hotcobra03
Active Member
Having trouble with getting full thread.from mobile can a moderator turn this to a couple page choices?
Replaced TPS Sensor - still get .15 volts ???
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hotcobra03
Active Member
I like to make a comment. Im not 17 im 45. I have been a mechanic all my life.our type of shop was the one you went to after the pros have failed. I am new to this type of stuff . After being chewed out ,i kept read threads and was stunned when this didnt follow fords procedures. Than cut the wire was next. Than hissin50 im learning from. Than the code 53.ford says code 63 attempt to generate code 53. Now your code 63,the 4th pin test in pin test DH tps,thats like a 1min test. As long as that was the right test. What ford tells me here. check voltage vref to signal return. 1~disconnect tp harness connector at tb. Inspect for damaged pins,corrosion,loose wires , ect. 2~dvom on 20 volt scale 3~koeo measure voltage between vref and signal return at the tp vechicle harness connector.4~ is voltage between 4.0 and 6.0 volts? Results? yes .action to take? Replace tps. Result is no. Action to take, go to pin test C. Sorry but it seams your still having a problem
joel5.0
Member
hotcobra03
Active Member
Update-
Got a new TPS. Checked voltage on the green wire and got .14v
So I guess it is not the TPS sensor.
Just for giggles, I swapped in a known good C3W EEC. Got .14 volts again on the green wire of the TPS. So I guess that rules out the EEC.
The only thing left is the wiring harness.
Time to start jumping wires
hotcobra03
Active Member
code 63
DH5 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS TO TP SENSOR
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts?
Yes No
KEY OFF. GO to DH6 . GO to C1 .
C1 WAS VREF GREATER THAN 6.0 VOLTS?
Was VREF greater than 6.0 volts when measured in the previous test step?
Yes No
KEY OFF. GO to C35 (to check VREF for short to power). GO to C2 .
Update-
Got a new TPS. Checked voltage on the green wire and got .14v
So I guess it is not the TPS sensor.
Just for giggles, I swapped in a known good C3W EEC. Got .14 volts again on the green wire of the TPS. So I guess that rules out the EEC.
The only thing left is the wiring harness.
Time to start jumping wires
DH5 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS TO TP SENSOR
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts?
Yes No
KEY OFF. GO to DH6 . GO to C1 .
C1 WAS VREF GREATER THAN 6.0 VOLTS?
Was VREF greater than 6.0 volts when measured in the previous test step?
Yes No
KEY OFF. GO to C35 (to check VREF for short to power). GO to C2 .
hotcobra03
Active Member
troubleshooting help?
any other codes ? if so any of them on the same signal return or vref circuit ?
any other codes ? if so any of them on the same signal return or vref circuit ?
With KOEO and TPS sensor disconnected, voltage at connector between VREF-orange and SIGRTN- black is 4.9 volts.
What is next step??
hotcobra03
Active Member
the paper book i have i cant copy.the 2003 pin test is the same but wire colors are different. I will try my best.2003 PCED OBD SECTION 5: Pinpoint Tests
Procedure revision date: 08/19/2002
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DH: Throttle Position (TP) Sensor DH: Introduction
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DH1 KOEO AND KOER DTC P1124: CHECK FOR OTHER DTCS
Check for DTC P1400 or P0405 in KOEO or KOER Self-Test.
Is KOEO or KOER DTC P1400 or P0405 present with KOEO DTC P1124?
Yes No
RETURN to Section 4, Powertrain Diagnostic Trouble Code (DTC) Charts for DTC P1400 or P0405. KEY OFF. GO to DH2 .
DH2 CHECK FOR STUCK THROTTLE PLATE OR LINKAGE
Visually inspect the throttle linkage and throttle plate for binding or sticking.
Verify the throttle plate and linkage is at closed throttle position.
Does the throttle move freely and return to closed throttle position?
Yes No
Throttle plate and linkage are OK. GO to DH8 . REPAIR as necessary.
DH3 DTC P1120: CHECK TP CIRCUIT FOR FRAYED WIRES OR CORROSION ON CONNECTORS
Key off.
Complete a visual inspection of pins on harness connector at the TP sensor for corrosion.
Complete a visual inspection of the harness wires between the TP sensor and the PCM for insulation fraying and corrosion.
Is a fault present?
Yes No
REPAIR as necessary. GO to DH4 .
