Engine Controls - Tests W/codes - Eec-Iv: Other Mercury Cougar VII

SERVICE CODES

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

KOEO & KOER Codes (Hard Faults)

These codes indicate faults are present at time of testing. A hard fault may cause CHECK ENGINE or MALFUNCTION INDICATOR LIGHT (MIL) to glow and remain on until fault is repaired. If KOEO or KOER codes are retrieved during KOEO SELF-TEST or KOER SELF-TEST, use SERVICE CODE REFERENCE CHARTS to find correct testing and repair procedures.

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 during KOEO SELF-TEST. Some codes may turn on MIL or CHECK ENGINE light. Corresponding soft trouble code will be retained in ECA memory. If fault does not reoccur within 40 warm-up cycles (80 cycles on some models), ECA will automatically clear code.

Technician may clear service codes from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problems. See INTERMITTENTS in TESTS W/O CODES article in the ENGINE PERFORMANCE Section.

RETRIEVING CODES

Service codes are retrieved from EEC-IV system through self-test connector. Various methods and test equipment may be used to access these codes

1. Analog Volt-Ohmmeter (VOM).
2. Scan tester.
3. In-Dash Malfunction Indicator Light (MIL) or CHECK ENGINE light.

SELF-TEST CONNECTOR LOCATIONS

Separator Pulse

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

Pass Codes

A Code 11 or 111 indicates no service codes were recorded in that portion of test; system passes that portion of test. If Code 11 or 111 is not retrieved in KOEO SELF-TEST, codes retrieved during KOER SELF-TEST may not be valid. Code 11 or 111 (pass code) must be obtained in KOEO SELF-TEST. A Code 11-1-11 or 111-1-111 output during KOEO SELF-TEST indicates no KOEO code or Continuous Memory Code was recorded. Separator code may appear as "10" instead of "1" on some test equipment.

Continuous Memory Codes

These codes result from information stored by ECA during continuous self-test monitoring. Codes are displayed after separator pulse code in KOEO SELF-TEST. Use these codes for diagnosis only when KOEO SELF-TEST and KOER SELF-TEST result in Code 11 or 111 (pass code) and all steps under QUICK TEST are successfully completed. (A few codes are exceptions which may be checked after KOEO codes have been repaired). 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 SERVICE CODE REFERENCE CHARTS .

Fast Codes

At start of KOEO SELF-TEST and after Wide Open Throttle (WOT) request in KOER SELF-TEST, ECA outputs short bursts of information, known as FAST CODES, which were used by manufacturer during assembly. With most equipment, these code bursts are not visible; an entire code sequence lasts less than 1/2 second. If this fluctuation is visible on test equipment, ignore it.

Scheme 147

Scheme 148

CLEARING CODES

To clear codes from ECA memory, start KOEO SELF-TEST . When service codes appear on test equipment or CHECK ENGINE light, disconnect jumper wire from Self-Test Input (STI) connector. If using STAR Series Tester, unlatch center button. This procedure erases Continuous Memory Codes from ECA memory. If problem has not been corrected or fault is still present, hard code will immediately be reset in ECA memory.

VISUAL CHECK & EQUIPMENT HOOKUP

Complete all steps in BASIC TESTING article in the ENGINE PERFORMANCE Section before proceeding to self-diagnostic tests. Ensure vacuum hoses and EEC-IV wiring harnesses are properly connected.

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

Analog Volt-Ohmmeter (VOM)

1) Turn ignition switch to OFF position. Set VOM at 0-15V DC range. Connect positive lead of VOM to positive battery terminal.

2) Connect negative VOM lead to Self-Test Output (STO) terminal of self-test connector. (Scheme 150) Connect timing light, and go to KOEO SELF-TEST. Activate KOEO SELF-TEST by connecting jumper wire from Self-Test Input (STI) pigtail to signal return terminal of self-test connector with ignition on.

Scan Tester

Follow scan tester manufacturer's instructions to hook up equipment and record service codes.

STAR Series Tester

Turn ignition switch to OFF position. Connect color-coded adapter cable leads to diagnostic tester. Connect 2 service connectors of adapter cable to vehicle self-test connector and STI pigtail connector. Connect timing light. Go to KOEO SELF-TEST .

CHECK DCL Light (Continental), CHECK ENGINE Light Or Malfunction Indicator Light (MIL)

Turn ignition on. Connect a jumper wire between Self-Test Input (STI) pigtail and signal return terminal of self-test connector. Go to KOEO SELF-TEST .

