Engine Controls - Tests W/codes - 7.5L Eec-Iv: Other Ford Pickup F350

KOEO & KOER Codes (Hard Faults)

These codes indicate faults are present at time of testing. A hard fault may cause Malfunction Indicator Light (MIL) to go on and remain on until fault is repaired. If KOEO or KOER codes are retrieved during KOEO SELF-TEST or KOER SELF-TEST, use DIAGNOSTIC TROUBLE CODE REFERENCE CHART to find correct testing and repair procedures to be performed.

Continuous Memory Codes (Soft Faults)

These codes indicate a fault that may or may not be present at time of testing. These codes are used to diagnose intermittent problems. Continuous Memory Codes are retrieved after KOEO SELF-TEST . Some codes may turn on Malfunction Indicator Light (MIL). Corresponding soft fault trouble code will be retained in PCM memory. If fault does not reoccur within 40 warm-up cycles (80 cycles on some models), PCM will automatically clear code, or technician may clear codes from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problem. See INTERMITTENTS in the TESTS W/O CODES - 7.5L EEC-IV article.

RETRIEVING CODES

Diagnostic trouble codes are retrieved from EEC-IV system through Data Link Connector (DLC). Various methods and test equipment may be used to access these codes

1. Analog Volt-Ohmmeter (VOM).
2. Scan tester.
3. Malfunction Indicator Light (MIL) light.
4. STAR series Tester.

DATA LINK CONNECTOR (DLC) LOCATIONS

Separator Code

Single 1/2-second separator pulse is issued 6-9 seconds after last KOEO code. Continuous Memory Codes (intermittent faults) are then displayed 6-9 seconds after 1/2-second separator code. (Scheme 385) Some digital test equipment may display separator code as "10" instead of "1".

Pass Codes

A Code 111 indicates no diagnostic trouble codes were recorded in that portion of test; system passes that portion of test. If Code 111 is not retrieved in KOEO SELF-TEST , codes retrieved during KOER SELF-TEST may not be valid. Code 111 (pass code) must be obtained in KOEO SELF-TEST. A Code 111-1-111 output during KOEO SELF-TEST indicates no KOEO code or Continuous Memory Code was recorded.

Continuous Memory Codes

Continuous Memory Codes are displayed after separator pulse code in KOEO SELF-TEST . These codes result from information stored by PCM during continuous self-test monitoring. These codes indicate faults recorded within last 40 engine starts (80 engine starts on some models). Fault may or may not be currently present. See the DIAGNOSTIC TROUBLE CODE DEFINITION CHARTS . Use these codes for diagnosis only when KOEO SELF-TEST and KOER SELF-TEST result in Code 111.

Fast Codes

At start of KOEO SELF-TEST and after Wide Open Throttle (WOT) request in KOER SELF-TEST , PCM outputs short bursts of information, known as FAST CODES, which were used by manufacturer during assembly. These codes contain the identical information as slow codes, but are transmitted at 100 times the normal rate. With most equipment (except Super Star II tester), these code bursts are not visible. An entire code sequence lasts less than 1/2second.

Scheme 384

Scheme 385

CLEARING CODES

To clear codes from PCM memory, start KOEO SELF-TEST . When diagnostic trouble codes appear on test equipment or Malfunction Indicator Light (MIL), disconnect jumper wire from Self-Test Input (STI) connector. If using STAR series tester, unlatch center button. This procedure erases Continuous Memory Codes from PCM memory. If problem has not been corrected or fault is still present, hard code will immediately be reset in PCM memory.

VISUAL CHECK

Complete all steps in BASIC TESTING - 7.5L article before proceeding to self-diagnostic tests. Inspect air cleaner and inlet ducting. Check coolant for proper level and mixture. Check transmission level and quality. Ensure all vacuum hoses and EEC-IV wiring harnesses are properly connected.

