistance is 5 ohms or more, repair open in Red/Light Green wire between diode and relay.
14. 14) Check PCM Relay Turn ignition off. Ensure breakout box is installed, PCM is disconnected and PCM relay is installed. Turn ignition on. Measure voltage between negative battery terminal and breakout box test pins No. 71 and 97. If battery voltage is present and fault is still present, replace PCM. If battery voltage is not present, replace PCM relay.

PINPOINT TEST B: REFERENCE VOLTAGE

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

1. 1) Check Vehicle Battery Power Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM to breakout box. Turn ignition on. Measure voltage between test pins No. 55, 71 and 97 and test pins No. 25, 51, 76, 77 and 103 at breakout box. If all readings are more than 10.5 volts and within one volt of each other, go to next step. If any reading is 10.5 volts or less or not within one volt of each other, go to TEST A, step 1) .
2. 2) Check VREF Voltage Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is 4-6 volts, go to next step. If voltage is less than 4 volts, go to step 5) . If voltage more than 6 volts, go to step 4) .
3. 3) Check VREF & SIG RTN Circuits Turn ignition off. Disconnect suspect sensor connector. Disconnect PCM from breakout box. Measure resistance between test pin No. 90 at breakout box and VREF circuit terminal at suspect sensor wiring harness connector. Also, measure resistance between test pin No. 91 at breakout box and SIG RTN circuit terminal at suspect sensor wiring harness connector. If both readings are less than 5 ohms, no problem is indicated at this time. Fault may be intermittent. If any reading is 5 ohms or more, locate and repair open in VREF or SIG RTN circuit. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check For Excess Voltage Disconnect PCM connector from breakout box. Disconnect scan tool. Turn ignition on. Measure voltage between negative battery terminal and test pin No. 90 at breakout box. If voltage is less than 5 volts, replace PCM. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is 5 volts or more, locate and repair short to power. Reconnect all components and repeat QUICK TEST.
5. 5) Check SIG RTN Circuit Turn ignition off. Measure resistance between test pin No. 91 and test pins No. 25, 51, 76 and 103 at breakout box. If all readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, replace PCM.
6. 6) Check For Shorted Accelerator Pedal (AP) Sensor Disconnect AP sensor connector. Sensor is located above accelerator pedal. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace AP sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Shorted Camshaft Position (CMP) Sensor Disconnect CMP sensor connector. Sensor is located in front of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace CMP sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check For Shorted Injection Control Pressure (ICP) Sensor Disconnect ICP sensor connector. Sensor is located on top left side of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace ICP sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check Exhaust Back Pressure (EPB) Sensor Disconnect EPB sensor connector. Sensor is located on top left of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage 4 volts or more, replace EPB sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check For Shorted Manifold Absolute Pressure (MAP) Sensor Disconnect MAP sensor connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace MAP sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check For Shorted Barometric Pressure (BARO) Sensor Disconnect BARO sensor connector. Sensor is located behind left side of instrument panel. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace BARO sensor. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
12. 12) Check For Shorted VREF Circuit Disconnect PCM connector from breakout box. Ensure all 6 sensors are disconnected. Measure resistance between test pin No. 90 and test pins No. 25, 51, 76, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, replace PCM. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, locate and repair short to ground. Reconnect all components and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 0113 DTC 0113 indicates sensor signal voltage is more than self-test maximum. Check for following possible causes: Faulty sensor. Faulty harness connector. Faulty Powertrain Control Module (PCM). Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Turn ignition on. Using scan tool, access IAT V PID (voltage) from PID/DATA MONITOR & RECORD menu. If voltage is 4.9 volts or more, go to next step. If voltage is less than 4.9 volts, go to step 8) .
2. 2) Induce Opposite Failure Disconnect IAT sensor connector. Connect a jumper wire between negative battery terminal and terminal "B" (Gray/Yellow wire) at IAT sensor wiring harness connector. If reading is more than zero volts, go to step 4) . If reading is zero volts, go to next step.
3. 3) Check SIG RTN Circuit Turn ignition off. Measure resistance between ground and terminal "A" (Gray/Red wire) at IAT sensor wiring harness connector. If resistance is less than 5 ohms, replace IAT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Sensor Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal "B" (Gray/Yellow wire) at IAT sensor wiring harness connector and test pin No. 39 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Gray/Yellow wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) DTC 0112 DTC 0112 indicates sensor signal is less than self-test minimum. Possible causes for this DTC are: Circuit grounded in wiring harness. Faulty sensor. Faulty harness connector. Faulty Powertrain Control Module (PCM). Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Turn ignition on. Using scan tool, access IAT V PID (voltage) from PID/DATA MONITOR & RECORD menu. If voltage is .13 volt or less, go to next step. If voltage is more than .13 volt, go to step 8) .
6. 6) Induce Opposite Failure Observe scan tool and disconnect IAT sensor connector. If voltage is 4.59 volts or more, replace IAT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is less than 4.59 volts, go to next step.
7. 7) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 39 and test pins No. 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, locate and repair short to ground in Gray/Yellow wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Continuous Memory DTC 0112 Or 1113: Check Sensor DTCs 0012 and 0013 indicate possible intermittent fault. Possible causes for this DTC are: Faulty sensor. Faulty sensor connector. Open or grounded circuit in harness. Faulty PCM. With scan tool connected, turn ignition on. Access IAT V PID (voltage) from PID/DATA MONITOR & RECORD menu. While observing scan tool, tap on sensor to simulate road shock. Wiggle sensor connector. If no change in voltage occurs, go to next step. If any change in voltage occurs, isolate fault and repair as necessary.
9. 9) Check Wiring Harness While observing IAT V PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (voltage fluctuates), isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is found, go to next step.
10. 10) Inspect PCM & Wiring Harness Connectors Turn ignition off. Disconnect PCM 104-pin connector and IAT connector. Inspect connectors for damaged pins, corrosion and loose wires. If connectors and terminals are damaged, repair as necessary and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If connectors and terminals are okay, fault cannot be duplicated at this time and testing is complete.

1. 1) DTC 0236 DTC 0236 indicates faulty turbo boost sensor circuit performance. Possible causes for this DTC are: Damaged MAP sensor hose. Faulty MAP sensor. Low turbo boost. Intake manifold or crossover leaks. Inspect MAP sensor hose for damage, misrouting or restriction. Replace hose as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If hose is okay, go to next step.
2. 2) MAP Sensor Frequency Check Disconnect MAP sensor connector. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect DVOM to MAP sensor. Set DVOM to frequency scale. Turn ignition on. If frequency is 90-115 Hz, leave MAP sensor tester connected and go to next step. If frequency is not 90-115 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) MAP Sensor Pressure Check Disconnect MAP sensor vacuum hose. Using Pressure Adapter (014-00761), apply 10 psi to MAP sensor. If frequency is 135-155 Hz, go to next step. If frequency is not 135-155 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) MAP Sensor Performance Test Reconnect vacuum hose to MAP sensor. Disconnect MAP sensor vacuum hose from intake manifold. Install a pressure (boost) gauge to intake manifold. Road test vehicle and accelerate vehicle to achieve full boost. If boost is 12 psi or more, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If boost is less than 12 psi, inspect intake manifolds and crossover tubes for leaks. Check turbo condition. Repair as necessary.
5. 5) KOEO DTC 0237 Or 0235 Possible causes for these faults are: Faulty MAP sensor. Open or shorted wiring harness circuits. Faulty PCM. Turn ignition off. Disconnect MAP sensor connector. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect banana plugs of tester into DVOM. Turn ignition on and observe tester. If Green light is on, VREF and SIG RTN circuits are okay. Go to next step. If voltage reading is less than 4 volts and Red light is on or no light is on, go to step 11) . If voltage reading is more than 6 volts and Red light on, go to step 14) .
6. 6) Check For Short To Ground In MAP Sensor Signal Circuit Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect MAP sensor connector. Measure resistance between test pin No. 34 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in MAP sensor signal circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Short To Power In MAP Sensor Signal Circuit Turn ignition on. Measure resistance between test pin No. 34 and test pins No. 55, 71 and 97 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to power in MAP sensor signal circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check For Shorted VREF-To-MAP Sensor Signal Circuit Turn ignition off. Measure resistance between test pins No. 34 and 90 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, VREF is shorted to MAP sensor signal circuit. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check MAP Sensor Signal Circuit Continuity Measure resistance between test pin No. 34 at breakout box and Light Green/Black wire at MAP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Green/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check PCM Connect PCM to breakout box. Turn ignition on. Measure voltage between ground and Light Green/Black wire at MAP sensor wiring harness connector. If voltage is 4.5-5.5 volts, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is not 4.5-5.5 volts, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check VREF Circuit Voltage Disconnect MAP sensor tester from MAP sensor, leaving tester connected to MAP sensor vehicle wiring harness connector. Turn ignition on and observe tester. If Green light is on, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If Red light is on or no light is on, go to next step.
12. 12) Check VREF Circuit Continuity Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect MAP sensor connector. Measure resistance between Brown/White wire at MAP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire between MAP sensor connector and PCM connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
13. 13) Check SIG RTN Circuit Continuity Measure resistance between test pin No. 34 at breakout box and Gray/Red wire at MAP sensor wiring harness connector. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
14. 14) Check For Short To Power Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 90 at breakout box. If voltage is less than .25 volt, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is .25 volt or more, locate and repair short to power in VREF circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
15. 15) KOEO DTC 0238 DTC 0238 indicates high input in turbo boost sensor circuit. Possible causes for this DTC are: Faulty MAP sensor. Faulty PCM. Disconnect MAP sensor connector. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect banana plugs of tester into DVOM. Set DVOM to frequency scale. Turn ignition on. If frequency is more than 125 Hz, replace MAP sensor. Clear DTCs, and repeat QUICK TEST. If frequency is 125 Hz or less, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
16. 16) Continuous Memory DTC 0237 Or 0235 Continuous Memory DTC 0237 indicates low input to turbo boost sensor. DTC 0235 indicates MAP sensor signal is inactive. Possible causes for these faults are: Faulty MAP sensor. Open or shorted wiring harness circuits. Faulty PCM. Turn ignition off. Disconnect MAP sensor connector. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect banana plugs of tester into DVOM. Set DVOM to frequency scale. Turn ignition on. If frequency is 105-115 Hz, go to next step. If frequency is not 105-115 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
17. 17) Check MAP Sensor While observing DVOM frequency, tap on sensor to simulate road shock. Wiggle sensor connector. If no change in frequency occurs, go to next step. If any change in frequency occurs, locate and repair intermittent open in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
18. 18) MAP Sensor Pressure Check Disconnect MAP sensor vacuum hose. Using Pressure Adapter (014-00761), apply 10 psi to MAP sensor. While observing DVOM, tap on sensor to simulate road shock. Wiggle sensor connector. If no change in frequency occurs, go to next step. If any change in frequency occurs, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
19. 19) Check SIG RTN Circuit Remove MAP sensor tester. Leave MAP sensor disconnected. Connect DVOM between ground and Gray/Red wire at MAP sensor wiring harness connector. Set DVOM to ohms scale. While observing DVOM, wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. If fault is indicated (resistance fluctuates), repair intermittent open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is found, go to next step.
20. 20) Check VREF Circuit Turn ignition on. Connect DVOM between ground and Brown/White wire at MAP sensor wiring harness connector. Set DVOM to volt scale. While observing DVOM, wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. If fault is indicated (voltage fluctuates), locate and repair intermittent open circuit in Brown/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is found, go to next step.
21. 21) Check MAP Sensor Signal Circuit Continuity Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect MAP sensor connector. Measure resistance between test pin No. 34 and Light Green/Black wire at MAP sensor wiring harness connector. Resistance should be less than 5 ohms. While observing DVOM, wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. If resistance stays at less than 5 ohms, go to next step. If resistance does not stay at less than 5 ohms, locate and repair intermittent open circuit in Light Green/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
22. 22) Check For Short To Ground Measure resistance between test pin No. 34 and test pins No. 25, 51, 76, 77 and 103 at breakout box. While observing DVOM, wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. If all readings are more than 10 k/ohms, go to next step. If any reading is less than 10 k/ohms, locate and repair intermittent short to ground in Light Green/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
23. 23) Check For Short To Power Turn ignition on. Measure voltage between ground and test pin No. 34 at breakout box. While observing DVOM, wiggle and bend small sections of wiring harness starting at MAP sensor wiring harness connector and working toward PCM. If voltage stays at zero volts, fault cannot be duplicated at this time and testing is complete. If voltage does not stay at zero volts, locate and repair intermittent open circuit in Light Green/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
24. 24) Continuous Memory DTC 0238 Continuous Memory DTC 0238 indicates high input to turbo boost sensor circuit. Possible causes for this DTC are: Faulty MAP sensor. Open or shorted wiring harness circuits. Faulty PCM. Turn ignition off. Disconnect MAP sensor connector. Connect MAP sensor tester between MAP sensor and MAP sensor wiring harness connector. Connect banana plugs of tester into DVOM. Set DVOM to frequency scale. Turn ignition on. Observe DVOM and tap on MAP sensor to simulate road shock. If frequency reading changes to more than 125 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If frequency reading does not change to more than 125 Hz, go to next step.
25. 25) Check MAP Sensor Disconnect MAP sensor vacuum hose. Using Pressure Adapter (014-00761), apply 10 psi to MAP sensor. While observing DVOM, tap on sensor to simulate road shock. Wiggle sensor connector. If frequency reading changes to more than 300 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If frequency reading does not change to more than 300 Hz, fault cannot be duplicated at this time and testing is complete.
26. 26) MAP Harness Check Using a vacuum pump from Rotunda Pressure Adapter Kit (014-00761) or equivalent, apply 10 in. of vacuum. Observe frequency reading while performing the following: Grasp the vehicle harness close to the sensor connector. Wiggle and shake the vehicle while working towards the PCM. If frequency reading goes above 300 Hz, repair intermittent circuit failure. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If frequency reading does not go above 300 Hz, failure is intermittent. Unable to duplicate at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
27. 27) KOEO DTC 0237 (1995 Model) DTC 0237 indicates low input to turbo boost sensor circuit. Possible causes for this DTC are: Faulty MAP sensor. Faulty PCM. Turn ignition off. Disconnect MAP sensor connector. Using Flex Probes from New Generation Star (NGS) tester, jumper VREF and SIG RTN circuits from wiring harness connector to MAP sensor connector. Connect a jumper wire between Light Green/Black wire at MAP sensor connector to SIG INPUT on NGS tester. Select frequency meter. Use 4-volt DC scale. Turn ignition on. If frequency reading is 95-125 Hz, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If frequency reading is not 95-125 Hz, replace MAP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

PINPOINT TEST E: ACCELERATOR PEDAL SENSOR

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

1. 1) DTC 0123 DTC 0123 indicates AP sensor circuit high input. Possible causes for this DTC are: Damaged accelerator pedal assembly. AP sensor not installed properly. Faulty AP sensor. Short to power in wiring harness. Faulty Powertrain Control Module (PCM). With scan tool connected, turn ignition on. Access AP PID (voltage) from PID/DATA MONITOR & RECORD menu. While observing scan tool, slowly depress accelerator pedal. If voltage reading changes to more than 4.5 volts, go to next step. If voltage reading does not change to more than 4.5 volts, fault cannot be duplicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Induce Opposite Failure Disconnect AP sensor connector. AP sensor is mounted above accelerator pedal. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. If voltage reading changes from more than 4.5 volts to zero volts when connector is disconnected, circuit is okay. Replace accelerator pedal assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage reading does not change from more than 4.5 volts to zero volts when connector is disconnected, go to next step.
3. 3) Check AP Sensor Signal Wire Turn ignition on. Measure voltage between ground and AP signal circuit terminal (Gray/White wire) at AP sensor wiring harness connector. 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 89 at breakout box. If voltage is present, locate and repair short to power in Gray/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is not present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) DTC 0122 DTC 0122 indicates AP sensor circuit low input. Possible causes for this DTC are: Damaged accelerator pedal assembly. AP sensor not installed properly. Faulty AP sensor. Grounded wiring harness. Faulty Powertrain Control Module (PCM). With scan tool connected, turn ignition on. Access AP PID (voltage) from PID/DATA MONITOR & RECORD menu on tester. While observing scan tool, slowly depress accelerator pedal. If voltage reading changes to less than .37 volt, go to next step. If voltage reading does not change to less than .37 volt, fault cannot be duplicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Induce Opposite Failure Disconnect AP sensor connector. Connect a jumper wire between VREF circuit terminal (Brown/White wire) and AP sensor signal circuit terminal (Gray/White wire) at AP sensor wiring harness connector. If voltage reading changes from less than .37 volt to more than 4.5 volts with jumper connected, circuit is okay. Replace accelerator pedal assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage reading does not change from less than .37 volt to more than 4.5 volts with jumper connected, go to next step.
7. 7) Check VREF Circuit Voltage Turn ignition on. Measure voltage between ground and VREF circuit terminal (Brown/White wire) at AP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open in VREF circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check SIG RTN Circuit Turn ignition off. Measure resistance between ground and SIG RTN circuit terminal (Gray/Red wire) at AP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in SIG RTN circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check AP sensor Circuit Continuity Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between AP sensor signal circuit terminal (Gray/White wire) and test pin No. 89 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in AP signal circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check For Short To Ground Turn ignition off. Ensure AP sensor is disconnected. Measure resistance between test pin No. 89 and test pins No. 51, 76, 77 and 103 at breakout box. If each reading is more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in AP sensor signal circuit (Gray/White wire). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check VREF Circuit Continuity Measure resistance between VREF circuit terminal (Brown/White wire) at AP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in VREF circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
12. 12) Check SIG RTN Circuit Continuity Measure resistance between SIG RTN circuit terminal (Gray/Red wire) at AP sensor wiring harness connector and test pin No. 91 at breakout box. If resistance less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance 5 ohms or more, locate and repair open in SIG RTN circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