Scheme 149

Scheme 150

COMPUTED TIMING CHECK

Turn ignition off, and wait 10 seconds. Using jumper wire or test equipment, activate KOER SELF-TEST . If engine starts and stalls (or stalls during self-test), go to Circuit Test S. Start engine, and check for following

1. If Code 98 or 998 is displayed, EEC-IV system is operating in Failure Mode Effects Management (FMEM). Vehicle cannot be diagnosed in KOER SELF-TEST; rerun KOEO SELF-TEST.
2. Check computed timing after last service code has been displayed. Timing will remain fixed for 2 minutes after last code has been retrieved unless self-test is deactivated.
3. Computed timing, at crankshaft, should equal base timing (see vehicle emission decal) plus 20 degrees BTDC. This timing may vary 3 degrees (+/-). If computed timing is within specification, perform «KOER SELF-TEST»(ref-22732-S38507632482001010300000) . If timing is not within specification, go to step 2) of CIRCUIT TEST PA (TFI), of CIRCUIT TEST PB (DIS) or of CIRCUIT TEST PC (EDIS).

ADDITIONAL SYSTEM FUNCTIONS

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

CHECK DCL LIGHT (CONTINENTAL), CHECK ENGINE LIGHT & MALFUNCTION INDICATOR LIGHT (MIL)

CHECK DCL light, CHECK ENGINE light and MIL are intended to alert driver of certain malfunctions in EEC-IV system.

Light may also be used to retrieve service codes stored in ECA. When hooked up for KOEO SELF-TEST or KOER SELF-TEST, light will display all codes which turn on light during vehicle operation, not just Continuous Memory Codes.

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.

If light comes on and then goes off during vehicle operation, code causing light to glow will be stored in ECA memory as a Continuous Memory Code.

Light should come on when ignition is turned on and go out when engine is started. If hard fault codes are not present, ECA turns out light when it receives a Profile Ignition Pick-Up (PIP) signal. If light does not come on, see SYMPTOMS in TESTS W/O CODES article in the ENGINE PERFORMANCE Section.

OUTPUT STATE CHECK

OUTPUT STATE CHECK is used as an aid in servicing output actuators associated with EEC-IV system. It allows technicians to energize and de-energize most system output actuators on command. This mode is entered from KOEO SELF-TEST after all codes have been retrieved. Leave SELF-TEST activated, and depress throttle to initiate test sequence. Each time throttle is depressed and released, output actuators will change state (from on to off or off to on).

Failure Mode Effects Management (FMEM), Code 98 Or 998

FMEM mode allows system operation when sensors fail or transmit signals that are out of normal operating range. During FMEM mode, ECA substitutes a mid-range signal for defective sensor while continuing to monitor sensor. If faulty sensor's signals return to normal operating range, ECA will use those signals. A Code 98 or 998 will be displayed when FMEM mode is in effect.

CIRCUIT TESTS

Note. A breakout box, connected to vehicle harness at ECA, 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. Circuit diagrams at beginning of each test identify circuit and wire colors.

HOW TO USE CIRCUIT TESTS

1) Ensure all non-EEC related faults found while performing steps in BASIC TESTING article have been corrected. DO NOT perform any CIRCUIT TEST unless specifically instructed by a QUICK TEST procedure. Follow each test step in order until fault is found. DO NOT replace any part unless directed to do so. When more than one code is retrieved, start with first code displayed.

2) CIRCUIT TESTS ensure electrical circuits are okay before sensors or other components are replaced. Always test circuits for continuity between sensor and ECA. Test all circuits for short to power, opens or short to ground. Voltage Reference (VREF) and Voltage Power (VPWR) circuits should be tested with KOEO or as specified in CIRCUIT TESTS.

3) DO NOT measure voltage or resistance at ECA. DO NOT connect any test light unless specified in testing procedure. All measurements are made by probing rear of connector. Isolate both ends of a circuit and turn ignition off when checking for shorts or continuity, unless instructed otherwise.

4) Disconnect solenoids and switches from harness before measuring continuity and resistance or applying voltage. After each repair, check all component connections and repeat QUICK TEST .

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 is defined as a resistance reading of less than 10,000 ohms to ground, unless stated otherwise in CIRCUIT TEST.

Preliminary Instructions (A/T)

Record and clear continuous memory codes. Warm engine to normal operating temperature. In Low gear, accelerate hard to 35 MPH and coast down to a stop. Shut off engine. Perform KOEO SELF-TEST . Go to step 1).

Preliminary Instructions (M/T)

Record and clear continuous memory codes. Warm engine to normal operating temperature. Accelerate moderately to 40 MPH. Start in first gear, shifting no higher than second gear. Coast down to idle, and stop. Shut engine off. Perform KOEO SELF-TEST , and record continuous memory codes. Go to step 1).