VEHICLE PREPARATION & EQUIPMENT HOOKUP

Apply parking brake, and place shift lever in Park (A/T) or Neutral (M/T) position. Block drive wheels. Turn off all electrical accessories. Connect appropriate test equipment to vehicle as follows

Scheme 386

1. Step 1) Turn ignition off. Set VOM at 0-15V DC range. Connect positive lead of VOM to positive battery terminal.
2. Step 2) Connect negative VOM lead to Self-Test Output (STO) terminal of Data Link Connector (DLC). (Scheme 386) Go to KOEO SELF-TEST. Activate «KOEO SELF-TEST»(ref-23602-S20745302252001010300000) by connecting jumper wire from Self-Test Input (STI) pigtail to signal return (SIG RTN) terminal at DLC with ignition on.

Scan Tester

Follow manufacturer's instructions to hook up equipment. Record diagnostic trouble codes.

STAR Series Tester

Turn ignition off. Connect color-coded adapter cable leads to diagnostic tester. Connect 2 service connectors of adapter cable to vehicle Data Link Connector (DLC) and STI pigtail connector. If using Super STAR II tester, select EEC-IV and Fast modes. On all models, go to KOEO SELF-TEST .

Malfunction Indicator Light (MIL)

Turn ignition on. Connect a jumper wire between Self-Test Input (STI) pigtail and signal return (SIG RTN) terminal of Data Link Connector (DLC). (Scheme 387) Go to KOEO SELF-TEST.

Scheme 387

ADDITIONAL SYSTEM FUNCTIONS

Additional diagnostic system features are available to help diagnose driveability problems and service EEC-IV systems.

MIL is intended to alert driver of certain malfunctions in EEC-IV system. Light may also be used to retrieve diagnostic trouble codes stored in PCM. When hooked up for KOEO SELF-TEST or KOER SELF-TEST, light will display all codes which turn on light during vehicle operation.

Light should come on when ignition is turned on and go out when engine is started. If light comes on and then goes off during vehicle operation, code causing light to come on will be stored in PCM memory as a Continuous Memory Code. If light comes on during vehicle operation, vehicle should be inspected as soon as possible. Immediately turning off engine is not necessary; vehicle can be driven with light on.

Failure Mode Effects Management (FMEM) Code 998

FMEM mode allows system operation when sensors fail or transmit signals that are out of normal operating range. During FMEM mode, PCM substitutes a mid-range signal for defective sensor while continuing to monitor sensor. If faulty sensor's signals return to normal operating range, PCM will use those signals. A Code 998 will be displayed when FMEM mode is in effect.

SUMMARY

If no diagnostic trouble code is present but driveability problem still exists, go to TESTS W/O CODES - 7.5L EEC-IV article for diagnosis by symptom or intermittent diagnostic procedures.

Scheme 388

Scheme 389

Scheme 390

CIRCUIT TESTS

Note. A breakout box, connected to vehicle harness at PCM, is necessary to perform most circuit tests. References to Test Pin No. found in CIRCUIT TEST steps refer to test terminals on manufacturer breakout box overlay. Circuit diagrams at beginning of each test identify circuit and wire colors.

HOW TO USE CIRCUIT TESTS

1. Step 1) Ensure all non-EEC-IV related faults found while performing steps in the «BASIC TESTING - 7.5L»(ref-23716) article have been corrected. Follow each test step in order until fault is found. When more than one code is retrieved, start with first code displayed.
2. Step 2) CIRCUIT TESTS ensure electrical circuits are okay before sensors or other components are replaced. Always test circuits for continuity between sensor and PCM. Test all circuits for short to power, open or short to ground. Voltage Reference (VREF) and Voltage Power (VPWR) circuits should be tested with ignition on unless otherwise specified in CIRCUIT TESTS.
3. Step 3) DO NOT measure voltage or resistance at PCM. DO NOT connect any test light unless specified in testing procedure. All measurements are made by probing rear of connector. Turn ignition off and isolate both ends of a circuit and turn ignition off when checking continuity.
4. Step 4) Disconnect solenoids and switches from harness before measuring continuity and resistance or applying voltage. After each repair, reconnect all component connections and repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
5. Step 5) An open circuit is defined as a resistance reading of greater than 5 ohms. This specification tolerance may be too high for some items in EEC-IV system. If resistance approaches 5 ohms, always clean suspect connector and coat it with protective dielectric silicone grease. A short to ground is defined as a resistance reading of less than 10,000 ohms, unless stated otherwise in CIRCUIT TEST. NOTE: In the following tests, circuit diagrams and illustrations are courtesy of Ford Motor Co. CIRCUIT TESTS are grouped as follows. AA-C - No Start & Voltage Tests DA-DS - Input Sensor Tests FD - Additional Input Component Tests H-J - Fuel Control Systems KC-TG - PCM Output Tests