PINPOINT TEST F: SPEED CONTROL COMMAND SWITCH

1. 1) DTC 0565, 0566, 0567, 0568 Or 0569: Speed Control DTC 0565, 0566, 0567, 0568 Or 0569 will set if PCM does not detect when switch has been pressed during «KOER SWITCH SELF-TEST»(ref-23600-S05518326102001010300000). Possible causes for these faults are: Switch not depressed during test. Faulty speed control switch. Faulty SCCS circuit. Open or short in SC GND circuit. Open in power supply circuit. With scan tool connected, turn ignition on. Access SCCS PID from PID/DATA MONITOR & RECORD menu on tester. DO NOT depress any switches. If voltage is 10 volts, go to step 5). If voltage is zero volts, go to step 8). If voltage is 6.58-6.78 volts, go to next step.
2. 2) ON Switch Function Check Depress ON switch. If voltage is 10 volts, go to next step. If voltage is not 10 volts, go to step 20) (Econoline), or step 11) (Pickup).
3. 3) OFF Switch Function Check Depress OFF switch. If voltage is zero volts, go to next step. If voltage is not zero volts, go to step 31) (Econoline W/air bag), or step 17) (Pickup and Econoline W/O air bag).
4. 4) Command Switches Function Depress RESUME, COAST and SET/ACCEL switches. Observe voltage reading on scan tool as each switch is depressed. Compare readings with specification. See «SPEED CONTROL COMMAND SWITCH PID SPECIFICATIONS»(ref-23600-S23374663822002011500000) table. If voltage reading agrees with voltage specification, repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If DTC is still present, replace PCM. If any voltage reading does not agree with voltage specification, replace speed control switch assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). SPEED CONTROL COMMAND SWITCH PID SPECIFICATIONS Switch Volts Coast.48-.88 Set/Accel 2.54-2.94 Resume 4.46-4.86
5. 5) Check For Shorted Command Switch Remove horn pad. Disconnect speed control switch 3-pin connector. If voltage reading is 6.58-6.78 volts, switch assembly is shorted. Replace speed control switch assembly. If voltage reading is not 6.58-6.78 volts, go to next step.
6. 6) Check Sliding Contact (Clockspring) Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. If voltage reading is 6.58-6.78 volts, clockspring is shorted to power. Replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If voltage reading is not 6.58-6.78 volts, go to next step.
7. 7) Signal Circuit Check Turn ignition off. Ensure steering column connector and speed control switch 3-pin connector are disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 61 at breakout box. If voltage reading is zero volts, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If voltage reading is not zero volts, locate and repair short to power in Light Blue/Black wire. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
8. 8) Check For Shorted Command Switch Remove horn pad. Disconnect speed control switch 3-pin connector. If voltage is 6.58-6.78 volts, clockspring wiring harness in steering column is shorted to ground. Replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If voltage is not 6.58-6.78 volts, go to next step.
9. 9) Check Sliding Contact (Clockspring) Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. If voltage reading is 6.58-6.78 volts, clockspring and wiring harness in steering column are shorted to ground. Replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If voltage reading is not 6.58-6.78 volts, go to next step.
10. 10) Signal Circuit Check Turn ignition off. Ensure steering column connector is disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 61 and test pins No. 25, 51, 76, 77 and 103 at breakout box. If each reading is more than 10 k/ohms, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If any reading is 10 k/ohms or less, locate and repair short to ground in Light Blue/Black wire. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
11. 11) Check Fuse Remove and inspect No. 3 fuse (15-amp) from power distribution center in engine compartment. If fuse is okay, go to next step. If fuse is blown, check for cause of blown fuse. Repair as necessary and replace fuse. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
12. 12) Check Continuity From Fuse To Horn Pad Remove horn pad. Disconnect 3-pin speed control switch connector. Remove No. 3 fuse from power distribution center. Measure resistance between non-powered side of No. 3 fuse holder and Dark Blue wire at speed control switch 3-pin connector. If resistance is less than 75 ohms, go to step 14). If resistance is 75 ohms or more, go to next step.
13. 13) Check Clockspring Resistance Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. Measure resistance of Dark Blue wire between 3-pin speed control switch connector and 10-pin connector (steering column side of connector). If resistance less than 5 ohms, locate and repair open circuit between fuse No. 3 and steering column connector. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
14. 14) Check Speed Control Switch Remove horn pad. Depress On switch. Measure resistance between Dark Blue wire and Light Blue/Black wire at speed control switch 3-pin 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
15. 15) Check Clockspring Disconnect speed control switch 3-pin connector. Measure resistance of Light Blue/Black wire between 3-pin connector and steering column 10-pin connector. If resistance less than 5 ohms, go to next step. If resistance 5 ohms or more, locate and repair open circuit in Light Blue/Black wire. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
16. 16) Check Circuit No. 151 Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect steering column 10-pin wiring harness connector. Connector located below steering column. Measure resistance between test pin No. 61 at breakout box and terminal No. 5 (Light Blue/Black wire) at steering column 10-pin wiring harness connector. If resistance less than 5 ohms, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
17. 17) Check Switch Ground Remove horn pad. Turn ignition on. Disconnect speed control switch 3-pin connector. Measure voltage between terminals "A" and "C" at clockspring side of speed control switch 3-pin connector. see scheme 16 If battery voltage is present, replace speed control switch assembly. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If battery voltage is not present, go to next step.
18. 18) Check For Open Clockspring Circuit Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. Measure resistance of Dark Green/Orange wire between terminal "A" at speed control switch 3-pin connector and terminal No. 2 at steering column 10-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
19. 19) Check For Open Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Dark Green/Orange wire at terminal No. 2 of steering column 10-pin connector and test pin No. 40 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, locate and repair open circuit in Dark Green/Orange wire. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
20. 20) Check Fuse Remove and inspect fuse "R" (15-amp) from power distribution center in engine compartment. If fuse is okay, go to next step (Econoline W/air bag), or step 26) (Econoline W/O air bag). If fuse is blown, check for cause of blown fuse. Repair as necessary and replace fuse. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
21. 21) Check Continuity From Fuse "R" To Horn Pad Remove horn pad. Disconnect 3-pin speed control switch connector. Remove fuse "R" from power distribution center. Measure resistance between non-powered side of fuse "R" holder and Yellow/Light Blue wire at speed control switch 3-pin connector. If resistance is less than 75 ohms, go to next step. If resistance is 75 ohms or more, go to step 25).
22. 22) Check Speed Control Switch Depress speed control On switch. Measure resistance between Yellow/Light Blue wire and Light Blue/Black wire at speed control switch 3-pin 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
23. 23) Check For Open Circuit Turn ignition off. Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. Measure resistance between terminal No. 5 (Light Blue/Black wire) at 10-pin wiring harness connector and test pin No. 61 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue/Black wire. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
24. 24) Check Clockspring Disconnect speed control switch 3-pin connector. Measure resistance of Light Blue/Black wire between 3-pin connector and terminal No. 5 at steering column 10-pin connector. If resistance is less than 5 ohms, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
25. 25) Check Clockspring Resistance Disconnect steering column 10-pin connector. Measure resistance of Yellow/Light Blue wire between 3-pin connector and terminal No. 6 at steering column 10-pin connector (steering column side). If resistance is less than 5 ohms, locate and repair open circuit between fuse "R" and steering column 10-pin wiring harness connector. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
26. 26) Check For Continuity Between Horn Pad & Fuse "R" Remove horn pad. Disconnect speed control switch 3-pin connector. Measure resistance of Yellow/Light Blue wire between non-powered side of fuse "R" holder and terminal "C" speed control switch 3-pin connector (clockspring side). If resistance is less than 75 ohms, go to next step. If resistance 75 ohms or more, go to step 30).
27. 27) Check Speed Control Switch Depress speed control On switch. Measure resistance between Yellow/Light Green wire and Light Blue/Black wire at speed control switch 3-pin 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
28. 28) Check For Open Circuit Turn ignition off. Disconnect steering column 10-pin wiring harness connector. Connector is located below steering column. Measure resistance between terminal No. 5 (Light Blue/Black wire) at 10-pin wiring harness connector and test pin No. 61 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue/Black wire. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
29. 29) Check Clockspring Contact Disconnect speed control switch 3-pin connector. Measure resistance of Light Blue/Black wire between 3-pin connector and terminal No. 5 at steering column 10-pin connector. If resistance is less than 5 ohms, replace PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
30. 30) Check Clockspring Resistance Disconnect steering column 10-pin connector. Measure resistance of Yellow/Light Green wire between 3-pin connector and terminal No. 6 at steering column 10-pin connector (steering column side). If resistance is less than 5 ohms, locate and repair open circuit between fuse "R" and steering column 10-pin wiring harness connector. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace clockspring. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
31. 31) Ground Check At Switch Remove horn pad. Turn ignition on. Disconnect 3-pin speed control switch harness connector. Measure voltage between Black wire and Yellow/Light Blue wire at speed control switch 3-pin connector. If battery voltage is present, replace faulty speed control switch assembly. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If battery voltage is not present, go to next step.
32. 32) Check For Open In Air Bag Sliding Contact Ensure 3-pin speed control switch harness connector is disconnected. Disconnect steering column 10-pin connector. Measure resistance of Black wire between 3-pin speed control switch harness connector and steering column 10-pin connector. If resistance is less than 5 ohms, go to next step. if resistance is 5 ohms or more, replace faulty air bag sliding contact.
33. 33) Check For Open In Orange/Yellow Wire) Ensure ignition is off. Disconnect PCM 104-pin connector. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Orange/Yellow wire between steering column 10-pin harness connector and test Pin 40 at breakout box. If resistance is less than 5 ohms, replace faulty PCM. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, repair open in Orange/Yellow wire between PCM and steering column 10-pin harness connector.

1. 1) DTC 0340, 0341 & 0340: Clear Memory & Attempt To Regenerate DTC Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Clear continuous DTCs. Using scan tool, access RPM PID from PID/DATA MONITOR & RECORD menu. Crank engine while monitoring RPM PID. If PID indicates cranking RPM, go to next step. If PID does not indicate cranking RPM, go to step 3) .
2. 2) Check For DTC 0344 Or 0341 Start and run engine until coolant is at normal operating temperature. Raise engine speed to 3300 RPM for 2 minutes. Turn ignition off. Check for Continuous Memory DTCs. If DTC 0344 or 0341 is set, go to next step. If DTC 0344 or 0341 is not set, fault is intermittent. Go to step 12) .
3. 3) Check CMP Signal Turn ignition off. Disconnect CMP sensor connector. Measure resistance between ground and terminal "A" (Light Blue wire) at CMP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, go to step 9) .
4. 4) Check CMP Circuit No. 351 Turn ignition on. Measure voltage between ground and terminal "B" (Brown/White wire) at CMP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, VREF circuit is defective. Go to TEST B, step 1) .
5. 5) Check CMP Circuit No. 795 Measure voltage between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, go to step 7) .
6. 6) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. Measure voltage between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If battery voltage is present, locate and repair short to power in Dark Green wire. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) . If battery voltage is not present, replace CMP sensor.
7. 7) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and terminal "C" (Dark Green wire) at CMP sensor wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Dark Green wire. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) . If resistance is 5 ohms or more, go to next step.
8. 8) Check For Open Circuit Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Dark Green wire at CMP sensor wiring harness connector and test pin at breakout box. If resistance less than 5 ohms, an open circuit exists at PCM terminal No. 49. Inspect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all components and go to step 11) . If resistance 5 ohms or more, locate and repair open circuit in Dark Green wire. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) .
9. 9) Check For Open In CMP Sensor Ground Circuit Turn ignition off. Ensure CMP sensor is disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Light Blue wire at CMP sensor wiring harness connector and test pin No. 65 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue wire. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) .
10. 10) Check For CMP Sensor Ground Through PCM Connect PCM to breakout box. Measure resistance between ground and test pins No. 25, 51, 76, 77 and 103. If all readings are less than 5 ohms, PCM internal ground is not supplied to terminal No. 65. Reconnect all components and go to next step. If any reading is 5 ohms or more, locate and repair open in ground circuit. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) .
11. 11) Confirm PCM Fault Repeat steps 1) and 2) . If fault is still present, replace PCM. If fault is not present, no problem is indicated at this time. Testing is complete.
12. 12) Check For Intermittent Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM. To prevent vehicle from starting, disconnect Injector Driver Module (IDM) relay. Relay is located in power distribution center in engine compartment. Connect DVOM between test pins No. 49 and 65 at breakout box. Rotate crankshaft (by hand) until voltage toggles from battery voltage to .3-2.7 volts. If lower voltage reading .3-2.7 volts, go to next step. If lower voltage reading not .3-2.7 volts, go to step 3) .
13. 13) Check Wiring Harness Rotate crankshaft (by hand) until voltage stays at .3-2.7 volts. While observing DVOM, wiggle wiring harness. If a fault occurs, voltage reading will jump to battery voltage or zero volt. If fault occurs, locate and repair intermittent in wiring harness. Confirm repair using scan tool and accessing RPM PID from PID/DATA MONITOR & RECORD menu and by repeating steps 1) and 2) . If no fault occurs, no problem is indicated at this time. Repeat steps 1) and 2) .

1. 1) DTC 0500 DTC 0500 indicates PCM detected incorrect output from Vehicle Speed Sensor (VSS) sometime during vehicle operation. Possible causes for this DTC are: PSOM output to PCM. PSOM (+) and PSOM (-) wiring harness circuits. Faulty PCM. Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pins No. 33 and 58 at breakout box. If resistance is 21,000-55,000 ohms, go to step 4). If resistance is not 21,000-55,000 ohms, go to next step.
2. 2) Check PSOM Circuit Continuity Ensure ignition is off. Disconnect PSOM wiring harness connector. PSOM is located behind left side of instrument panel. Measure resistance between test pin No. 58 at breakout box and PSOM (+) circuit (Gray/Black wire) at PSOM wiring harness connector. Also, measure resistance between test pin No. 33 at breakout box and PSOM (-) circuit (Pink/Orange wire) at PSOM wiring harness connector. If any reading is 5 ohms or more, locate and repair open circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If both readings are less than 5 ohms or less, go to next step.
3. 3) Check For Short Circuit Ensure ignition is off. Measure resistance between test pin No. 58 and test pins No. 33, 51 and 71 at breakout box. If any reading is 10 k/ohms or less, repair short circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If all readings are more than 10 k/ohms, go to next step.
4. 4) Check Rear Anti-Lock Brake System (RABS) Sensor Turn ignition off. Disconnect RABS sensor connector. Sensor is located on rear differential assembly. Measure resistance between sensor terminals. If resistance is not 1300-1550 ohms, replace RABS sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 1300-1550 ohms, go to next step.
5. 5) Check PSOM Output Voltage Turn ignition off. Connect PCM to breakout box. Connect wiring harness connector to PSOM. Set New Generation Star (NGS) tester for frequency measurement with a 4-volt DC scale. Connect NGS tester probes between test pins No. 33 and 58 at breakout box. Road test vehicle at 40 MPH or 60 MPH. Frequency should by 88-92 Hz at 40 MPH or 128-132 at 60 MPH. If frequency is as specified, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If frequency is not as specified, no fault is indicated at this time. Check for faulty instrument cluster, cruise control system or RABS.