1) Continuous Memory Code 29/452 Code 29/452 indicates ECA detected incorrect output from VSS sometime during vehicle operation. Possible causes for this code are

1. Faulty VSS.
2. Open or shorted circuit.
3. Faulty ECA.

Perform appropriate drive cycle procedure. See procedures in PRELIMINARY INSTRUCTIONS (A/T) or PRELIMINARY INSTRUCTIONS (M/T). Ensure driveability complaint can be verified. If Code 29/452 is still present or driveability complaint can be verified, go to step 2). If code is not present or complaint cannot be verified, fault cannot be duplicated at this time. Clear codes, and see SYMPTOMS in TESTS W/O CODES article in the ENGINE PERFORMANCE Section.

2) Check VSS Circuit Continuity Turn ignition off. Disconnect VSS sensor. Remove ECA 60-pin connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Measure resistance between VSS DIF (+) terminal at VSS wiring harness connector and test pin No. 3 at breakout box. Measure resistance between VSS DIF (-) terminal at VSS wiring harness connector and test pin No. 6 at breakout box. If any resistance reading is more than 5 ohms, service open circuit in VSS wiring harness and repeat step 1). If both resistance readings are 5 ohms or less, go to step 3).

3) Check VSS Circuits For Shorts To Power Or Ground Turn ignition off. Ensure ECA and VSS are disconnected. Set DVOM on 200-k/ohm scale. On 1.9L A/T, locate 4EAT module under dash between steering column and left kick panel. Disconnect both 4EAT transmission module wiring harness connectors. On all models, measure resistance between test pin No. 3 and test pins No. 6, 37 and 40 at breakout box. If all readings are greater than 500 ohms, go to step 5) (1.9L A/T) or step 4) (except 1.9L A/T). If any reading is less than 500 ohms, repair shorts in VSS wiring harness and repeat step 1).

4) Check VSS Resistance Turn ignition off, and wait 10 seconds. Disconnect VSS wiring harness connector. Measure resistance across VSS terminals. If reading is not 190-250 ohms, replace VSS and repeat step 1). If resistance is 190-250 ohms, replace ECA and repeat step 1).

5) Check For Shorted 4EAT Module 1.9L A/T has a VSS circuit input to 4EAT module. This test checks VSS circuit to ensure it is not shorted inside 4EAT module. Turn ignition off. Connect both 4EAT transmission module wiring harness connectors. Measure resistance between test pin No. 3 and test pins No. 6, 37 and 40. If any resistance is more than 500 ohms, reconnect ECA and go back to step 4). If each resistance is not greater than 500 ohms, check for fault in transmission system.

Engine Starts

1. Fuel pump secondary circuit shorted to power.
2. Fuel pump relay contacts always closed.
3. Open in Fuel Pump Monitor (FPM) circuit between ECA and connection to POWER-TO-PUMP circuit.
4. HEGO short to power (dual HEGO applications).
5. Faulty ECA.

No Start

1. Inertia switch not reset or electrically open.
2. Open circuit in or between ECA and fuel pump.
3. Faulty ground connection at fuel pump.

If engine starts, go to step 21). If engine does not start, go to step 24).

21) Check Fuel Pump Operation Turn ignition on. Wait 5 seconds. Listen for fuel pump operation. If fuel pump is off, go to step 23). If fuel pump is on, go to step 22).

22) 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 . If fuel pump is on with relay disconnected, repair short to power in POWER-TO-PUMP/FPM circuit. (For models with relay block, also check fuel pump prime plug circuit). Repeat QUICK TEST.

23) Check Continuity Of Fuel Pump Monitor (FPM) Circuit Turn ignition off. Disconnect ECA 60-pin connector. Inspect and repair any damaged terminals. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Disconnect fuel pump relay. Measure resistance between test pin No. 8 (No. 19 on Escort, Mustang and Tracer) at breakout box and POWER-TO-PUMP circuit at fuel pump relay wiring harness connector. If resistance is less than 5 ohms, go to step 35) (dual HEGO) or replace ECA and repeat QUICK TEST (single HEGO). If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST.

24) Check Inertia Switch Turn ignition off. Disconnect fuel pump inertia switch. Ensure switch is reset. Measure resistance of inertia switch (between GND pin and FP pin on Escort and Tracer). (Scheme 151) If resistance is less than 5 ohms, reconnect switch and check for open in POWER-TO-PUMP circuit, poor fuel pump ground or open in fuel pump. If resistance is 5 ohms or more, reset or replace inertia switch. Repeat QUICK TEST.

Inertia Switch (Escort & Tracer). Scheme 151

Note. A break in step numbering sequence occurs at this point. Procedure skips from step 24) to step 30). No test procedures have been omitted.