Continuous Memory Codes 179, 182, 188 & 191

These codes identify a rich fuel condition resulting in adaptive fuel strategy leaning fuel system to compensate.

Possible causes for these codes are

1. Incorrect fuel pressure.
2. Faulty fuel injector or circuit.
3. Leaking or restricted air intake.
4. Faulty MAP sensor.
5. Restricted air or fuel filter.

If other codes are present, repair as necessary. If no other codes are present, go to next step.

1. Step 2) Check Fuel Pressure Release fuel system pressure. With ignition off, install fuel pressure gauge. Ensure manifold vacuum is connected to fuel pressure regulator. Start engine and allow to idle. If fuel system pressure is not within specification, repair as necessary. See FUEL SYSTEM in the «SYSTEM/COMPONENT TESTS - 7.5L EEC-IV»(ref-23717) article. If fuel system pressure is within specification, go to next step.
2. Step 3) Check System Ability To Hold Fuel Pressure With fuel pressure gauge installed, cycle ignition off and on 3-4 times to pressurize fuel system ( DO NOT start engine). If fuel pressure remains at specification for 60 seconds, go to next step. If fuel pressure does not remain at specification for 60 seconds, repair fuel system as necessary. See FUEL SYSTEM in the «SYSTEM/COMPONENT TESTS - 7.5L EEC-IV»(ref-23717) article.
3. Step 4) Check MAP Frequency Turn ignition off. Connect MAP tester to MAP sensor. see scheme 14in CIRCUIT TEST DF. Turn ignition on. If MAP voltage is within specification, go to next step. See «MAP SENSOR VOLTAGE OUTPUT»(ref-23602-S33967405742001010300000) table. If voltage is not within specification, check wiring to MAP sensor for corrosion and other damage. Repair as necessary. Clear KAM, and repeat «QUICK TEST»(ref-23602-S41551070932001010300000). If wiring is okay, replace MAP sensor. Clear KAM, and repeat QUICK TEST.
4. Step 5) Cylinder Balance Test Connect a tachometer to engine. Start engine, and run at idle. Disconnect and reconnect injectors individually, noting RPM drop as each injector is disconnected. IAC motor will attempt to re-establish RPM. If each injector produces a momentary drop in RPM, original fault is in ignition system. If each injector does not produce a momentary drop in RPM, go to next step.
5. Step 6) Check Injector & Circuit Resistance Turn ignition off. Disconnect PCM 60-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (T83L-50-EEC-IV), leaving PCM disconnected. Measure resistance of injector bank No. 1 between test pins No. 37 and 58 at breakout box. Also, measure resistance of injector bank No. 2 between test pins No. 37 and 59 at breakout box. If each resistance is within specification, go to step 12). See «INJECTOR BANK RESISTANCE»(ref-23602-S24428920662001010300000) table. If resistance is not as specified, go to next step. INDIVIDUAL INJECTOR RESISTANCE (1) Engine Ohms Pickup 11-18 (1) Resistance values are for a single injector. INJECTOR BANK RESISTANCE Engine Ohms Pickup 3.0-4.0
6. Step 7) Check Continuity Of Fuel Injector Circuit Turn ignition off. Disconnect suspect injector wiring harness connector at injector. Measure resistance between test pins No. 37 and 57 at breakout box and each injector VPWR terminal at wiring harness connector. Also, measure resistance between injector test pin(s) at breakout box and same injector circuit terminal at each injector wiring harness connector. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit. Remove breakout box, reconnect all components and drive vehicle for 5 miles at 55 MPH. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000).
7. Step 8) Check Injector Circuit For Short To Power Or Ground Turn ignition off. With breakout box installed and PCM disconnected, disconnect suspect fuel injector wiring harness connector. Measure resistance between injector test pin(s) and test pins No. 37, 40, 46, 57 and 60. Also, measure resistance between injector test pin(s) at breakout box and chassis ground. If each reading is more than 10,000 ohms, go to next step. If all readings are 10,000 ohms or less, repair short circuit. Remove breakout box, reconnect all components and drive vehicle for 5 miles at 55 MPH. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000).
8. Step 9) Isolate Faulty Injector Circuit Turn ignition off. With PCM disconnected, disconnect all injectors on suspect bank. Connect one injector and measure resistance between test pins No. 37 and 58 (injector bank 1) or between test pins No. 37 and 59 (injector bank No. 2). Disconnect injector, and repeat process for all other injectors. See «INDIVIDUAL INJECTOR RESISTANCE»(ref-23602-S08523011952001010300000) table. If all injectors are within specification, go to next step. If any injector is not within specification, replace injector(s). Remove breakout box, and reconnect components. Drive vehicle for 5 miles at 55 MPH. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000).
9. Step 10) Check Injector Drive Signal With ignition off, connect PCM to breakout box. Connect a non-powered, 12-volt test light between test pins No. 37 and 58 at breakout box. Connect another test light between test pins No. 37 and 59 at breakout box. Crank or start engine. If test lights glow dimly, system is operating correctly. Clean injectors, and drive vehicle for 5 miles at 55 MPH. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000). If either test light does not glow dimly (no light/bright light), replace PCM. Reconnect all components, and drive vehicle for 5 miles at 55 MPH. Repeat QUICK TEST.