1. 1) DTC 0703: Check BOO PID Using scan tool, access BOO PID from PID/DATA MONITOR & RECORD menu. Turn ignition on. While observing PID, firmly depress and release brake pedal. If PID reading indicates ON only, go to next step. If PID reading does not indicate ON only, go to step 4) .
2. 2) Check BOO Switch Turn ignition on. Disconnect BOO switch connector. If BOO PID reading switched to OFF, replace BOO switch. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If BOO PID reading did not switch to OFF, go to next step.
3. 3) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Light Green wire at BOO switch wiring harness connector. If battery voltage is present, locate and repair short to power in Light Green wire. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, short to battery voltage is at PCM terminal No. 92. Inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 11) .
4. 4) Check BOO PID If BOO PID reading indicates OFF only, go to step 6) (Econoline), or go to next step (Pickup). If BOO PID reading does not indicate OFF only, fault is intermittent. Go to step 13) .
5. 5) Check Fuse No. 13 (15-Amp) Remove and inspect fuse No. 13 from instrument panel fuse block. If fuse is okay, go to step 9) to check for open circuit. If fuse is blown, go to step 7) to check for short to ground.
6. 6) Check Fuse No. 1 (15-Amp) Remove and inspect fuse No. 1 from instrument panel fuse block. If fuse is okay, go to step 9) to check for open circuit. If fuse is blown, go to next step to check for short to ground.
7. 7) Check For Short to Ground Measure resistance between ground and Light Green/Red wire at BOO switch wiring harness connector. If resistance is less than 10 k/ohms, locate and repair short to ground in wiring harness between fuse block and BOO switch. Replace fuse and reconnect connectors. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. If resistance is 10 k/ohms or more, go to next step.
8. 8) Check Circuit No. 511 For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Light Green wire at BOO switch wiring harness connector. If resistance is less than 10 k/ohms, locate and repair short to ground in Light Green wire. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. If resistance is 10 k/ohms or more, short to ground is at PCM terminal No. 92. Inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 12) .
9. 9) Check For Open Circuit Ensure BOO switch is disconnected and fuse No. 1 (Econoline) or fuse No. 13 (Pickup) is removed. Measure resistance of Light Green/Red wire between BOO switch wiring harness connector and output side of appropriate fuse holder. If resistance is less than 5 ohms, circuit between BOO switch and fuse block is okay. Go to next step. If resistance is 5 ohms or more, locate and repair open in wiring harness between fuse block and BOO switch connector. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation.
10. 10) Check For Open BOO Switch Turn ignition on. Connect a jumper wire between BOO switch wiring harness connector terminals. Using scan tool, access BOO PID from PID/DATA MONITOR & RECORD menu. If PID reading indicates ON, replace BOO switch. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. If PID reading does not indicate ON, remove jumper wire and go to next step.
11. 11) Check For Open In Circuit No. 511 Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure resistance between Light Green at BOO switch wiring harness connector and test pin No. 92 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Green wire. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation.
12. 12) Confirm PCM Fault Turn ignition on. Using scan tool, access BOO PID from PID/DATA MONITOR & RECORD menu. If PID reading switches from ON to OFF, no problem is indicated at this time. If PID reading does not switch from ON to OFF, replace PCM. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation.
13. 13) Check For Intermittent Open Or Short Circuit Ensure BOO switch is disconnected. Turn ignition on. Connect a jumper wire between BOO switch wiring harness connector terminals. Confirm BOO PID reading on scan tool indicates ON and brakelights also on. While observing BOO PID, wiggle/bend small sections of wiring harness starting at BOO switch connector and working toward PCM. If fault is indicated (PID changes to OFF), isolate fault in wiring harness and repair as necessary. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. If no fault is indicated, go to next step.
14. 14) Check For Intermittent Short To Power Remove fuse No. 1 (Econoline), or No. 13 (Pickup). Confirm BOO PID reading on scan tool indicates OFF and brakelights also off. While observing BOO PID, wiggle/bend small sections of wiring harness starting at BOO switch connector and working toward PCM. If fault is indicated (PID changes to ON), isolate fault in wiring harness and repair as necessary. Confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. If no fault is indicated, fault cannot be duplicated at this time. Reconnect all connectors and confirm repair using scan tool and accessing BOO PID from PID/DATA MONITOR & RECORD menu and with brakelight operation. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

PINPOINT TEST L: MALFUNCTION INDICATOR LIGHT

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

1. 1) Check MIL Fault If any KOEO or Continuous Memory DTCs are present, service DTCs prior to continuing with this test. If MIL is always illuminated, go to next step. If MIL is not always illuminated, go to step 3) .
2. 2) Check Circuit No. 659 For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Turn ignition on. If MIL is illuminated, locate and repair short to ground in circuit No. 658 (Pink/Light Green wire). Reconnect all connectors and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If MIL is off, replace PCM. Reconnect all connectors and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) MIL Always Off Disconnect Manifold Absolute Pressure (MAP) sensor. Start engine. If MIL is illuminated, no problem is indicated at this time. Reconnect MAP sensor and clear DTCs. If MIL is off, reconnect MAP sensor, turn engine off and go to next step.
4. 4) Check Ignition Feed Circuit Turn ignition on. Measure voltage between ground and power side of fuse No. 18 (Econoline), or No. 17 (Pickup) holder (Red Light Green wire) at instrument panel fuse block. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Red/Light Green wire or replace defective ignition switch. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check Fuse Remove and inspect fuse No. 18 (Econoline), or No. 17 (Pickup). If fuse is okay, go to next step. If fuse is blown, locate and repair short to ground in Red/Yellow wire. Replace fuse. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check For Open In Circuit No. 640 Ensure fuse No. 18 (Econoline), or No. 17 (Pickup) is removed. Remove MIL bulb. Measure resistance of Red/Yellow wire between non-powered side of fuse holder and MIL bulb socket. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red/Yellow wire. Reconnect all components, clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check MIL Bulb Check MIL bulb. If bulb is okay, go to next step. If bulb is bad, replace bulb. Clear DTCs and check MIL operation.
8. 8) Check Circuit No. 658 Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Pink/Light Green wire at MIL bulb socket and test pin No. 2 at breakout box. If resistance is less than 5 ohms, circuit No. 658 is okay. Replace PCM. Check MIL operation. If resistance is 5 ohms or more, locate and repair open circuit in Pink/Light Green wire. Reconnect all components, clear DTCs and check MIL operation.

1. 1) DTC 0475: Check For Ground In Circuit 574 (Black/Pink Wire) DTC 0475 indicates a circuit failure has occurred in EPR control solenoid circuit. Possible causes for this DTC are: Shorted to power. Faulty EPR solenoid. Open or shorted circuit. Faulty PCM. Disconnect EPR connector. EPR is located on top of engine. Turn ignition off. Measure resistance between ground and terminal "A" (Black/Pink wire) at EPR wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black/Pink wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
2. 2) Check EPR Coil Measure resistance between EPR terminals. If resistance is 2.5-12.0 ohms, go to next step. If resistance is not 2.5-12.0 ohms, replace EPR. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
3. 3) Check For Short To Power Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect PCM connector. Measure voltage between ground and terminal "B" (Gray/Red wire) at EPR wiring harness connector. If battery voltage is not present, go to next step. If battery voltage is present, locate and repair short to power in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
4. 4) Check For Short To Ground Disconnect PCM connector. Measure resistance between ground and terminal "B" (Gray/Red wire) at EPR wiring 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
5. 5) Perform Output State Check Reconnect PCM connector. Attach New Generation Star (NGS) scan tool. Turn ignition on. Connect DVOM between ground and terminal "B" (Gray/Red wire) at EPR harness connector. Using NGS tester, perform KOEO OUTPUT STATE SELF-TEST. See «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. If voltage does not toggle between 12 volts and zero volts, go to next step. If voltage toggles between 12 volts and zero volts, reconnect all components. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and «KOER SELF-TEST»(ref-23600-S20126232932001010300000). If DTC is still present, replace PCM.
6. 6) Check For Open Circuit Ensure EPR is disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Gray/Red wire between EPR harness connector and test pin No. 42 at breakout box. If resistance is less than 5 ohms, reconnect all components. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and «KOER SELF-TEST»(ref-23600-S20126232932001010300000). If DTC is still present, replace PCM. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
7. 7) DTC 0476 DTC 0476 indicates an Exhaust Back Pressure Regulator (EPR) malfunction was detected during «KOEO SELF-TEST»(ref-23600-S10365652382001010300000). Possible causes for this DTC are: Stuck or damaged butterfly. Misadjusted or damaged linkage. Restricted exhaust. Exhaust leaks. Faulty EPR. Faulty Exhaust Back Pressure (EBP) Sensor. Faulty PCM. Repair any KOEO EBP sensor DTCs before continuing with this test. Visually inspect butterfly tang. see scheme 21 If tang is open, go to next step. If tang is not open, repair damaged linkage or butterfly as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
8. 8) Check For Exhaust Restriction Ensure scan tool is connected to Data Link Connector (DLC). 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, go to next step. If EBP PID reading is 28 psi or more, repair restricted exhaust system. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
9. 9) Check EBP Sensor Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Turn ignition on. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. Start engine and record EBP PID reading. While observing scan tool, briefly accelerate engine several times. If EBP PID reading increases 4 psi or more, go to next step. If EBP PID reading does not increase 4 psi or more, replace EBP sensor and retest system.
10. 10) Check For Exhaust Leaks Inspect turbo pipe, crossover pipe and exhaust manifolds for leaks. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If no exhaust leaks are found, go to next step.
11. 11) Check EBP During KOEO Self-Test Disconnect EBP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between EBP sensor and sensor harness connector. Start engine. Measure voltage between signal circuit and signal ground at ICP/EBP adapter cable. Perform «KOER SELF-TEST»(ref-23600-S20126232932001010300000). If voltage increases 1.5-2.5 volts and then decreases as test ends, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If voltage does not increase 1.5-2.5 volts and then decreases as test ends, go to next step.
12. 12) EPR Visual Inspection Observe EPR valve linkage while performing «KOER SELF-TEST»(ref-23600-S20126232932001010300000). If linkage moves during self-test, adjust EPR linkage and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If linkage does not move during self-test, replace EPR valve. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).

PINPOINT TEST N: CLUTCH PEDAL POSITION SWITCH

Note. This pinpoint test applies to Pickup only.

1. 1) DTC 0704: Check CPP Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. With clutch pedal released, observe CPP PID reading. If CPP PID reading indicates ON only, go to next step. If CPP PID reading does not indicate ON only, go to step 4) .
2. 2) Check CPP Switch Turn ignition on. Disconnect CPP switch. If CPP PID reading switches to OFF, replace CPP switch. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If CPP PID reading does not switch to OFF, go to next step.
3. 3) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Tan/Light Blue wire at CPP switch wiring harness connector. If battery voltage is present, locate and repair short to power in Tan/Light Blue wire. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If battery voltage not present, short to battery voltage is at terminal No. 29 at PCM. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 11) .
4. 4) Check CPP PID Depress clutch pedal to floor. Check CPP PID reading. If CPP PID reading indicates OFF only, go to next step. If CPP PID reading does not indicate OFF only, fault may be intermittent. Go to step 12) .
5. 5) Check Fuse No. 18 (10-Amp) Remove and inspect fuse No. 18 from instrument panel fuse block. If fuse blown, go to next step to check for short to ground. If fuse is okay, go to step 8) .
6. 6) Check For Short To Ground Ensure CPP switch is disconnected. Measure resistance between ground and White/Purple wire at CPP switch wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in White/Purple wire. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If resistance is 5 ohms or more, go to next step.
7. 7) Check For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Tan/Light Blue wire at CPP switch wiring harness connector. If resistance is less than 10 k/ohms, locate and repair short to ground in Tan/Light Blue wire. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If resistance is 10 k/ohms or more, check for short to ground at terminal No. 29 at PCM. Inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to next step.
8. 8) Check For Open Circuit Turn ignition off. Ensure CPP switch is disconnected. Measure resistance of White/Purple wire between No. 18 fuse holder and CPP switch wiring harness connector. If resistance is less than 5 ohms, circuit is okay. Go to next step. If resistance is 5 ohms or more, locate and repair open circuit in White/Purple wire. Confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal.
9. 9) Check CPP Switch Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and White/Purple wire at CPP switch wiring harness connector. Check CPP PID reading. If CPP PID reading does not indicate ON, go to next step. If CPP PID reading indicates ON, replace CPP switch. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal.
10. 10) Check Circuit No. 306 Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Tan/Light Blue wire at CPP switch wiring harness connector and test pin No. 29 at breakout box. If resistance is less than 5 ohms, check for open at terminal No. 29 at PCM. Inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Tan/Light Blue wire. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal.
11. 11) Confirm PCM Fault Turn ignition on. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. While observing CPP PID reading, depress and release clutch pedal. If CPP PID switches from ON to OFF, no problem is indicated at this time. If CPP PID does not switch from ON to OFF, replace PCM. Confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal.
12. 12) Check For Intermittent Ensure CPP switch is disconnected. Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and White/Purple wire at CPP switch wiring harness connector. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. CPP PID should indicate ON. While observing CPP PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (CPP PID switches to OFF), isolate fault and repair as necessary. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If no fault is indicated, go to next step.
13. 13) Check For Intermittent Short To Power Ensure CPP switch is disconnected. Remove fuse No. 18 at instrument panel fuse block. Turn ignition on. Connect a jumper wire between Tan/Light Blue wire and White/Purple wire at CPP switch wiring harness connector. Using scan tool, access CPP PID from PID/DATA MONITOR & RECORD menu. CPP PID reading should indicate OFF. While observing CPP PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (CPP PID switches to ON), isolate fault and repair as necessary. Reconnect all connectors and confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal. If no fault is indicated, no problem is indicated at this time. Confirm repair using scan tool and monitoring CPP PID from PID/DATA MONITOR & RECORD menu while operating clutch pedal and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 0571: Check BPA Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). See «VEHICLE PREPARATION & EQUIPMENT HOOKUP»(ref-23600-S29011134782001010300000) under QUICK TEST. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. With brake pedal applied, observe BPA PID reading. If BPA PID reading indicates ON only, go to next step. If BPA PID reading does not indicate ON only, go to step 5) .
2. 2) Check BPA Switch Turn ignition on. Disconnect BPA switch. If BPA PID does not switch to OFF, go to step 4) (Econoline), or go to next step (Pickup). If BPA PID switches to OFF, replace BPA switch. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
3. 3) Check For Short To Battery Voltage In Black/Yellow Wire Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Black/Yellow wire at BPA switch wiring harness connector. If battery voltage is present, locate and repair short to power in Black/Yellow wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. If battery voltage is not present, short to voltage is at terminal No. 31 at PCM. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors, go to step 13) .
4. 4) Check For Short To Battery Voltage In Red/Light Green Wire Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Red/Light Green wire at BPA switch wiring harness connector. If battery voltage is present, locate and repair short to power in Red/Light Green wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. If battery voltage is not present, short to voltage is at terminal No. 31 at PCM. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors, go to step 13) .
5. 5) Check BPA PID Using scan tool observe BPA PID reading. Depress and release brake pedal. If BPA PID reading indicates OFF only, go to step 7) (Econoline), or go to next step (Pickup). If BPA PID reading does not indicate OFF only, fault may be intermittent. Go to step 14) .
6. 6) Check Fuse No. 5 (15-Amp) Remove and inspect fuse No. 5 from instrument panel fuse block. If fuse is blown, replace fuse. If fuse blows again, go to step 8) . If fuse is okay, check BPA switch and circuit for open. Go to step 10) .
7. 7) Check Fuse No. 1 (15-Amp) Remove and inspect fuse No. 1 from instrument panel fuse block. If fuse is blown, replace fuse. If fuse blows again, go to step 19) . If fuse is okay, check BPA switch and circuit for open. Go to step 16) .
8. 8) Check Purple/Orange Wire For Short To Ground Ensure BPA switch is disconnected. Measure resistance between ground and Purple/Orange wire at BPA switch wiring harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Purple/Orange wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
9. 9) Check Black/Yellow Wire For Short To Ground Disconnect PCM 104-pin connector. Measure resistance between ground and Black/Yellow wire at BPA switch wiring harness connector. If resistance is more than 10 k/ohms, go to step 21) . If resistance is 10 k/ohms or less, locate and repair short to ground in Black/Yellow wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
10. 10) Check BPA Switch Turn ignition on. Ensure BPA switch is disconnected. Connect a jumper wire between Black/Yellow wire and Purple/Orange wire at BPA switch wiring harness connector. Using scan tool, check BPA PID reading. If BPA PID reading indicates ON, replace BPA switch. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. If BPA PID reading does not indicate ON, go to next step.
11. 11) Check Purple/Orange Wire For Open Turn ignition off. Measure resistance of Purple/Orange wire between BPA switch wiring harness connector and No. 5 fuse holder. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Purple/Orange wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
12. 12) Check Black/Yellow Wire For Open Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Black/Yellow wire at BPA switch wiring harness connector and test pin No. 31 at breakout box. If resistance is less than 5 ohms, check for open at terminal No. 31 at PCM. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors, go to next step. If resistance 5 ohms or more, locate and repair open circuit in Black/Yellow wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
13. 13) Confirm PCM Fault Turn ignition on. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. While observing BPA PID reading, depress and release brake pedal. If BPA PID switches from ON to OFF, no problem is indicated at this time. If BPA PID does not switch from ON to OFF, replace PCM. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
14. 14) Check For Intermittent Open Or Short Ensure BPA switch is disconnected. Turn ignition on. Connect a jumper wire between Black/Yellow wire and Purple/Orange wire at BPA switch wiring harness connector. 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 toward PCM. If fault is indicated (BPA PID switches to OFF), isolate fault and repair as necessary. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. If no fault is indicated, go to next step.
15. 15) Check For Intermittent Short To Power Ensure jumper wire is still connected. Remove fuse No. 5 at instrument panel fuse block. Turn ignition on. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. BPA PID should indicate OFF. While observing BPA PID reading, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (BPA PID switches to ON), isolate fault and repair as necessary. Reconnect all components and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal. If no fault is indicated, no problem is indicated at this time. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
16. 16) Check Light Green/Red Wire For Open Turn ignition off. Measure resistance of Light Green/Red wire between BPA switch wiring harness connector and No. 1 fuse holder. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Light Green/Red wire. Reconnect all connectors and confirm repair using scan tool and accessing BPA PID from PID/DATA MONITOR & RECORD menu while applying brake pedal.
17. 17) Check For Open BPA Switch Reinstall fuse No. 1. Ensure BPA switch is disconnected. Turn ignition on. Connect a jumper wire between Red/Light Green wire and Light Green/Red wire at BPA switch wiring harness connector. Using scan tool, access BPA PID from PID/DATA MONITOR & RECORD menu. If BPA PID reading indicates ON, replace BPA switch and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If BPA PID reading does not indicate ON, go to next step.
18. 18) Check Red/Light Green Wire For Open Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of Red/Light Green wire between BPA switch wiring harness connector and test pin No. 31 at breakout box. If resistance is less than 5 ohms, replace PCM and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Red/Light Green wire and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
19. 19) Check Light Green/Red Wire For Short To Ground Remove fuse No. 1 at instrument panel fuse block. Measure resistance between ground and Light Green/Red wire at BPA switch wiring harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Light Green/Red wire. Replace fuse and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
20. 20) Check Red/Light Green Wire For Short To Ground Remove fuse No. 1 at instrument panel fuse block. Disconnect PCM 104-pin connector. Measure resistance between ground and Red/Light Green wire at BPA switch wiring harness connector. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Red/Light Green wire. Replace fuse and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
21. 21) Check PCM For Internal Short Disconnect BPA connector. Connect PCM connector to breakout box. Measure resistance between test pin No. 31 and test pins No. 25, 76, 77 and 103 at breakout box. If all readings are more than 10 k/ohms, no problem is indicated at this time. If any reading is 10 k/ohms or less, replace PCM. Reinstall fuse and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1536 Or NGS Tester PID PBA: Determine Cause Of PBA Not Changing States This DTC indicates that PCM does not detect a PBA state change during KOER SELF-TEST. Possible causes for this DTC are: Low brake fluid. Short to ground or power. Open circuit. Faulty Powertrain Control Module (PCM). Start engine and observe BRAKE warning and ABS warning lights (bulb check). If both lights are on, go to next step. If one or both lights are off, repair wiring in bulb circuit(s) as necessary. After repair is completed, perform bulb check again to confirm repair.
2. 2) Check For Brake System Problem Turn ignition on. Ensure parking brake is fully off. Check BRAKE warning and ABS warning lights. If one or both lights are illuminated, a fault exists in brake system. Check and repair manual or ABS brake system as necessary. See appropriate ANTI-LOCK or DISC & DRUM article in BRAKES. If both lights are off, go to next step.
3. 3) Check PBA Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. Observe PBA PID reading and cycle parking brake. If PBA PID reading indicates ON only, go to next step. If PBA PID reading does not indicate ON only, go to step 6) .
4. 4) Check PBA Switch Turn ignition on. Disconnect PBA switch. If PBA PID switches to OFF, replace PBA switch. Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. If PBA PID does not switch to OFF, go to next step.
5. 5) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector. Measure resistance between ground and Purple/White wire at PBA switch wiring harness connector. If resistance is less than 10 k/ohms, locate and repair short to ground in Purple/White wire. Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. If resistance is 10 k/ohms or more, inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 9) .
6. 6) Check PBA PID Using scan tool, observe PBA PID reading. Cycle parking brake. If PBA PID reading indicates OFF only, go to next step. If PBA PID reading does not indicate OFF only, fault may be intermittent. Go to step 10) .
7. 7) Check PBA Switch Turn ignition on. Ensure PBA switch is disconnected. Connect a jumper wire between ground and Purple/White wire at PBA switch wiring harness connector. Using scan tool, check PBA PID reading. If PBA PID reading indicates ON, replace PBA switch. Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. If PBA PID reading does not indicate ON, go to next step.
8. 8) Check Purple/White Wire For Open Disconnect jumper wire. Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 4 at breakout box. If battery voltage is present, open is at terminal No. 4 at PCM. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to next step. If battery voltage is not present, locate and repair open circuit in circuit No. 162 (Light Green/Red wire), or circuit No. 977 (Purple/White wire). Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake.
9. 9) Confirm PCM Fault Turn ignition on. Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. While observing PBA PID reading, cycle parking brake. If PBA PID switches from ON to OFF, no problem is indicated at this time. If PBA PID does not switch from ON to OFF, replace PCM. Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake.
10. 10) Check For Intermittent Short To Ground Ensure PBA switch is disconnected. Turn ignition on. Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. PBA PID reading should indicate OFF. While observing PBA PID, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (PBA PID switches from OFF to ON), isolate fault and repair as necessary. Reconnect all connectors and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. If no fault is indicated, go to next step.
11. 11) Check For Intermittent Open Apply parking brake. Using scan tool, access PBA PID from PID/DATA MONITOR & RECORD menu. PBA PID should indicate ON. While observing PBA PID reading, wiggle and bend small sections of wiring harness working toward PCM. If fault is indicated (PBA PID switches from ON to OFF), isolate fault and repair as necessary. Reconnect all components and confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. Repeat «KOER SELF-TEST»(ref-23600-S20126232932001010300000) under QUICK TEST. If no fault is indicated, no problem is indicated at this time. Confirm repair using scan tool and accessing PBA PID from PID/DATA MONITOR & RECORD menu while applying and releasing parking brake. Repeat «KOER SELF-TEST»(ref-23600-S20126232932001010300000) under QUICK TEST.