30) Code 96/543 Code 96/543 indicates fuel pump secondary circuit failure between BATT (+) supply and FPM connection to POWER-TO-PUMP circuit. Following are possible causes

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

1. HEGO short to power (dual HEGO models).
2. Faulty ECA.

If engine starts, go to step 35) (dual HEGO) or replace ECA and repeat QUICK TEST (single HEGO). If engine does not start, go to step 31).

31) Check For BATT (+) To Fuel Pump Relay Turn ignition off. Disconnect fuel pump relay. Connect DVOM between BATT (+) terminal at fuel pump relay wiring harness connector and negative battery terminal. If voltage is 10.5 volts or more, go to step 32). If voltage is less than 10.5 volts, check fuse/fusible link for BATT (+) supply to fuel pump relay. If fuse/fusible link is okay, repair open circuit in BATT (+) circuit. Repeat QUICK TEST .

32) Check POWER-TO-PUMP Circuit Continuity Turn ignition off. With 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. Reconnect relay and repeat QUICK TEST . If resistance is 10 ohms or more, repair open circuit in POWER-TO-PUMP circuit between FPM splice and fuel pump relay. Repeat QUICK TEST .

Note. A break in step numbering sequence occurs at this point. Procedure skips from step 32) to step 35). No test procedures have been omitted.

AOD-E & AXOD-E

With transmission gear selector in OVERDRIVE position, moderately accelerate vehicle to 50 MPH for at least 15 seconds. Transmission should be in 4th gear. While holding speed steady, lightly apply and release brake for about 5 seconds. Stop and park vehicle for a minimum of 20 seconds with transmission gear selector in DRIVE position. Repeat procedure 5 times.

E4OD

With transmission gear selector in DRIVE position, press Overdrive Cancel Switch (LED should light). Moderately accelerate vehicle to 40 MPH for at least 15 seconds (30 seconds above 4000' elevation). Transmission should be in 3rd gear. While holding speed steady, press Overdrive Cancel Switch (LED should go off) and accelerate from 40 MPH to 50 MPH. Transmission should shift from 3rd gear to 4th gear. Hold speed steady for 15 seconds. While holding speed steady, lightly apply and release brakes to turn brakelights on. Maintain 50 MPH for about 5 seconds. Stop and park vehicle for a minimum of 20 seconds with transmission gear selector in DRIVE position. Repeat procedure 5 times.

All Models

After completing appropriate DRIVE CYCLE TEST, perform KOEO and CONTINUOUS MEMORY CODE SELF-TEST. If Code 99/624, 67/634 or 651 is present, go to step 92). If none of these codes are present but Code 29/452 is present, go to CIRCUIT TEST DP for all other models. If Code 11/111 is present, fault cannot be duplicated at this time.

92) Code 99/624, 67/634 Or 651 Code 99/624 and 651 indicate Electronic Pressure Control (EPC) failure. Code 67/634 indicates that Manual Lever Position (MLP) sensor is out of calibration. Possible causes for these faults are

1. Faulty EPC solenoid.
2. Faulty MLP sensor.
3. Circuit open or grounded.
4. Damaged ECA connector pins.

Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Connect ECA to breakout box. To test EPC solenoid, connect DVOM to EPC test pin and EPC VPWR test pin at breakout box. To test MLP sensor, connect DVOM to MLP test pin and test pin No. 46 at breakout box. For EPC solenoid and MLP sensor, turn ignition on. Voltage for EPC should be less than 10 volts. Voltage for MLP should be less than 5 volts. Shake and bend EPC/MLP wiring harness. Lightly tap on components to simulate road shock. Voltage should remain stable. If voltage changes or exceeds specification, fault in circuit is indicated. If fault is indicated, isolate and repair as necessary. Clear continuous memory codes, and repeat QUICK TEST . If no faults are found, problem cannot be located at this time.

93) Check Circuit Harness & Connectors Shake and bend EEC-IV wiring harness. Lightly tap on components to simulate road shock. Perform KOEO Continuous Monitor Mode. See CIRCUIT TEST KOEO CONTINUOUS MEMORY CODES . If fault is indicated, isolate and repair as necessary. Clear continuous memory codes, and repeat QUICK TEST . If no faults are found, problem cannot be located at this time.

CIRCUIT TEST KOEO CONTINUOUS MEMORY CODES

SUMMARY

If no service code (or pass code 11-1-11 or 111-1-111) is present but driveability problem still exists, proceed to EEC-IV DIAGNOSIS BY SYMPTOM . If driveability problem still cannot be located, go to TESTS W/O CODES article in the ENGINE PERFORMANCE Section for intermittent diagnosis procedures.