Engine Starts

1. Fuel pump secondary circuit shorted to power.
2. Fuel pump relay contacts always closed.
3. Open FPM circuit between PCM and junction to POWER-TO-PUMP circuit.
4. Faulty PCM.

No Start

1. IFS switch circuit open or not reset.
2. Open circuit in or between PCM and fuel pump.
3. Faulty ground connection at fuel pump.
4. Faulty fuel pump.

On models with dual fuel tanks, ensure tank selector is in same position it was when KOEO Code 542 was set. On all models, attempt to start engine. If engine starts, go to next step. If engine does not start, go to step 15).

1. Step 11) Check Fuel Pump Operation Turn ignition on. Wait 5 seconds. Listen for fuel pump operation. If fuel pump is off, go to step 13). If fuel pump is on, go to next step.
2. Step 12) Check For Fuel Pump Relay Always Closed Turn ignition off. Disconnect fuel pump relay. Turn ignition on. If fuel pump is off with relay disconnected, replace fuel pump relay and repeat «QUICK TEST»(ref-23602-S41551070932001010300000) . If fuel pump is on with relay disconnected, repair short to power in POWER-TO-PUMP or FPM circuit. Repeat QUICK TEST.
3. Step 13) Check Continuity Of Fuel Pump Monitor (FPM) Circuit Turn ignition off. Disconnect PCM 60-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving PCM disconnected. Disconnect fuel pump relay. Measure resistance between test pin No. 8 at breakout box and POWER-TO-PUMP circuit at fuel pump relay wiring harness connector. If resistance is less than 5 ohms, replace PCM and repeat «QUICK TEST»(ref-23602-S41551070932001010300000) . If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 13) to step 15). No test procedures have been omitted.
4. Step 15) Check Inertia Fuel Shutoff (IFS) Switch Turn ignition off. Disconnect IFS switch. See «INERTIA FUEL SHUTOFF SWITCH LOCATION»(ref-23602-S08918529152002011500000) table. Ensure switch is reset. Measure resistance between IFS switch terminals. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, reset or replace IFS switch. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000) . INERTIA FUEL SHUTOFF SWITCH LOCATION Application Location Pickup Behind Right Kick Panel
5. Step 16) Check POWER-TO-PUMP Circuit Turn ignition off. Ensure IFS is disconnected. Disconnect fuel pump relay. Measure resistance of POWER-TO-PUMP circuit between IFS switch and fuel pump relay wiring harness connector. If resistance is less than 5 ohms, reconnect fuel pump relay and go to next step. If resistance is 5 ohms or more, repair open in POWER-TO-PUMP circuit. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
6. Step 17) Check Fuel Pump Ground Circuit Turn ignition off. Ensure IFS switch is disconnected. Disconnect fuel pump. On models with dual fuel tanks, disconnect fuel pump that was selected in step 10). On all models, measure resistance of fuel pump motor ground circuit between fuel pump wiring harness connector and chassis ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in fuel pump ground circuit. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