1. 1) DTC 0381 This DTC indicates that PCM has detected a glow plug warning light circuit malfunction. Possible causes for this DTC are: Open WAIT TO START light. Open or grounded circuit. Faulty Powertrain Control Module (PCM). Start engine and observe WAIT TO START light. If light stays on, go to next step. If light does not stay on, go to step 3) .
2. 2) Check Black/Pink Wire For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. If WAIT TO START light illuminates, locate and repair short in circuit No. 464 (Black/Pink wire) between WAIT TO START light and PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If WAIT TO START light is off, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check Fuse Turn ignition off. Check fuse No. 18 (15-amp) (Econoline), or No. 17 (10-amp) (Pickup), located in instrument panel fuse block. If fuse is okay, go to next step. If fuse is blown, go to step 5) .
4. 4) Check Bulb Remove and inspect WAIT TO START bulb. If bulb is okay, go to step 6) . If bulb is bad, replace bulb. Reconnect all connectors, clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check Red/Yellow Wire For Short To Ground Ensure WAIT TO START bulb is removed and ignition is off. Measure resistance between ground and Red/Yellow wire at WAIT TO START bulb socket. If resistance is more than 10 k/ohms, replace fuse. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 10 k/ohms or less, locate and repair short to ground in Red/Yellow wire. Replace fuse. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check Red/Yellow Wire For Open Turn ignition on. Measure voltage between ground and Red/Yellow wire at WAIT TO START bulb socket. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open circuit in Red/Yellow wire between fuse and WAIT TO START light. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check Black/Pink Wire For Open Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Black/Pink wire at WAIT TO START bulb socket and test pin 80 at breakout box. If resistance is less than 5 ohms, replace PCM. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Black/Pink wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 0380: Check If Glow Plugs Are On Continuously This DTC indicates that PCM has detected a glow plug relay control circuit malfunction. Possible causes for this DTC are: Short to power. Open or grounded circuit. Faulty glow plug relay. Faulty Powertrain Control Module (PCM). Disconnect glow plug relay connector. Relay is located on top of engine. Turn ignition on. Measure voltage between ground and Red/Light Green wire at glow plug relay connector. If battery voltage is present, go to next step. If battery voltage is not present, check for blown fuse "U" (Econoline), or fuse No. 22 (Pickup). If fuse is okay, locate and repair open in Red/Light Green wire between power distribution box in engine compartment and glow plug relay. If fuse is blown, locate and repair short to ground in Red/Light Green wire between power distribution box in engine compartment and glow plug relay.
2. 2) Check Relay Coil Resistance Turn ignition off. Measure resistance between glow plug relay terminals "A" (Purple/Orange wire terminal) and "B" (Red/Light Green wire terminal). If resistance is 5-15 ohms, go to next step. If resistance is not 5-15 ohms, replace relay. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check Purple/Orange Wire For Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure voltage between ground and test pin No. 101 at breakout box. If battery voltage is present, locate and repair short to ground in Purple/Orange wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, go to next step.
4. 4) Check Purple/Orange Wire For Short To Ground Turn ignition off. Measure resistance between ground and Purple/Orange wire at glow plug relay wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Purple/Orange wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, go to next step.
5. 5) Check Purple/Orange Wire For Open Measure resistance of Purple/Orange wire between glow plug relay wiring harness connector and test pin No. 101 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open in Purple/Orange wire between PCM and glow plug relay connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1663 This DTC indicates that PCM has detected a FDCS circuit malfunction. Possible causes for this DTC are: Faulty IDM. Open or grounded circuit. Faulty Powertrain Control Module (PCM). Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950) and connect PCM connector to breakout box. Turn ignition on. Measure voltage between ground and test pin No. 95 at breakout box. If voltage is .5-.7 volt, go to next step. If voltage is less than .5 volt, go to step 3) . If battery voltage is present, go to step 4) .
2. 2) Perform KOEO Output State Self-Test Attach New Generation Star (NGS) scan tool. Turn ignition on. Using NGS tester, perform «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. Measure voltage between ground and test pin No. 95 at breakout box while depressing and releasing accelerator pedal. If voltage does not toggle between .5-.7 volt and 12 volts, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage toggles between .5-.7 volt and 12 volts, fault is intermittent. Go to step 7) .
3. 3) Check Brown/Orange Wire For Continuity Turn ignition off. Disconnect PCM connector from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between terminal No. 17 (Brown/Orange wire) at IDM connector and test pin No. 95 at breakout box. If resistance is less than 5 ohms, go to step 5) . If resistance is 5 ohms or more, locate and repair open circuit in Brown/Orange wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Brown/Orange Wire For Short To Power Turn ignition on. Measure voltage between ground and test pin No. 95 at breakout box. If battery voltage is not present, go to step 6) . If battery voltage is present, locate and repair short to power in Brown/Orange wire between PCM connector and IDM connector.
5. 5) Check Brown/Orange Wire For Short To Ground Turn ignition off. Measure resistance between test pin No. 95 and test pins No. 25, 51, 76, 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. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check PCM Output State Function Connect PCM to breakout box. Ensure IDM is disconnected. Turn ignition on. Using NGS tester, perform «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. Measure voltage between ground and test pin No. 95 at breakout box while depressing and releasing accelerator pedal. If voltage does not toggle between .5-.7 volt and zero volts, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage toggles between .5-.7 volt and zero volts, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Intermittent Clear DTCs. Start engine and allow it to idle. Wiggle and bend small sections of wiring harness starting at IDM connector and working toward PCM. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If DTC 1663 is present, locate and repair intermittent in Brown/Orange or Gray/Red wire between IDM and PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1663 is not present, no problem is indicated at this time.

1. 1) DTC 1298 & 1668 DTC 1298 (1995 models) and DTC 1668 (1995-96 models) indicate that a communication error has occurred between PCM and IDM. DTC 1668 indicates a PCM/IDM communication error. Possible causes for this DTC are: Open fuse. IDM relay. Open or short in IDM enable circuit. Open or short in EF circuit. Open or short in FDCS circuit. IDM powering circuits. Faulty Powertrain Control Module (PCM). Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) , retrieve Continuous Memory DTCs and perform the following: If DTC 1668 is present, go to next step. If DTCs P1667 and P1663 are present with or without DTC P1668, go to step 6) . If DTC 1298 is present with DTC 1668, replace IDM. If DTC 1667 is present with DTC 1668, go to TEST V, step 1) . If DTC P1663 is present with DTC 1668, go to TEST T, step 1) . If DTC P1662 is present with DTC 1668, go to TEST W, step 1) .
2. 2) Check Gray/White Wire For Open Install breakout box. Leave PCM disconnected. Disconnect IDM harness connector. Measure resistance of Gray/White wire between breakout box test Pin No. 48 and IDM harness connector terminal No. 4. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/White wire. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check Gray/White Wire For Short To Ground Measure resistance of Gray/White wire between IDM and negative battery terminal. 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. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Gray/White Wire For Short To Power Turn ignition on. Measure voltage between breakout box Test Pin No. 48 and negative battery terminal. If voltage is present, repair short to power in Gray/White wire. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is not present, go to next step.
5. 5) Check Gray/Red Wire For Continuity Measure resistance of Gray/Red wire between breakout box test Pin No. 91 and IDM harness connector terminal No. 2. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Red wire. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check IDM Power Supply Ensure PCM is connected and IDM is disconnected. Turn ignition on. Measure voltage between IDM harness connector terminal No. 14 (Dark Green/Light Green wire) and negative battery terminal. If battery voltage is present, go to next step. If battery voltage is not present, go to TEST W, step 6) .
7. 7) Check IDM Ground Turn ignition off. Measure resistance between IDM harness connector terminal No. 26 (Black/White wire) and negative battery terminal. 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 IDM and chassis ground. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Measure Frequency On EF Circuit Connect PCM to breakout box. Ensure IDM is connected to harness. Connect NGS Tester as follows: Install NGS tester to DLC. Connect test probe between NGS common and breakout box test Pin No. 77 (ground). Connect second test probe between NGS signal and breakout box test Pin No. 48 (EF line). Select VEHICLE and ENGINE. Select DIGITAL MEASUREMENT SYSTEM. Change voltage level to 4-volt DC. Press link button to choose a PID. Select PID/DATA MONITOR & RECORD. Select RPM PID. Press START. Turn ignition on. Measure frequency at 1000, 2000 and 3000 RPM. Refer to «ENGINE SPEED-TO-FREQUENCY SIGNAL»(ref-23600-S39684398052002012500000) table. If all frequencies are as specified for each RPM value, replace PCM. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any frequency value is not as specified for that RPM value, replace IDM. Reconnect connectors. Clear DTCs and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . ENGINE SPEED-TO-FREQUENCY SIGNAL Engine Speed - RPM Frequency - Hz. 1000 66 2000 133 3000 200

1. 1) DTC 1667 DTC P1667 indicates PCM has detected a failure on CID circuit. Possible causes for DTCs are: Faulty Injector Driver Module (IDM). Open or short in CID circuit. Faulty Powertrain Control Module (PCM). Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) , retrieve Continuous Memory DTCs and perform the following: If only DTC 1667 is present, go to next step. If DTCs 1663 and 1667 are present, with or without DTC 1668, go to step 6) . If only DTC 1298 is present, replace IDM. If DTC P1662 is also present, go to TEST W, step 1) .
2. 2) Check Voltage On CID Circuit (Yellow/Light Blue Wire) DTC 1667 indicates there is a short to power, short to ground or an open at CID circuit. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950). Connect PCM connector to breakout box. Turn ignition on. Measure voltage between ground and test pin No. 96 at breakout box. If voltage is .5-.7 volt, go to next step. If voltage is less than .5 volt, go to step 4) . If voltage is more than 4 volts, go to step 5) .
3. 3) Perform KOEO Output State Self-Test Attach New Generation Star (NGS) scan tool. Turn ignition on. Using NGS tester, perform «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. Measure voltage between ground and test pin No. 96 at breakout box. If voltage does not toggle between .5-.7 volt and 12 volts, replace PCM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage toggles between .5-.7 volt and 12 volts, fault is intermittent. Go to step 8) .
4. 4) Check For Open On CID Circuit (Yellow/Light Blue Wire) Turn ignition off. Disconnect PCM connector from breakout box. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between terminal No. 16 (Yellow/Light Blue wire) at IDM connector and test pin No. 96 at breakout box. If resistance is less than 5 ohms, go to step 6) . If resistance is 5 ohms or more, locate and repair open circuit in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check Yellow/Light Blue Wire For Short To Power Disconnect PCM from breakout box. Turn ignition on. Measure voltage between test Pin No. 96 and ground Pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If battery voltage is present, locate and repair short to power in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, go to step 7) .
6. 6) Check Yellow/Light Blue Wire For Short To Ground Turn ignition off. Measure resistance between test pin No. 96 and test pins No. 25, 51, 76, 77 and 103 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check PCM Output State Function Turn ignition off. Connect PCM connector to breakout box. Install New Generation Star (NGS) scan tool to DLC. Turn ignition on. Using NGS tester, perform «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. Measure voltage between test pin No. 96 and test pins No. 25, 51, 76, 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. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage toggles between .5-.7 volt and zero volts, replace IDM. Reconnect connectors. Clear DTCs, and repeat QUICK TEST.
8. 8) Check For Intermittent Reconnect connectors. Clear DTCs. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) under QUICK TEST. If DTC 1663 is reset, replace PCM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1663 is not reset, no problem is indicated at this time. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) DTC P1218 Turn ignition on. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and perform the following: If DTC 1218 was present without 1667, go to next step. IF DTCs 1663, 1667 and 1668 are also present with DTC P1218, go to TEST U, step 6) . If DTC 1667 is present with 1218, go to step 2) . If DTC 1298 is also present, REPLACE IDM. If DTC 1662 is also present, Go to TEST W, step 1) .
10. 10) Check For Intermittent Open On CID Circuit (Yellow/Light Blue Wire) Turn ignition off. Install breakout box, leave PCM disconnected. Disconnect IDM connector. Check for intermittent open on CID circuit. Measure resistance of Yellow/Light Blue wire between IDM harness connector terminal No. 16 and breakout box test Pin No. 96. Grasp harness close to IDM connector. Wiggle and shake harness while working your way back to PCM connector, while looking for a spike on DVOM. If resistance stays less than 5 ohms throughout procedure, go to next step. If resistance jumps to 5 ohms or more during procedure, repair open in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check For Intermittent Short To Power On CID Circuit (Yellow/Light Blue Wire) Turn ignition on. Measure voltage between test Pin No. 96 and ground Pins No. 25, 51, 76, 77, 91 and 103 at breakout box. Grasp harness close to IDM connector. Wiggle and shake harness while working your way back to PCM connector, while looking for a spike on DVOM. If a voltage reading suddenly appears during wiggle test, repair short to power in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage does not appear during wiggle test, reconnect connectors. Clear DTCs. Road test vehicle, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC reappears, replace IDM.
12. 12) DTC P1219 Turn ignition on. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and perform the following: If DTC 1219 was present without 1667, go to next step. IF DTCs 1663, 1667 and 1668 are also present with DTC P1219, go to TEST U, step 6) . If DTC 1667 is present with 1219, go to step 2) . If DTC 1298 is also present, REPLACE IDM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1662 is also present, Go to TEST W, step 1) .
13. 13) Check For Intermittent Short To Ground On CID Circuit (Yellow/Light Blue Wire) Turn ignition off. Install breakout box, leave PCM disconnected. Disconnect IDM connector. Measure resistance between test Pin No. 96 and ground Pins No. 25, 51, 76, 77, 91 and 103 at breakout box. Grasp harness close to IDM connector. Wiggle and shake harness while working your way back to PCM connector, while looking for a spike on DVOM. If resistance changes to less than 10 k/ohms during wiggle test, repair short to ground in Yellow/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 10 k/ohms or more during wiggle test, reconnect connectors. Clear DTCs. Road test vehicle, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC reappears, replace IDM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1662: Verify Battery Voltage At IDM Primary Circuit DTC 1662 indicates PCM has detected an IDM-EN circuit malfunction. Possible causes for this DTC are: Open fuse. Open or shorted IDM-EN circuit. Faulty IDM relay. Faulty Powertrain Control Module (PCM). Remove IDM relay from power distribution box. Turn ignition on. Measure voltage between chassis ground and White/Black wire at IDM relay wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, repair open in White/Light Blue wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Check For Short To Ground Turn ignition off. Measure resistance between chassis ground and White/Black wire at IDM relay wiring harness connector. If resistance is 10 k/ohms or less, go to next step. If resistance is more than 10 k/ohms, go to step 4) .
3. 3) Check White/Black Wire For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector. Measure resistance between chassis ground and White/Black wire at IDM relay wiring harness connector. If resistance is 10 k/ohms or less, repair short to ground in White/Black wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is more than 10 k/ohms, replace PCM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Verify PCM Is Enabling IDM Relay Turn ignition off. Measure resistance between IDM relay cavity (White/Black wire) and battery ground. Turn ignition on, while observing DVOM. If resistance changes to less than 5 ohms, replace IDM relay. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance stays 5 ohms or more, go to next step.
5. 5) Check White/Black Wire For Open Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance of White/Black wire between IDM relay cavity and test Pin No. 70 at breakout box. If resistance is less than 5 ohms, replace PCM. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in White/Black wire between PCM and IDM relay. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) DTC 1663 & 1667, With Or Without P1668: Check For DTC 1662 Ensure IDM and PCM are connected. Turn ignition on. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) under QUICK TEST. If DTC 1662 is present, go to step 1) . If DTC 1662 is not present, go to next step.
7. 7) Check MAXI Fuse Ensure PCM is connected. Turn ignition on. On Econoline, measure voltage between negative battery terminal and Gray 16-gage fuse link "F", located at starter motor relay. On Pickup, measure voltage between negative battery terminal and MAXI fuse No. 8, located in power distribution box in engine compartment. On all models, if battery voltage is present on both sides of fuse link or MAXI fuse, go to next step. If battery voltage is not present on both sides of fuse link or MAXI fuse, repair short to ground in Dark Green/Light Green wire and replace fuse link or MAXI fuse. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check Yellow Wire For Open Turn ignition off. On Econoline, disconnect fuse link "F" from power supply. On Pickup, ensure MAXI fuse No. 8 is removed from power distribution box. On all models, remove IDM relay. On Econoline, measure resistance of Yellow wire between fuse link "F" and appropriate IDM relay cavity. On Pickup, measure resistance of Yellow wire between non-powered side of MAXI fuse No. 8 and IDM relay cavity. On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Yellow wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check Dark Green/Light Green Wire For Open Disconnect IDM connector. Measure resistance of Dark Green/Light Green wire between IDM harness connector terminal No. 14 and appropriate IDM relay cavity. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Green/Light Green wire. Reconnect connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check IDM Relay Reinstall IDM relay. On Econoline, ensure fuse link "F" is disconnected. On Pickup, ensure MAXI fuse No. 8 is removed. On all models, ensure IDM is disconnected. Turn ignition on. On Econoline, measure resistance between fuse link "F" (Yellow wire) and IDM harness connector terminal No. 14 (Dark Green/Light Green wire). On Pickup, measure resistance between non-powered side of MAXI fuse No. 8 (Yellow wire) and IDM harness connector terminal No. 14 (Dark Green/Light Green wire). On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace IDM relay. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check IDM Ground Circuit Measure resistance of Black/White wire between negative battery terminal and IDM harness connector terminal No. 26. If resistance is less than 5 ohms, replace IDM. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open in Black/White wire. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

PINPOINT TEST X: INJECTION PRESSURE REGULATOR

Note. Engine will not operate with an IPR circuit that is not functioning.

1. 1) DTCs 1283: Check Power Feed Circuit This DTC indicates that PCM has detected a IPR circuit malfunction. Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. Remove PCM relay from power distribution box in engine compartment. Measure resistance of Red wire between IPR connector and PCM relay wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Check IPR Coil Resistance Measure resistance between IPR terminals. If resistance is 5-20 ohms, go to next step. If resistance is 5 ohms or more, replace IPR. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check IPR Control Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 83 and test pins No. 71 and 97 at breakout box. Also, measure resistance between test pin No. 83 and test pins No. 25, 51, 76, 77 and 103 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground or power in Yellow/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Wiring Harness Continuity Check for continuity in Yellow/Red wire between test pin No. 83 at breakout box and IPR wiring harness connector. If continuity exists, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If continuity does not exist, locate and repair open circuit in Red/Yellow wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) DTC 1282: Excessive Injection Control Pressure This DTC indicates excessive injection control pressure was detected during continuous diagnostic monitoring. Possible causes for this DTC are: Intermittent short to ground in IPR circuit. Stuck IPR. Turn ignition off. Disconnect IPR connector. IPR is located on top of engine. Attempt to start vehicle. If engine starts, replace IPR. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If engine does not start, go to next step.
6. 6) Check For Intermittent Short To Ground Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between ground and test pin No. 83 at breakout box. Resistance should be more than 10 k/ohms. Wiggle and bend small sections of wiring harness starting at IPR connector and working toward PCM. If fault is indicated (resistance 10 k/ohms or less), isolate fault and repair as necessary. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is indicated, no problem is indicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC resets, replace PCM.
7. 7) KOER DTC 1211 This DTC indicates that control pressure was low during self-test. Possible causes for this DTC are: Low reservoir oil level. Poor oil quality. Injector "O" ring leak. Faulty IPR valve. Faulty Injection Control Pressure (ICP) sensor. Faulty oil pressure pump. Faulty Powertrain Control Module (PCM). Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If any DTCs are set, service DTCs as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no DTCs are set, go to next step.
8. 8) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm), go to next step. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check Injection Control Pressure (ICP) Sensor Ensure scan tool is connected to Data Link Connector (DLC). 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check For Oil Aeration Again, using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Ensure ignition is on (engine off). Depress accelerator pedal to wide open throttle for 3 minutes. If ICP PID reading increases to more than 1250 psi, change oil and repeat test. If ICP PID reading does not increase to more than 1250 psi, go to next step.
11. 11) Check ICP Sensor Disconnect ICP sensor connector. Install ICP/EBP Adapter Cable (D94T-50-A) between ICP sensor and sensor wiring harness connector. Start engine. Measure voltage between ICP signal circuit and ground at ICP/EBP adapter cable. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If voltage increases to more than 3 volts and then decreases to about one volt during ICP portion of test, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage does not increase to more than 3 volts and then decrease to about one volt during ICP portion of test, go to next step.
12. 12) Injector Leak Check Disconnect high pressure hose from right cylinder head. Using Oil High Pressure Leakage Adapter Set (D94T-6600-A), plug right high pressure hose. Using scan tool, monitor IPR PID reading. Start engine and record IPR PID reading. Turn ignition off. Reconnect right cylinder head high pressure hose. Disconnect high pressure hose from left cylinder head. Using oil high pressure leakage adapter set, plug left high pressure hose. Again, monitor IPR PID reading. Start engine and record IPR PID reading. If IPR PID readings are not within 2 percent of each other, repair internal oil leak on cylinder head with the higher IPR PID reading. If both IPR PID readings are within 2 percent of each other, replace IPR and retest system. If DTC 1211 is still set, go to next step.
13. 13) Check Oil System Pressure Perform INJECTION CONTROL PRESSURE TEST and check for pressurized oil leaks. See HARD START/NO START DIAGNOSIS in I - SYSTEM & COMPONENT TESTS - 7.3L DIESEL article. Repair as necessary. If no leaks are found, replace high pressure oil pump.
14. 14) Continuous Memory DTC 1211 This DTC indicates that injector control pressure was not to specification during normal driving conditions. Possible causes for this DTC are: Low reservoir oil level. Poor oil quality. Injector "O" ring leak. Faulty IPR valve. Faulty oil pressure pump. Faulty Powertrain Control Module (PCM). Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If any DTCs are set, service DTCs as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no DTCs are set, go to next step.
15. 15) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm), go to next step. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
16. 16) Check Injection Control Pressure (ICP) Sensor Ensure scan tool is connected to Data Link Connector (DLC). 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
17. 17) Check For Oil Aeration Again, using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Ensure ignition is on (engine off). Depress accelerator pedal to wide open throttle for 3 minutes. If ICP PID reading increases to more than 1250 psi, change oil and repeat test. If ICP PID reading does not increase to more than 1250 psi, go to next step.
18. 18) Perform KOER SELF-TEST Perform «KOER SELF-TEST»(ref-23600-S20126232932001010300000) . If DTC 1211 is set, go to step 11) . If DTC 1211 is not set, no problem is indicated at this time.