7. Step 18) Check Power To Fuel Pump Turn ignition off. Ensure IFS switch and fuel pump are disconnected. Measure resistance of POWER-TO-PUMP circuit between IFS switch and fuel pump wiring harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in POWER-TO-PUMP circuit. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
8. Step 19) Check Fuel Pump Resistance Turn ignition off. Ensure IFS switch and fuel pump are disconnected. Measure resistance between POWER-TO-PUMP terminal and ground terminal at fuel pump. If resistance is less than 10 ohms, no problem is indicated at this time. If resistance is 10 ohms or more, replace fuel pump and repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
9. Step 20) Code 543 Code 543 indicates fuel pump secondary circuit failure between B+ circuit and FPM connection to POWER-TO-PUMP circuit. Following are possible causes

1. Open circuit between B+ and FPM connection to POWER-TO-PUMP circuit.
2. Fuel pump relay contacts are always open.

1. Faulty PCM.

Attempt to start engine. If engine starts, replace PCM and repeat QUICK TEST . If engine does not start, go to next step.

1. Step 21) Check For B+ To Fuel Pump Relay Turn ignition off. Disconnect fuel pump relay. Measure voltage between B+ terminal at fuel pump relay wiring harness connector and negative battery terminal. If voltage is 10.5 volts or more, go to next step. If voltage is less than 10.5 volts, check fuse/fusible link. If fuse/fusible link is okay, repair open B+ circuit. Repeat «QUICK TEST»(ref-23602-S41551070932001010300000) .
2. Step 22) Check POWER-TO-PUMP Circuit Continuity Turn ignition off. Leave fuel pump relay disconnected. Measure resistance between POWER-TO-PUMP terminal at fuel pump relay wiring harness connector and negative battery terminal. If resistance is less than 10 ohms, replace fuel pump relay and repeat «QUICK TEST»(ref-23602-S41551070932001010300000) . If resistance is 10 ohms or more, repair open POWER-TO-PUMP circuit between FPM junction and fuel pump relay. Repeat QUICK TEST. NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 22) to step 90). No test procedures have been omitted.
3. Step 90) Continuous Memory Code 542 Code 542 indicates one of the following conditions: Faulty ground circuit at fuel pump. FPM or POWER-TO-PUMP circuit short to power. IFS switch not reset. Fuel pump relay contacts stuck closed. Open circuit in or between fuel pump and FPM circuit at PCM. FUEL PUMP circuit is activated at a time that is not programmed into PCM strategy. Engine stall due to excessive load.

Code 513

Code 513 indicates PCM internal voltage is not to specification. Possible causes for this fault are

1. Low battery voltage.
2. Faulty PCM.

Turn ignition off. Measure voltage between battery terminals. If voltage is more than 10.5 volts, replace PCM and repeat QUICK TEST . If voltage is 10.5 volts or less, service charging system as necessary. Repeat QUICK TEST.