1. 1) DTC 0198 DTC 0198 indicates EOT sensor is out of self-test range (high). Possible causes for this DTC are: Open circuit. Damaged connector. Faulty EOT sensor. Faulty Powertrain Control Module (PCM). Turn ignition off. Disconnect EOT sensor connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and Gray/Red wire at EOT sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire (SIG RTN circuit). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Induce Opposite Failure Turn ignition on. Connect a jumper wire between EOT sensor wiring harness connector. Check for DTCs. If DTC 0197 is set, replace EOT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0197 is not set, go to next step.
3. 3) Check For Open Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Light Green/Red wire at EOT sensor wiring harness connector and test pin No. 38 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Light Green/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) DTC 0197: Induce Opposite Failure DTC 0197 indicates EOT sensor is out of self-test range (low). Possible causes for this DTC are: Grounded circuit. Faulty EOT sensor. Faulty Powertrain Control Module (PCM). Damaged connector. Turn ignition off. Disconnect EOT sensor connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If DTC 0198 is set, replace EOT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0198 is not set, go to next step.
5. 5) Check For Short To Ground Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 38 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, locate and repair short to ground in EOT sensor circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Continuous Memory DTC 0197 Or 0198: Check Sensor DTC 0197 indicates EOT sensor is out of self-test range (low). DTC 0198 indicates EOT sensor is out of self-test range (high). Possible causes for these faults are: Open or grounded circuit. Faulty EOT sensor. Faulty Powertrain Control Module (PCM). Turn ignition off. Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access EOT PID from PID/DATA MONITOR & RECORD menu. Observe EOT PID reading and tap on EOT sensor to simulate road shock. Wiggle EOT wiring harness connector. If EOT PID reading switches to 212°F (100°C), go to step 9) . If EOT PID reading does not switch to 212°F (100°C), go to next step.
7. 7) Check Wiring Harness Again, access EOT PID from PID/DATA MONITOR & RECORD menu. Observe EOT PID reading and wiggle wiring harness starting at EOT sensor and working toward PCM. If EOT PID reading switches to 212°F (100°C), locate and repair intermittent in wiring harness. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If EOT PID reading does not switch to 212°F (100°C), go to next step.
8. 8) Check PCM Connector Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If connector is okay, no problem is indicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Inspect EOT Connector Disconnect and inspect EOT sensor connector for damaged pins, corrosion and loose wires. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If connector is okay, replace EOT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) DTC 0195 Or 0196: Check Sensor These DTCs indicate engine oil temperature is not warm enough to perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-23600-S17927227932001010300000) . Engine oil temperature must be more than 165°F (74°C). Possible causes for this DTC are: Engine not fully warmed up. Low oil level. Damaged EOT sensor or sensor circuit. Faulty thermostat. EOT sensor circuit fault. Road test vehicle. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0195 Or 0196 is still present, go to next step. If DTC 0195 or 0196 is not present, service any other DTCs that are present.
11. 11) EOT Sensor Check Ensure engine is at normal operating temperature. Turn ignition off. Using scan tool, access EOT PID from PID/DATA MONITOR & RECORD menu. While observing EOT PID reading, tap on sensor to simulate road shock. If EOT PID reading fluctuates or switches to less than 165°F (74°C), replace EOT sensor. Clear DTCs. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If EOT PID reading does not fluctuate or switch to less than 165°F (74°C), go to next step.
12. 12) Check Wiring Harness Again, access EOT PID from PID/DATA MONITOR & RECORD menu. Observe EOT PID reading and wiggle wiring harness starting at EOT sensor and working toward PCM. If EOT PID reading fluctuates, locate and repair intermittent in wiring harness. Clear DTCs. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If EOT PID reading does not fluctuate, go to next step.
13. 13) Check PCM Connector Turn ignition off. Disconnect EOT sensor connector and PCM 104-pin connector. Inspect connectors for damage and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If connect is okay, no problem is indicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1280: Low ICP Circuit Input This DTC indicates injector control signal is out of self-test range (low). Possible causes for this DTC are: Biased ICP sensor/PCM. Open ICP sensor circuit. Open VREF circuit. Shorted ICP sensor circuit. Faulty Powertrain Control Module (PCM). Disconnect ICP sensor connector. Turn ignition on. Measure voltage between ground and Brown/White wire (VREF circuit) at ICP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Brown/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Check SIG RTN Circuit Measure voltage between Brown/White wire and Gray/Red wire at ICP sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Gray/Red wire (SIG RTN circuit). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check ICP Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Dark Blue/Light Green wire at ICP wiring harness connector and test pin No. 87 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check VREF Circuit Measure resistance between Brown/White wire at ICP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check SIG RTN Circuit Measure resistance between Gray/Red wire at ICP sensor wiring harness connector and test pin No. 91 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check For Short To Ground Measure resistance between test pin No. 87 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Short Connect PCM connector to breakout box. Measure resistance between test pin No. 87 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, replace ICP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) DTC 1281: High ICP Circuit Input This DTC indicates injector control signal is out of self-test range (high). Possible causes for this DTC are: Biased ICP sensor/PCM. Shorted ICP sensor circuit. Faulty Powertrain Control Module (PCM). Disconnect ICP sensor connector. Turn ignition on. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1280 is set, replace ICP sensor. Clear DTCs, and repeat QUICK TEST. If DTC 1280 is not set, go to next step.
9. 9) Check For Short To Power Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in Light Blue/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check For Short Connect PCM connector to breakout box. Measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10 k/ohms, replace ICP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) KOEO DTC 1212: High ICP Circuit Input This DTC indicates injector control signal is more than expected. Possible causes for this DTC are: Biased ICP sensor. Shorted ICP sensor circuit. Open ICP SIG RTN circuit. Faulty Powertrain Control Module (PCM). Turn ignition off. Disconnect ICP sensor connector. Measure resistance between ground and Gray/Red wire at ICP sensor wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair short to ground in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
12. 12) Check For Short To Power Turn ignition on. Measure voltage between ground and Dark Blue/Light Green wire at ICP sensor wiring harness connector. If voltage is less than .25 volt, go to next step. If voltage is .25 volt or more, locate and repair short to power in ICP signal circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
13. 13) Check ICP Sensor Turn ignition off. Reconnect ICP sensor connector. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. If ICP PID reading indicates zero psi, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If ICP PID reading does not indicate zero psi, replace ICP sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
14. 14) Continuous Memory DTC 1212 This DTC indicates that there was no ICP signal present during cranking. Possible causes for this DTC are: Empty/low oil reservoir. Injection Pressure Regulator (IPR) circuit fault. Faulty IPR valve. Faulty ICP sensor. Faulty high pressure pump. If any KOEO DTCs are set, service DTCs as necessary before continuing with this test. If DTC 1212 is still set, go to next step. If no KOEO DTCs are set, go to next step (for a no-start), or step 19) (for vehicle starts).
15. 15) Check Oil Reservoir Level Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm), go to next step. If oil level is not within 1" (25.4 mm), check and repair cause of low fluid. Top off fluid. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If vehicle does not start, go to next step.
16. 16) Check Injection Control Pressure (ICP) Sensor Disconnect ICP sensor connector. Attempt to start vehicle. If vehicle starts, replace ICP sensor and retest. If vehicle does not start, go to next step.
17. 17) Check Oil System Pressure Perform INJECTION CONTROL PRESSURE TEST and check for pressurized oil leaks. See HARD START/NO-START DIAGNOSIS in I - SYSTEM & COMPONENT TESTS - 7.3L DIESEL article. Repair as necessary. If no leaks are found, go to next step.
18. 18) Injection Pressure Regulator Check Reconnect all hoses and ICP sensor connector. Replace IPR valve. Ensure oil reservoir level is full. Attempt to start vehicle. If vehicle starts, replacing IPR valve corrected fault. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If vehicle does not start, replace high pressure oil pump. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
19. 19) Check For Intermittent 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. If ICP PID reading fluctuates, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If ICP PID does not fluctuate, go to next step.
20. 20) Check Injection Pressure Regulator (IPR) Circuit Inspect wiring harness and connectors between IPR valve and PCM. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If wiring harness and connectors are okay, no problems are indicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
21. 21) DTC 1284 This DTC indicates ICP sensor circuit failure has occurred while performing «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-23600-S17927227932001010300000) . Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If ICP circuit fault is indicated, service DTC as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no ICP fault is indicated, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) Step 1) DTC 0221 Or 0220 This DTC indicates a malfunction has occurred in Idle Validation Switch (IVS) circuit. Possible causes for this DTC are: Faulty accelerator pedal assembly. Open circuit. Short to power in IVS circuit. Faulty Powertrain Control Module (PCM). Turn ignition off. Reconnect ICP sensor connector. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access AP and IVS PID from PID/DATA MONITOR & RECORD menu. If IVS PID reading indicates ON with accelerator pedal released, go to step 10) . If IVS PID reading does not indicate ON with accelerator pedal released, go to next step.
2. 2) Check IVS Transition Voltage Observe AP (voltage) and IVS (state) PID reading and slowly depress accelerator pedal. If IVS PID reading switches to ON at .4-1.6 volts, replace accelerator pedal assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If IVS PID does not switch to ON at .4-1.6 volts, go to next step.
3. 3) Check IVS Observe IVS PID reading and fully depress accelerator pedal. If IVS PID reading switches to ON at any time, replace accelerator pedal assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If IVS PID does not switch to ON at any time, go to next step.
4. 4) Check IVS Resistance Disconnect IVS and inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. If resistance is less than 5 ohms, go to step 8) (Econoline), or go to next step (Pickup). If resistance is 5 ohms or more, replace accelerator assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check Fuse No. 3 (3-Amp) Turn ignition on. Remove and inspect fuse No. 3 located in instrument panel fuse box. If fuse is okay, go to next step. If fuse is blown, determine cause of blown fuse and replace fuse. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check Circuit No. 16 Remove fuse No. 17 at power distribution box in engine compartment. Measure resistance between non-powered side of No. 17 fuse holder (Yellow wire) and power side of No. 3 fuse holder (Red/Light Green wire) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit between fuse holders. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check Circuit No. 276 Turn ignition off. Measure resistance of Brown wire between non-powered side of No. 3 fuse holder and IVS wiring harness connector. If resistance is less than 5 ohms, go to step 9) . If resistance is 5 ohms or more, locate and repair open circuit in Brown wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check Resistance Of Red/Light Green Wire Turn ignition off. Ensure IVS connector is disconnected. Remove fuse "U" (30-amp) from power distribution box. Measure resistance between non-power side of fuse "U" and IVS harness connector terminal (Red/Light Green wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red/Light Green wire between power distribution box and IVS. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
9. 9) Check Resistance Of Red/Orange Wire Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Red/Orange wire at IVS wiring harness connector and test pin No. 5 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, locate and repair open circuit in Red/Orange wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check For Short To Power Disconnect IVS connector. If IVS PID reading indicates OFF, replace accelerator pedal assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If IVS PID does not indicate OFF, locate and repair short to power in Red/Orange wire between PCM and IVS wiring harness connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 0261, 0264, 0267, 0270, 0273, 0276, 0279 Or 0282: Check For Short To Ground In Low Side Circuit These DTCs indicate a short to ground on low side circuit between Injector Driver Module (IDM) and injector. Identify DTC and refer to «INJECTOR DTC 0261-0282 CIRCUIT IDENTIFICATION»(ref-23600-S05232390642002011500000) table to determine which circuit to check. INJECTOR DTC 0261-0282 CIRCUIT IDENTIFICATION Cylinder No. DTC Low Circuit No. (Wire Color) 1 0261 555 (Tan) 2 0264 556 (White) 3 0267 557 (Brown/Yellow) 4 0270 558 (Brown/Light Blue) 5 0273 559 (Tan/Black) 6 0276 560 (Light Green/Orange) 7 0279 561 (Tan/Red) 8 0282 562 (Light Blue) Turn ignition off. Disconnect suspect injector connector at valve cover gasket. Measure resistance between ground and suspect circuit terminal at engine wiring harness 42-pin connector. see scheme 50 Connector is located on top of left side wheelwell. See «INJECTOR DTC 0261-0282 CIRCUIT IDENTIFICATION»(ref-23600-S05232390642002011500000) table. 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. 2) Check For Short To Ground Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between ground and suspect circuit at glow plug injector adapter. If resistance is more than 10 k/ohms, fault may be intermittent. Go to step 5). If resistance is 10 k/ohms or less, go to next step.
3. 3) Inspect Wiring Harness For Short Remove valve cover. Disconnect suspect injector connector. Inspect Under Valve Cover (UVC) wiring harness for short to ground. Replace wiring harness as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If wiring harness is okay, replace injector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
4. 4) Check For Short Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Measure resistance at IDM wiring harness connector between suspect injector circuit terminal, and all other circuits of IDM connector and to ground. If all readings are more than 10 k/ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If any reading is 10 k/ohms or less, locate and repair short between injector connector at valve cover and IDM connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
5. 5) Check For Intermittent Short To Ground Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine. Reconnect all other connectors. Connect DVOM between ground and suspect injector circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to less than 10 k/ohms at any time, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
6. 6) DTC 0262, 0265, 0268, 0271, 0274, 0277, 0280, 0283 Or 1261-1268: Check For Short To B+ Or To High Side In Low Side Circuit These DTCs indicate that low side circuit is shorted to power or high side circuit is shorted between IDM and fuel injector. Identify DTC and refer to «INJECTOR DTC & CIRCUIT IDENTIFICATION»(ref-23600-S34890388962001010300000) table to determine which circuit to check. Turn ignition on. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Disconnect suspect injector connector at valve cover gasket. Also, disconnect remaining injector connector on same cylinder bank. Measure resistance between positive battery terminal and low side circuit terminal at suspect injector connector at valve cover gasket. Also, measure resistance between positive battery terminal and high side circuit terminal at suspect injector connector at valve cover gasket connector. If both readings are less than 10 k/ohms, go to next step. If any reading is 10 k/ohms or more, locate and repair short to power in suspect circuit between IDM and injector connector at valve cover gasket. INJECTOR DTC & CIRCUIT IDENTIFICATION Cylinder No. DTC Low Side Circuit (Wire Color) High Side Circuit (Wire Color) 1 1261-0262 555 (Tan) 1087 (Orange) 2 1262-0265 556 (White) 878 (Pink/Yellow) 3 1263-0268 557 (Brown/Yellow) 1087 (Orange) 4 1264-0271 558 (Brown/Light Blue) 878 (Pink/Yellow) 5 1265-0274 559 (Tan/Black) 1087 (Orange) 6 1266-0277 560 (Light Green/Orange) 878 (Pink/Yellow) 7 1267-0280 561 (Tan/Red) 1087 (Orange) 8 1268-0283 562 (Light Blue) 878 (Pink/Yellow)
7. 7) Check For Short To Valve Cover Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 2 ohms (engine cold), go to next step. If resistance 2 ohms or more, fault may be intermittent. Go to step 10).
8. 8) Check For Short Under Valve Cover Remove valve cover. Disconnect suspect injector connector. Measure resistance of both high and low side circuits between glow plug injector adapter and suspect injector connector. If both readings are more than 10 k/ohms, replace injector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If any reading is 10 k/ohms or less, go to next step.
9. 9) Check Gasket Harness Or UVC Short Low Side To High Side Remove Under Valve Cover (UVC) wiring harness. Measure resistance between low side and high side circuits at valve cover gasket wiring harness. If resistance is less than 5 ohms, replace gasket wiring harness. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, replace UVC wiring harness. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
10. 10) Check For Intermittent Low Side Short To Power Or High Side Turn ignition off. Disconnect IDM 40-pin connector. IDM is located in left side of engine. Disconnect all 4 injector connectors at valve cover gaskets. Connect DVOM between positive battery terminal and suspect injector low side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. Repeat wiggle test for suspect injector high side circuit. If resistance changes to less than 10 k/ohms at any time, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
11. 11) DTC 1271-1278: Check For Open Between Injector High Side To Low Side At Valve Cover Connector These DTCs indicate an open in low side circuit or high side circuit between IDM and fuel injector. Identify DTC and refer to «INJECTOR DTC 1271-1278 CIRCUIT IDENTIFICATION»(ref-23600-S18584162712002011500000) table to determine which circuit to check. Turn ignition off. Disconnect suspect injector connector at valve cover gasket. Install Glow Plug Injector Adapter (014-00935) to injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 5 ohms, go to step 13). If resistance 5 ohms or more, go to next step. INJECTOR DTC 1271-1278 CIRCUIT IDENTIFICATION Cylinder No. DTC Low Side Circuit (Wire Color) High Side Circuit (Wire Color) 1 (1) 1271 555 (Tan) 1087 (Orange) 2 (2) 1272 556 (White) 878 (Pink/Yellow) 3 (1) 1273 557 (Brown/Yellow) 1087 (Orange) 4 (2) 1274 558 (Brown/Light Blue) 878 (Pink/Yellow) 5 (1) 1275 559 (Tan/Black) 1087 (Orange) 6 (2) 1276 560 (Light Green/Orange) 878 (Pink/Yellow) 7 (1) 1277 561 (Tan/Red) 1087 (Orange) 8 (2) 1278 562 (Light Blue) 878 (Pink/Yellow) (1) Right cylinder head. (2) Left cylinder head.
12. 12) Check For Open In Injector Remove valve cover. Disconnect suspect injector connector. Measure resistance of high side circuit between injector connector and glow plug injector adapter. Also, measure resistance of low side circuit between injector connector and glow plug injector adapter. If both readings are less than 5 ohms, replace injector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If any reading 5 ohms or more, go to step 23).
13. 13) Check For Open In Low Side Circuit Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance of suspect low side circuit between wiring harness side of injector connector at valve cover gasket and IDM connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in low side circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
14. 14) Check For Open In High Side Circuit Measure resistance of suspect high side circuit between wiring harness side of injector connector at valve cover gasket and IDM connector. If resistance is less than 5 ohms, fault may be intermittent. Go to next step. If resistance is 5 ohms or more, repair open in high side circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
15. 15) Check For Intermittent Open Injector Circuit Ensure IDM is disconnected. Reconnect all other connectors. Connect DVOM between suspect injector low side circuit terminal and high side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. If resistance changes to more than 5 ohms at any time, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance does not change to more than 5 ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
16. 16) DTC 1291 Or 1292: Check For Short In High Side Circuit These DTCs indicate a short to ground or short to power in low side circuit between IDM and fuel injector. Identify DTC and refer to «INJECTOR DTC 1291/1292 CIRCUIT IDENTIFICATION»(ref-23600-S31063856232002011500000) table to determine which circuit to check. Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between ground and suspect high side circuit terminal at IDM wiring harness connector. If resistance is more than 10 k/ohms, go to step 18). If resistance is 10 k/ohms or less, go to next step. INJECTOR DTC 1291/1292 CIRCUIT IDENTIFICATION DTC Circuit No. (Wire Color) Bank 1291 1087 (Orange) Right 1292 878 (Pink/Yellow) Left
17. 17) Check For Short To Ground In High Side Circuit Disconnect both injector connectors at appropriate valve cover gasket. Measure resistance between ground and suspect high side circuit terminal at IDM wiring 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 between IDM connector and injector connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
18. 18) Check For Short To Power In High Side Circuit Turn ignition on. Measure resistance between positive battery terminal and suspect high side circuit terminal at IDM wiring harness connector. Also, measure resistance between positive battery terminal and other high side circuit terminal at IDM wiring harness connector. If both readings are more than 10 k/ohms, fault may be intermittent. Go to next step. If any reading is 10 k/ohms or less, repair short to power in high side circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
19. 19) Check For Intermittent Short To Power Ensure IDM is disconnected and ignition is on. Connect DVOM between positive battery terminal and suspect injector high side circuit terminal at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at suspect injector connector and working toward IDM. Repeat wiggle test for other injector high side circuit. If resistance changes to less than 10 k/ohms at anytime, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
20. 20) DTC 1293-1294: Check For Voltage On High Side Circuit These DTCs indicate an open in high side circuit between IDM and fuel injector. Identify DTC and refer to «INJECTOR DTC 1293/1294 CIRCUIT IDENTIFICATION»(ref-23600-S04436235502002011500000) table to determine which circuit to check. Turn ignition off. Disconnect both injector connectors at appropriate valve cover gasket. Turn ignition on. Measure voltage of high side circuit between ground terminal "C" at injector connector. If battery voltage is present, go to next step. If battery voltage is not present, go to step 24). INJECTOR DTC 1293/1294 CIRCUIT IDENTIFICATION DTC Circuit No. (Wire Color) Bank 1293 878 (Pink/Yellow) Right 1294 1087 (Orange) Left
21. 21) Check Injector Resistance Turn ignition off. Install Glow Plug Injector Adapter (014-00935) to suspect injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. If resistance is less than 5 ohms, fault may be intermittent. Go to step 15). If resistance is 5 ohms or more, go to next step.
22. 22) Check For Open In Wiring Harness Remove valve cover. Disconnect suspect injector connector. Measure resistance between injector connector and exterior valve cover gasket connector. If resistance is less than 5 ohms, replace injector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance is 5 ohms or more, go to next step.
23. 23) Determine Wiring Fault Disconnect Under Valve Cover (UVC) wiring harness from connector at valve cover gasket. Measure resistance between each terminal in valve cover gasket connector. If all readings are less than 5 ohms, connector is okay. Replace UVC wiring harness. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If any reading is 5 ohms or more, an open circuit exists in connector. Replace valve gasket. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
24. 24) Check For Open In High Side Circuit Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM located on left side of engine compartment. Ensure both injector connectors disconnected at appropriate valve cover gasket. Measure resistance of suspect high side circuit between IDM harness connector and terminal "C" at both suspect injector connectors. If all readings less than 5 ohms, fault may be intermittent. Go to step 15). If any reading 5 ohms or more, locate and repair open in high side circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
25. 25) DTC 0263, 0266, 0269, 0272, 0275, 0278, 0281 Or 0284: Cylinder Non-Contributing These DTCs indicate a cylinder is not contributing equally during «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-23600-S17927227932001010300000). Possible causes for this DTC are: Broken compression rings. Faulty injector assembly. Leaking or bent valve. Bent push rod. Broken rocker arm bolts. Bent connecting rod. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and «KOEO INJECTOR ELECTRICAL SELF-TEST (BUZZ TEST)»(ref-23600-S24396087592002012200000) under QUICK TEST. Record any continuous DTCs. If any DTCs are set, service DTCs as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If no DTCs are set, go to next step. CYLINDER CONTRIBUTION DTC IDENTIFICATION DTC Cylinder No. 0263 1 0266 2 0269 3 0272 4 0275 5 0266 6 0281 7 0284 8
26. 26) Cylinder Non-Contributing Perform TANDEM FUEL PUMP PRESSURE, AIR IN FUEL SYSTEM, LOW IDLE STABILITY and CRANKCASE PRESSURE TEST in ENGINE PERFORMANCE DIAGNOSIS in I - SYSTEM/COMPONENT TESTS - 7.3L DIESEL article. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If no problems are found, check engine mechanical condition. Repair as necessary. If engine mechanical condition is okay, replace injector assembly. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
27. 27) DTC 1297: Injector High Side Circuit Short Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between both high side circuit terminals (No. 23 and 24) at IDM wiring harness connector. 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 repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
28. 28) Check For Intermittent Between High Side Circuits Turn ignition off. Connect DVOM between both high side circuit terminals (No. 23 and 34) at IDM wiring harness connector. While observing DVOM, wiggle and bend small sections of wiring harness starting at IDM connector and working toward injector connectors. If resistance changes to less than 10 k/ohms at anytime, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000). If resistance does not change to less than 10 k/ohms, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
29. 29) DTC 1295 Or 1926: Multiple Concerns These DTCs indicate that more than one fault exists on right or left cylinder bank. A short and open on both low side and high side circuits could exist. DTC 1295 & 1296 IDENTIFICATION DTC Bank 1295 Right 1296 Left Turn ignition off. Disconnect Injector Driver Module (IDM) 40-pin connector. IDM is located in left side of engine compartment. Measure resistance between ground and each injector circuit terminal at IDM wiring harness connector. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, perform the following: If low side circuit short to ground was found, go to step 1). Repair short then return to this step. If high side circuit short to ground was found, go to step 16). Repair short then return to this step.
30. 30) Check For Short To Power Turn ignition on. Measure voltage between positive battery terminal and each injector circuit terminal at IDM wiring harness connector. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, perform the following: If low side circuit short to power was found, go to step 6). Repair short then return to this step. If high side circuit short to power was found, go to step 16). Repair short then return to this step.
31. 31) Check For High Side Circuits Shorted Together Turn ignition off. Measure resistance between high side circuit terminals (No. 23 and 24) at IDM wiring harness connectors. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short between high side circuits. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).
32. 32) Check For Open Circuit Disconnect all 4 injector connectors at valve cover gaskets. Measure resistance of all injector high side circuit terminals between valve cover gasket injector connector and IDM wiring harness connector. Also, measure resistance between all low side circuit terminals between valve cover gasket injector connector and IDM wiring harness connector. If all readings are less than 10 k/ohms, go to next step. If any reading is 10 k/ohms or more, repair open in appropriate circuit.
33. 33) Check For Open Circuit Under Valve Cover Install Glow Plug Injector Adapter (014-00935) to a injector connector at valve cover gasket. Measure resistance between high side and low side circuit terminals at glow plug injector adapter. Record resistance. Using glow plug injector adapter, measure resistance between high side and low side circuit terminals at remaining valve cover gasket injector connectors. If any reading is more than 5 ohms, go to step 12). If all readings are 5 ohms or less, reconnect all connectors. Clear DTCs, and repeat «KOEO INJECTOR ELECTRICAL SELF-TEST (BUZZ TEST)»(ref-23600-S24396087592002012200000) and «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) under QUICK TEST. If DTC 1295 or 1296 resets, replace IDM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000).

1. 1) DTC 0107: BARO Circuit Low Input This DTC indicates BARO sensor circuit low input was detected during «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) or during continuous diagnostic monitoring. Possible causes for this DTC are: Biased BARO sensor/PCM. Open BARO or VREF sensor circuit. Shorted SIG RTN or PWR GND circuit. Faulty PCM. Turn ignition off. Disconnect BARO sensor connector. Sensor is located below instrument panel, at base of steering column. Turn ignition on. Measure voltage between ground and Brown/White wire at BARO sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Brown/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
2. 2) Check SIG RTN Circuit Measure voltage between Gray/Red wire and Brown/White wire at BARO sensor wiring harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check BARO Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Dark Blue/Light Green wire at BARO sensor wiring harness connector and test pin No. 38 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Dark Blue/Light Green wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check VREF Circuit Measure resistance between Brown/White wire at BARO sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Brown/White wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check SIG RTN Circuit Measure resistance between Gray/Red wire at BARO sensor wiring harness connector and test pin No. 91 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check For Grounded Signal Circuit Measure resistance between test pin No. 84 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, go to next step. If any reading is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire (BARO signal circuit). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Grounded Signal Circuit Connect PCM connector to breakout box. Measure resistance between test pin No. 84 and test pins No. 25, 51, 76, 77, 91 and 103 at breakout box. If all readings are more than 10 k/ohms, replace BARO sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) DTC 0108: BARO Circuit High Input This DTC indicates BARO sensor circuit high input was detected during «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) or during continuous diagnostic monitoring. Possible causes for this DTC are: Biased BARO sensor/PCM. BARO sensor circuit shorted to VREF circuit. Turn ignition on. Disconnect BARO sensor connector. Sensor is located below instrument panel, at base of steering column. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If DTC 0107 is present, replace BARO sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0107 is not present, go to next step.
9. 9) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 84 and test pins No. 55, 71, 90 and 97 at breakout box. If all readings are more than 10 k/ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, locate and repair short to power in Dark Blue/Light Green wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1729 Or 1781: Perform Switch Functional Check Turn ignition on. Observe 4x4L indicator and switch to and from 4x4L. If indicator light agrees with lever position, go to next step. If indicator light does not agree with lever position, go to step 4) .
2. 2) Check 4x4L Parameter Identification (PID) Ensure scan tool is connected to Data Link Connector (DLC). Using scan tool, access 4x4L PID from PID/DATA MONITOR & RECORD menu. Observe 4x4L PID reading and switch to and from 4x4L. If 4x4L PID reading agrees with lever position, go to next step. If 4x4L PID reading does not agree with lever position, go to step 11) .
3. 3) Check For Intermittent While observing 4x4L PID, wiggle and bend all wiring harness circuits for 4x4L. If 4x4L PID switched states (on/off) at any time, isolate fault and repair as necessary. Reconnect all connectors. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If 4x4L PID did not switch states, no problem is indicated at this time. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Voltage At Switch Disconnect 4x4L switch 2-pin connector. Switch is located on front of transfer case. Measure voltage between ground and Light Blue/Black wire at 4x4L switch wiring harness connector. If battery voltage is present, replace 4x4L switch. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, go to next step.
5. 5) Check Indicator Light Observe 4x4L indicator light and shift to and from 4x4L. If indicator light always stays on, locate and repair short to ground between indicator light and switch connector. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If indicator light does not always stay on, go to next step.
6. 6) Check Voltage At Fuse Measure voltage between ground and both sides of fuse No. 17 at instrument panel fuse block. If battery voltage is present at both readings, go to step 9) . If battery voltage is not present at both readings, go to next step.
7. 7) Check Power Feed To Fuse Measure voltage between ground and power side of No. 17 fuse holder (Red/Light Green wire). If battery voltage is present, go to next step. If battery voltage is not present, repair open circuit in Red/Light Green wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check For Short To Ground Ensure 4x4 lever is not in LOW position. Turn ignition off. Measure resistance between ground and non-powered side of No. 17 fuse holder (Red/Yellow wire). If resistance is more than 10 k/ohms, replace fuse. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 10 k/ohms or less, locate and repair short to ground in Red/Yellow wire.
9. 9) Check 4x4L Bulb Turn ignition off. Remove and inspect 4x4L indicator bulb. Replace bulb as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If bulb is okay, go to next step.
10. 10) Check Voltage At Indicator Bulb Turn ignition on. Shift out of 4x4 Low. Measure voltage between ground and Red/Yellow wire at indicator bulb socket. If battery voltage is present, locate and repair open circuit in Light Blue/Black wire between indicator bulb and 4x4L switch. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
11. 11) Check Light Blue/Black Wire For Continuity Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect 4x4L switch connector. Measure resistance between Light Blue/Black wire at 4x4L switch wiring harness connector and test pin No. 14 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Light Blue/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
12. 12) Check Light Blue/Black Wire For Short To Ground Measure resistance between ground and Light Blue/Black wire at 4x4L switch wiring harness connector. If resistance is less than 10 k/ohms, locate and repair short to ground in Light Blue/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 10 k/ohms or more, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) DTC 1464: A/C On During KOER Cylinder Contribution Self-Test Turn A/C heater control switch off. Repeat «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-23600-S17927227932001010300000) . If DTC 1464 is set, go to next step. If DTC 1464 not set, fault may be intermittent. Go to step 4) .
2. 2) Check A/C Power Circuit For Short Turn ignition on. Disconnect A/C clutch connector. Measure voltage between ground and Gray/White wire at A/C clutch wiring harness connector. If battery voltage is present, locate and repair short to power. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, go to next step.
3. 3) Check For Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 41 at breakout box. If battery voltage is present, locate and repair short to power. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check For Intermittent Short To Power Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Connect DVOM between ground and test pin No. 41 at breakout box. While observing DVOM, wiggle and bend small sections of wiring harness staring at A/C clutch connector and working toward PCM. If voltage is ever present, locate and repair short to power. If voltage is never present, no problem is indicated at this time.

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

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

Identifying Data Link Connector (DLC) Circuits. Scheme 329

1. 1) Verify Self-Test Method Used Verify that correct procedure was used to activate «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and «KOER SELF-TEST»(ref-23600-S20126232932001010300000) for New Generation Star (NGS) scan tool. See «QUICK TEST»(ref-23600-S06329863082001010300000) . Verify NGS tester 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»(ref-23600-S06329863082001010300000) .
2. 2) Check PCM Output Ensure battery is fully charged and is not the cause of communication error. Attempt to start engine. If engine starts, go to next step. If engine does not start, go to TEST B, step 1) .
3. 3) Check B+ At Data Link Connector (DLC) Turn ignition off. Inspect DLC for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between positive battery terminal and terminal No. 16 at DLC. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in DLC B+ circuit. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check DLC Ground Circuit Turn ignition off. Measure resistance between ground and terminal No. 4 (Black wire) at DLC. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black wire. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check PWR GND Circuit Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 5 at DLC wiring harness connector and test pins No. 51, 76, 77 and 103 at breakout box. If all readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, locate and repair open circuit in PWR GND circuit. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
6. 6) Check BUS (-) Circuit Measure resistance between terminal No. 10 (Pink/Light Blue wire) at DLC wiring harness connector and test pin No. 15 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Pink/Light Blue wire. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) Check For Short To Ground Measure resistance between ground and test pin No. 15 at breakout box. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair BUS (-) circuit for short to ground (Pink/Light Blue wire). Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
8. 8) Check For Short To Power Turn ignition on. Measure voltage between test pin No. 15 and test pins No. 51, 76, 77 or 103 at breakout box. If voltage is more than one volt, locate and repair BUS (-) circuit for short to power in (Pink/Light Blue wire). Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is one volt or less, go to next step.
9. 9) Check DLC BUS (+) Circuit Resistance Turn ignition off. Measure resistance between terminal No. 2 (Tan/Orange wire) at DLC wiring harness connector and test pin No. 16 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair BUS (+) circuit for open in (Tan/Orange wire). Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check BUS (+) Circuit For Short To Power Turn ignition on. Measure voltage between terminal No. 16 (Tan/Orange wire) at DLC wiring harness connector and test pins No. 51, 76, 77 or 103 at breakout box. If voltage is more than one volt, locate and repair BUS (+) circuit for short to power in (Tan/Orange wire). Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If voltage is one volt or less, go to next step.
11. 11) Check For BUS (-) & BUS (+) Circuits Shorted Together Turn ignition off. Measure resistance between test pins No. 15 and 16 at breakout box. If resistance is more than 10 k/ohms, replace PCM. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 10 k/ohms or less, locate and repair short between BUS (-) and BUS (+) circuits. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .

1. 1) This DTC indicates that an internal failure has occurred in PCM. Perform this test only when directed here by QUICK TEST. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0605 is set, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0605 is not set, no problem is indicated at this time.

PINPOINT TEST AH: CONTINUOUS MEMORY FAILURE

Note. Installing a breakout box or disconnecting battery terminals will interrupt Keep Alive Power (KAPWR) to PCM. DTC 0603 may be stored in continuous memory.

1. 1) DTC 0603: Check KAPWR To PCM Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Connect a DVOM between test pins No. 55 and 76 at breakout box. While observing DVOM, wiggle and bend small sections of wiring harness starting at PCM and working toward instrument panel. If DVOM reading indicates less than 10.5 volts at anytime, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If reading does not indicate less than 10.5 volts at anytime, go to next step.
2. 2) Confirm DTC 0603 Clear DTCs. Wait 10 minutes to allow DTC to reset. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If DTC 0603 is still present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0603 is not present, no problem is indicated at this time.

1. 1) This DTC indicates an internal failure of PCM. If DTC 0606 is still present after servicing all other DTCs, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 0606 is not present, no problem is indicated at this time.

1. 1) Step 1) DTC 1780: Check Parameter Identification (PID) This DTC indicates TCS was not cycled during «KOER SWITCH SELF-TEST»(ref-23600-S05518326102001010300000) . Possible causes for this DTC are: TCS failure. TCS circuitry. TCS operation omitted during KOER SWITCH SELF-TEST. Faulty Powertrain Control Module (PCM). Turn ignition on. Connect New Generation Star (NGS) scan tool. On 1995 models, access CPP PID from PID/DATA MONITOR & RECORD menu. CPP represents TCS on scan tool. On 1996 models, access TCS PID from PID/DATA MONITOR & RECORD menu. On all models, observe PID reading and cycle TCS. TCS is located on end of shift lever. If PID reading indicates OFF (12 volts) with TCS depressed and ON (zero volts) with TCS released, TCS is okay. Go to step 15) . If PID reading does not indicate OFF (12 volts) with TCS depressed and ON (zero volts) with TCS released, go to next step.
2. 2) Check PID Reading For OFF Only Ensure ignition is on. Cycle TCS. If PID reading indicates OFF only, go to next step. If PID reading does not indicate OFF only, go to step 5) .
3. 3) Check For TCS Failed Closed Ensure ignition is on. Disconnect TCS connector. If PID reading does not indicate ON only, go to next step. If PID reading indicates ON only, replace TCS/TCIL. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Tan/White Wire For Short To Battery Power Turn ignition off. Disconnect PCM 104-pin connector. Turn ignition on. Measure voltage between ground and Tan/White wire at TCS wiring harness connector. If battery voltage is present, locate and repair short to power in Tan/White wire. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 12) .
5. 5) Check CPP PID For Open If PID reading indicates ON only, go to next step. If PID reading does not indicate ON only, fault may be intermittent. Go to step 13) .
6. 6) Check Fuse On Econoline, remove and inspect fuse No. 18 (15-amp) located in instrument panel fuse block. On Pickup, remove and inspect fuse No. 17 (10-amp) located in instrument panel fuse block. On all models, if fuse is blown, go to next step. If fuse okay, go to step 9) .
7. 7) Check For Short To Ground Disconnect TCS connector. Measure resistance between ground and Red/Yellow wire at TCS wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, go to next step.
8. 8) Check Tan/White Wire For Short To Ground Disconnect PCM 104-pin connector. Turn ignition on. Measure resistance between ground and Tan/White wire at TCS wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Tan/White wire. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is 5 ohms or more, inspect for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 12) .
9. 9) Check For Open Circuit Remove fuse No. 17 from instrument panel fuse block. Disconnect TCS connector. Turn ignition on. Measure voltage of Red/Yellow wire between non-powered side of fuse No. 18 (Econoline), or fuse No. 17 (Pickup) holder and TCS wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit between fuse holder and TCS connector. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
10. 10) Check TCS Connect a jumper wire between Tan/White wire and Red/Yellow wire at TCS wiring harness connector. Using scan tool, access CPP PID (1995 models) or TCS PID (1996 models) from PID/DATA MONITOR & RECORD menu. If PID reading indicates OFF, replace TCS/TCIL. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If PID reading does not indicated OFF, go to next step.
11. 11) Check Tan/White Wire For Open Turn ignition off. Ensure TCS is disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between Tan/White wire at TCS wiring harness connector and test pin No. 29 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Tan/White wire. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
12. 12) Confirm PCM Fault Turn ignition on. Using scan tool, access CPP PID (1995 models) or TCS PID (1996 models) from PID/DATA MONITOR & RECORD menu. If PID reading switches ON and OFF, no problem is indicated at this time. If PID reading does not switch ON and OFF, replace PCM. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
13. 13) Check For Intermittent Open Or Short Circuit Ensure jumper wire is connected between Red/Yellow wire at TCS wiring harness connector. Using scan tool, access CPP PID (1995 models) or TCS PID (1996 models) from PID/DATA MONITOR & RECORD menu. PID reading should indicate OFF. While observing PID, wiggle and bend small sections of wiring harness starting at TCS connector and working toward PCM. If a fault occurs, PID reading will switch between OFF and ON. If fault occurs, locate and repair intermittent in wiring harness. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault occurs, go to next step.
14. 14) Check For Intermittent Short To Power Remove fuse No. 17 from instrument panel fuse block. Ensure jumper wire is connected between Tan/White wire and Red/Yellow wire at TCS wiring harness connector. Using scan tool, access CPP PID (1995 models) or TCS PID (1996 models) from PID/DATA MONITOR & RECORD menu. PID reading should indicate ON. While observing PID, wiggle and bend small sections of wiring harness starting at TCS connector and working toward PCM. If a fault occurs, PID reading will switch to OFF. If fault occurs, locate and repair intermittent in wiring harness. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault occurs, no problem indicated at this time. Confirm repair using scan tool and monitoring CPP or TCS PID from PID/DATA MONITOR & RECORD menu while operating TCS switch. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
15. 15) DTC 1779: Check Transmission Control Indicator Light (TCIL) This DTC indicates PCM has detected a TCIL circuit malfunction. Turn ignition on. Cycle Transmission Control Switch (TCS) several times. If TCIL turns off and on, no problem is indicated at this time. If TCIL does not turn off and on, go to next step.
16. 16) Check Circuit No. 911 For Short To Power Disconnect TCS connector. Measure voltage between ground and White/Light Green wire at TCS wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, go to step 18) .
17. 17) Check PCM For Short To Power Disconnect PCM 104-pin connector. Measure voltage between ground and White/Light Green wire at TCS wiring harness connector. If battery voltage is present, locate and repair short to power in White/Light Green wire. Recheck TCIL operation. If battery voltage is not present, inspect PCM connector for damaged pins, corrosion and loose wires. Repair as necessary. Reconnect all connectors and go to step 21) .
18. 18) Check For Fault Disconnect TCS connector. Turn ignition on. Connect DVOM between ground and White/Light Green wire at TCS wiring harness connector. Using New Generation Star (NGS) tester, perform Output State Test. See «ADDITIONAL SYSTEM FUNCTIONS»(ref-23600-S31745820652001010300000) . If voltage does not toggle between 12 volts and zero volts, go to next step. If voltage toggles between 12 volts and zero volts, replace TCS/TCIL. Recheck TCIL operation.
19. 19) Check White/Light Green Wire For Short To Ground Turn ignition off. Disconnect PCM 104-pin wiring harness connector. Turn ignition on. Measure resistance between ground and White/Light Green wire at TCS wiring 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 White/Light Green wire. Recheck TCIL operation.
20. 20) Check White/Light Green Wire For Open Circuit Turn ignition off. Inspect PCM 104-pin connector for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between White/Light Green wire at TCS wiring harness connector and test pin No. 79 at breakout box. If resistance is less than 5 ohms, reconnect all connectors and go to next step. If resistance is 5 ohms or more, locate and repair open circuit in White/Light Green wire. Recheck TCIL operation.
21. 21) Confirm PCM Fault Turn ignition on. Cycle TCS switch several times. If TCIL turns OFF and ON, no problem is indicated at this time. If TCIL does not turn OFF and ON, replace PCM. Recheck TCIL operation.

1. 1) Perform KOEO Output State Self-Test: Check Transmission Electrical Operation DTC 0741, 0750, 0755, 1746, 1747, 1748 Or 1754 indicates electrical malfunction. Possible causes for this DTC are: Faulty solenoid assembly. VPWR circuit open or shorted to ground. Solenoid circuit open, or shorted to VPWR or GND. Faulty Powertrain Control Module (PCM). Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950). Connect PCM to breakout box. Turn ignition on. Reconnect PCM connector. Using New Generation Star (NGS) scan tool, perform «KOEO OUTPUT STATE SELF-TEST»(ref-23600-S11835786072002012200000) under QUICK TEST. Using DVOM measure voltage between ground and appropriate solenoid signal test pin at breakout box. See «TRANSMISSION & PCM SOLENOID SIGNAL TERMINAL IDENTIFICATION»(ref-23600-S29685858152002012800000) table. Cycle solenoid output on and off by depressing and releasing throttle. If voltage output changes by 0.5 volt or more, diagnose solenoids. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. If voltage output does not change by 0.5 volt or more, go to next step.
2. 2) Perform KOEO Output State Self-Test: Check Solenoid Electrical Operation DTC 1746 indicates EPC circuit open. DTC 1747 indicates EPC circuit shorted. DTC 1748 indicates EPC malfunction. Turn ignition off. Disconnect transmission wiring harness connector. Inspect terminals and repair if damaged. Reconnect connector. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950). Connect PCM to breakout box. Measure voltage between ground and test pin No. 81 at breakout box. If voltage is 8.5-9.5 volts, diagnose solenoids. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. If voltage is not 8.5-9.5 volts, go to next step.
3. 3) Check Solenoid & VPWR Circuit Continuity Turn ignition off. Disconnect transmission wiring harness connector. Disconnect PCM power relay. Relay is located in power distribution box in engine compartment. Measure resistance of Red wire between terminals No. 1 and 12 at transmission wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Red wire (circuit No. 361). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check Solenoid Signal & VPWR Circuit Continuity Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between suspect solenoid signal wire at transmission harness connector and same suspect test pin at breakout box. See «TRANSMISSION & PCM SOLENOID SIGNAL TERMINAL IDENTIFICATION»(ref-23600-S29685858152002012800000) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Check Solenoid Circuit For Short To Power Or Ground Leave ignition off and PCM disconnected. Leave transmission wiring harness connector disconnected. Measure resistance between test pins No. 71 or 97 and suspect solenoid test pin at breakout box. See «TRANSMISSION & PCM SOLENOID SIGNAL TERMINAL IDENTIFICATION»(ref-23600-S29685858152002012800000) table. Also, measure resistance between suspect solenoid test pin and test pins No. 25, 51, 77, 91 and 103 at breakout box. If any reading is less than 10 k/ohms, repair short circuit and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If all readings are 10 k/ohms or more, go to next step.
6. 6) Check Suspect Solenoid Reconnect transmission connector. Turn ignition on. Measure voltage between ground and suspect solenoid test pin at breakout box. If battery voltage is present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If battery voltage is not present, service solenoid. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS.

1. 1) DTC 0705, 0707, 0708, 1705 Or 1706: Check TR Sensor Alignment DTC 0705 indicates TR circuit malfunction. DTC 0707 indicates TR sensor is shorted to ground. DTC 0708 indicates an open in TR sensor circuit. DTC 1705 indicates TR sensor was not in Park during «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . DTC 1706 indicates high vehicle speed in Park. Possible causes for these faults are: Linkage not adjusted correctly. Transmission not in Park during SELF-TEST. Faulty TR sensor. Circuit open or grounded. Faulty Powertrain Control Module (PCM). Turn ignition off. Apply parking brake. Place transmission gear selector in Neutral. Place TR Sensor Gauge (T92P-70010-AH) in sensor slot. If gauge does not fit, loosen TR sensor mounting bolts and adjust sensor as necessary. If gauge fits, remove gauge and go to next step.
2. 2) Check TR Parameter Identification (PID) Turn ignition off. Apply brake. Using New Generation Star (NGS) scan tool, access TR PID from PID/DATA MONITOR & RECORD menu. Turn ignition on. Move shift lever through all gear ranges. If each gear does not register properly on scan tool, go to next step. If each gear registers properly on scan tool, go to step 6) .
3. 3) Check TR Sensor Circuit Continuity Turn ignition off. Disconnect TR sensor wiring harness connector. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between Light Blue wire at TR sensor wiring harness connector and test pin No. 64 at breakout box. Also, measure resistance between Gray/Red wire at TR sensor wiring harness connector and test pin No. 91 at breakout box. If all readings are less than 5 ohms, go to next step. If any reading is 5 ohms or more, locate and repair open circuit. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check TR Sensor Circuit For Short To Power & Ground Turn ignition off. Leave PCM and TR sensor disconnected. Measure resistance between test pin No. 64 and test pin No. 71 or 97 at breakout box. Also, measure resistance between test pin No. 64 and test pin No. 76, 77 or 91 at breakout box. If any reading is less than 10 k/ohms, repair short circuit and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If all readings are 10 k/ohms or more, go to next step.
5. 5) Check TR Sensor Resistance Turn ignition off. Connect TR sensor. Leave PCM disconnected. Unlock steering column. Measure resistance between test pins No. 64 and 91 at breakout box while cycling gear selector. See the «TR SENSOR SPECIFICATIONS»(ref-23600-S34490061182002011500000) table. If resistance is as specified, replace PCM and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is not as specified, replace TR sensor and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . TR SENSOR SPECIFICATIONS Gear Selected Resistance Voltage Park 3770-4607 4.23-4.68 Reverse 1304-1593 3.52-3.89 Neutral 660-807 2.80-3.10 Overdrive 361-442 2.09-2.31 Second 190-232 1.39-1.53 First 178-95 .68-.76
6. 6) Retest PCM Clear DTCs. Repeat «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) and check for continuous DTCs. If DTC 0705, 0707, 0708 or 1705 is present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTCs are not present, go to next step.
7. 7) Check For Intermittent Turn ignition on. Using New Generation Star (NGS) scan tool, access TRV PID from PID/DATA MONITOR & RECORD menu. While observing TRV PID, wiggle and bend small sections of wiring harness starting at TR sensor connector and working toward PCM. If PID value changes at anytime, isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If PID value does not change, no problem is indicated at this time.

1. 1) KOEO & KOER DTC 0712 This DTC indicates TFT sensor is out of self-test range. Possible causes for this DTC are: Transmission fluid level incorrect. Faulty TFT sensor. Shorted TFT sensor circuit. Faulty Powertrain Control Module (PCM). Turn ignition on. Disconnect transmission 12-pin Gray connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. If PID reading is more than 4.6 volts, replace TFT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If PID reading is 4.6 volts or less, go to next step.
2. 2) Check TFT Sensor Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between test pin No. 37 and test pins No. 25, 51, 76, 77 and 103 at breakout box. If all readings are more than 10 k/ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 10 k/ohms or less, go to next step.
3. 3) KOEO & KOER DTC 0713 This DTC indicates TFT sensor output exceeds self-test maximum voltage. Possible causes for this DTC are: Transmission fluid level incorrect. Open or shorted wiring harness circuit. Faulty TFT sensor. Faulty PCM. Turn ignition off. Disconnect transmission 12-pin Gray connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. If PID reading is 5 volts or more, locate and repair short to power in Orange/Black wire (circuit No. 932) between transmission connector and PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If PID reading is less than 5 volts, go to next step.
4. 4) Check SIG RTN Circuit Measure resistance between ground and Gray/Red wire at transmission connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
5. 5) Induce Opposite Failure Connect a jumper wire between terminals No. 7 (Orange/Black wire) and No. 8 (Gray/Red wire) at transmission wiring harness connector. If TFT PID reading is zero volts, replace TFT sensor. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If TFT PID is not zero volts, go to next step.
6. 6) Check TFT Signal Circuit Continuity Turn ignition off. Leave transmission connector disconnected. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 7 (Orange/Black wire) at transmission wiring harness connector and test pin No. 37 at breakout box. If resistance is 5 ohms or more, repair open circuit in Orange/Black wire. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
7. 7) KOEO & KOER DTC 1711: Increase/Decrease Transmission Fluid Temperature This DTC indicates TFT sensor is out of self-test range. Possible causes for this DTC are: Transmission fluid level incorrect. Fluid not at operating temperature Faulty TFT sensor. Shorted TFT sensor circuit. Faulty Powertrain Control Module (PCM). Clear DTCs. Road test vehicle to bring transmission fluid up to normal operating temperature. Repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1711 is still present, go to next step. If DTC 1711 is not present, transmission fluid was not at operating temperature. Testing is complete.
8. 8) Check Circuit Voltage Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. If PID reading is .2-4 volts, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If PID reading is not .2-4 volts, replace TFT sensor. If DTC 0172 is also set with DTC 1711, go to step 1) . If DTC 0713 is also set with DTC 1711, go to step 3) .
9. 9) Continuous Memory DTC 0712: Verify TFT SIG Voltage This DTC indicates TFT sensor circuit input voltage was less than acceptable during normal vehicle operation. Possible causes for these faults are: Transmission fluid level incorrect. Faulty TFT sensor. Shorted TFT sensor circuit. Faulty Powertrain Control Module (PCM). Turn ignition on. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. If PID reading is less than .5 volt, go to step 1) . If PID reading is .5 volt or more, go to next step.
10. 10) Check Wiring Harness Turn ignition on. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. While observing TFT PID, wiggle and bend small sections of wiring harness starting at transmission connector and working toward PCM. If fault is indicated (voltage fluctuates), isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is found, no problem is indicated at this time.
11. 11) Continuous Memory DTC 0713: Verify TFT SIG Voltage This DTC indicates TFT sensor circuit input voltage was more than acceptable during normal vehicle operation. Possible causes for these faults are: Transmission fluid level incorrect. Fluid not at operating temperature. Faulty TFT sensor. Shorted TFT sensor circuit. Faulty Powertrain Control Module (PCM). Turn ignition on. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. If PID reading is more than 4.8 volts, go to step 3) . If PID reading is 4.8 volts or less, go to next step.
12. 12) Check Wiring Harness Turn ignition on. Using New Generation Star (NGS) scan tool, access TFT PID from PID/DATA MONITOR & RECORD menu. While observing TFT PID, wiggle and bend small sections of wiring harness starting at transmission connector and working toward PCM. If fault is indicated (voltage fluctuates), isolate fault and repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If no fault is found, no problem is indicated at this time.
13. 13) Continuous Memory DTC 1783: Rerun KOEO Self-Test This DTC indicates a transmission overtemperature condition has occurred. Possible causes for these faults are: Faulty transmission cooling system. Excessive loading (trailer towing etc.). Faulty clutch. Incorrect transmission fluid level. Faulty transmission connector. Turn ignition off. Disconnect transmission 12-pin Gray connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any other transmission related DTCs are present, service DTCs as necessary. If no other transmission related DTCs are present, and DTC 1783 repeats, failure is caused by a transmission overtemperature condition. Check clutch, transmission fluid level and transmission cooling system. Repair as necessary.

1. 1) Verify Operation Procedure Verify vehicle has a 1995 or later calibration. Refer to auxiliary powertrain control manual provided with system to verify correct operation procedures and entry conditions. If entry conditions are met and correct calibration installed, go to next step. If entry conditions are not met or correct calibration is not installed, correct operation procedure or calibration level as necessary. Retest system. If system still does not operate. Go to next step.
2. 2) Check For DTCs If vehicle is equipped with pre-1995 calibration, New Generation Star (NGS) tester cannot be used to perform self-test. Update calibration and retest. If still unable to perform self-test, go to TEST AF, step 1) . Ensure auxiliary powertrain control system is off. Using NGS tester, perform KOEO and «KOER SELF-TEST»(ref-23600-S20126232932001010300000) . If any DTCs are present, service DTCs as necessary. If no DTCs are present, go to next step.
3. 3) Check KEY PWR Voltage Disconnect APCM connector. Connector is located center of instrument panel. Turn ignition on. Measure voltage between ground and terminal No. 2 at APCM wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in KEY PWR circuit.
4. 4) Check Ground Circuit Turn ignition off. Measure resistance between ground and terminal No. 1 (Black wire) at APCM wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Black wire.
5. 5) Check For Open In BUS (-) Circuit Measure resistance of Pink/Light Blue wire between terminal No. 2 at APCM wiring harness connector and Data Link Connector (DLC). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in BUS (-) circuit.
6. 6) Check For Open In BUS (+) Circuit Measure resistance of Tan/Orange wire between terminal No. 4 at APCM wiring harness connector and Data Link Connector (DLC). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in BUS (+) circuit.
7. 7) APCM Inoperative With Hazard Flashers Turn ignition off. Depress brake pedal. If hi-mount brakelight is illuminated, go to TEST K, step 1) . If hi-mount brakelight is off, go to next step.
8. 8) Check Hi-Mount Brakelight Remove and inspect hi-mount brakelight bulb. Replace bulb as necessary and retest system operation. If bulb is okay, go to next step.
9. 9) Check Ground Circuit Measure resistance of Black wire between ground and hi-mount brakelight bulb socket. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and open in ground circuit.
10. 10) Check For Power To Bulb Turn ignition off. Depress brake pedal. Measure voltage between ground and Dark Green wire at hi-mount brakelight bulb socket. If battery voltage is present, check for loose connection in bulb socket. Repair as necessary. If battery voltage is not present, repair open circuit.
11. 11) Econoline Cutaway Only: APCM Inoperative With Hazard Flashers Turn ignition off. Disconnect brake resistor, located on left "B" pillar. Measure resistance of Black wire between resistor harness connector and chassis ground. If resistance is less than 5.0 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black wire.
12. 12) Check Power To Resistor Apply brake pedal. Connect a test light between ground and Light Green wire at resistor harness connector. If test light is illuminated, go to next step. If test light is off, locate and repair open circuit in Light Green wire.
13. 13) Check Resistor Measure resistance between resistor terminals. If resistance is 260-280 ohms, reconnect resistor and go to TEST K, step 1) . If resistance is not 260-280 ohms, replace resistor. Recheck system operation.

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

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

Identifying Tachometer Circuit. Scheme 330

1. 1) Check Fuse Remove and inspect fuse No. 17 in instrument panel fuse block. If fuse is blown, locate and repair short to ground in Red/Yellow wire (circuit No. 640). Replace fuse. If fuse is okay, go to next step.
2. 2) Check Ground Circuit Turn ignition off. Disconnect instrument cluster Black 14-pin connector and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Measure resistance between ground and terminal No. 3 at instrument cluster wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in ground circuit (Black wire).
3. 3) Check Power To Tachometer Turn ignition on. Measure voltage between ground and terminal No. 13 (Red/Light Green wire) at instrument cluster wiring harness connector. If battery voltage is present, go to next step. If battery voltage is not present, locate and repair open in Red/Light Green wire.
4. 4) Check Signal Circuit Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Connect a jumper wire between terminal No. 3 (Black wire) at instrument cluster wiring harness connector and COM port at NGS tester. Connect another jumper wire between terminal No. 9 (White/Pink wire) at instrument cluster wiring harness connector and SIG port at NGS tester. Start engine. Using NGS tester, perform the following: Select VEHICLE and ENGINE. Select DIGITAL MEASUREMENT SYSTEM. Select FREQUENCY METER. Change level to 4-volt DC. Press LINK button to select a PID. Select PID/DATA MONITOR. Select RPM PID. Press START. Observe PID reading at specified engine RPM. See «RPM PID FREQUENCY SPECIFICATIONS»(ref-23600-S22762709572002011500000) table. If frequency is as specified, inspect instrument cluster printed circuit board for damage or open circuits. Repair as necessary. If printed circuit board is okay, replace tachometer. If frequency is not as specified, go to next step. RPM PID FREQUENCY SPECIFICATIONS RPM Hz 650 119-139 1500 290-310 3000 590-610
5. 5) Check For Open In TACH Signal Circuit Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure resistance between terminal No. 9 (White/Pink wire) at instrument cluster wiring harness connector and test pin No. 50 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in White/Pink wire.
6. 6) Check For Short To Ground Measure resistance between ground and test pin No. 50 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 White/Pink wire.
7. 7) Check For Short To Power Turn ignition on. Measure voltage between ground and test pin No. 50 at breakout box. If battery voltage is present, locate and repair short to power in White/Pink wire. If battery voltage is not present, replace PCM.

1. 1) DTC 1660 This DTC indicates that output circuit check is high. Possible causes for this DTC are: High system voltage. VREF circuit fault. Faulty Powertrain Control Module (PCM). Perform charging system and battery tests. See appropriate STARTING & CHARGING SYSTEMS article in ACCESSORIES & EQUIPMENT. Repair as necessary. If charging system is okay, go to next step.
2. 2) Check VREF Circuit Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Measure voltage between ground and test pin No. 90 at breakout box. If voltage is less than .25 volt, go to next step. If voltage is .25 volt or more, locate and repair short to power in VREF circuit (Brown/White wire). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check PCM Reconnect PCM connector. Perform «KOEO SELF-TEST»(ref-23600-S10365652382001010300000) . If DTC 1660 is still present, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If DTC 1660 is not present, no problem is indicated at this time.

PINPOINT TEST AS: OUTPUT CIRCUIT CHECK LOW

1. 1) DTC 1661 This DTC indicates that output circuit check is low. self-test range. Possible causes for this DTC are: Low battery voltage. VREF circuit fault. Faulty Powertrain Control Module (PCM). Perform charging system and battery tests. See appropriate STARTING & CHARGING SYSTEMS article in ACCESSORIES & EQUIPMENT. Repair as necessary. If charging system is okay, go to next step.
2. 2) Check VREF Circuit Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Disconnect Manifold Absolute Pressure (MAP) sensor connector. Measure resistance between Brown/White wire at MAP sensor wiring harness connector and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair VREF circuit (Brown/White wire). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
3. 3) Check VREF Circuit Turn ignition on. Measure resistance between test pins No. 71 and 97 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair VREF circuit (Brown/White wire). Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) .
4. 4) Check PCM Turn ignition off. Measure resistance between ground and test pins No. 25, 51, 76, 77 and 103 at breakout box. If all readings are less than 5 ohms, replace PCM. Clear DTCs, and repeat «QUICK TEST»(ref-23600-S06329863082001010300000) . If any reading is 5 ohms or more, fault exists in PWR GND circuit. Go to TEST A, step 10) to check PWR GND circuit.

1995 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (1 Of 3). Scheme 331

1995 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (2 Of 3). Scheme 332

1995 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (3 Of 3). Scheme 333

1995 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (1 Of 3). Scheme 334

1995 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (2 Of 3). Scheme 335

1995 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (3 Of 3). Scheme 336

1996 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (1 Of 3). Scheme 337

1996 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (2 Of 3). Scheme 338

1996 Econoline 7.3L Turbo Diesel PCM Wiring Diagram (3 Of 3). Scheme 339

1996 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (1 Of 3). Scheme 340

1996 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (2 Of 3). Scheme 341

1996 Pickup 7.3L Turbo Diesel PCM Wiring Diagram (3 Of 3). Scheme 342