DH4 CHECK FOR STUCK TP SENSOR
Key on, engine off.
Access TP PID (TP V PID).
Slowly move throttle from closed throttle position to wide open throttle position and observe the TP PID (TP V PID).
While opening the throttle, is the TP PID (TPV PID) reading below 9.85% (0.49 volt)?
Yes No
KEY OFF. GO to DH5 . GO to DH20 .
DH5 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS TO TP SENSOR
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts?
Yes No
KEY OFF. GO to DH6 . GO to C1 .
DH6 CHECK TP CIRCUIT FOR OPEN IN HARNESS
Note: Refer to the PCM connector pin numbers in the beginning of this pinpoint test.
Disconnect PCM.
Measure resistance of TP circuit between PCM harness connector pin and TP harness connector.
Is resistance less than 5.0 ohms?
Yes No
GO to DH7 . REPAIR open circuit.
DH7 CHECK TP SENSOR VOLTAGE TO PCM
Reconnect PCM and TP sensor.
Start engine and idle for 2 minutes.
Access TP PID (TP V PID).
Slowly open the throttle from closed position and observe PID(s).
Is TP PID (TP V PID) reading at any time between 3.42-9.85% (0.17-0.49 volt)?
Yes No
REPLACE TP sensor. If DTC P1120 is still present, GO to DH20 .
DH8 DTC P0123 OR P1124: ATTEMPT TO GENERATE THE OPPOSITE THROTTLE POSITION ANGLE (VOLTAGE) PID READING
Disconnect TP sensor.
Key on, engine off.
Access TP PID (TP V PID).
Is TP PID (TP V PID) less than 3.42% (0.17 volt)?
Yes No
GO to DH9 . KEY OFF. GO to DH10 .
DH9 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS AT TP SENSOR
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts?
Yes No
REPLACE TP sensor. GO to C1 .
DH10 CHECK TP CIRCUIT FOR SHORT TO VREF OR VPWR IN HARNESS
Note: Refer to the PCM connector pin numbers in the beginning of this pinpoint test.
Disconnect PCM.
Measure resistance between TP and VPWR circuits at the PCM harness connector.
Measure resistance between TP and VREF circuits at the PCM harness connector. (For 150 PIN PCM and 122 PCM PIN, measure to both VREF pins.)
Is each resistance greater than 10,000 ohms?
Yes No
REPLACE PCM (refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM) ). REPAIR short circuit.
DH11 DTC P0122: ATTEMPT TO GENERATE THE OPPOSITE THROTTLE POSITION ANGLE (VOLTAGE) PID READING
Note: An intermittent fault can cause a Continuous Memory DTC P0122. If a Continuous Memory DTC P0122 is still present after DH11 through DH14, GO to Z1 .
Disconnect TP sensor.
Jumper VREF circuit to TP circuit at the TP sensor harness connector.
Key on, engine off.
Note: If any scan tool communication concern exists, remove jumper and GO to DH14 .
Access TP PID (TP V PID).
Is TP PID (TP V PID) greater than 93% (4.65 volts)?
Yes No
REPLACE TP sensor. REMOVE jumper. GO to DH12 .
DH12 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts?
Yes No
KEY OFF. GO to DH13 . GO to C1 .
DH13 CHECK TP SENSOR CIRCUIT FOR OPEN IN HARNESS
Note: Refer to the PCM connector pin numbers in the beginning of this pinpoint test.
Disconnect PCM.
Measure resistance of TP circuit between PCM harness connector pin and TP sensor harness connector.
Is resistance less than 5.0 ohms?
Yes No
GO to DH14 . REPAIR open circuit.
DH14 CHECK TP CIRCUIT FOR SHORT TO PWR GND OR SIG RTN IN HARNESS
Disconnect PCM.
Disconnect scan tool from DLC.
Measure resistance between TP and PWR GND circuits at the PCM harness connector.
Measure resistance between TP and SIG RTN circuits at the PCM harness connector.
Are both resistances greater than 10,000 ohms?
Yes No
REPLACE PCM (refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM) ). REPAIR short circuit.
DH15 DTC P1121 OR P0068: CHECK RATIONALITY OPERATION BETWEEN TP AND MAF SENSORS
Attempt to start engine.
Does the engine run?
Yes No
GO to DH16 . CHECK for major leaks, cracks, and openings between MAF sensor and throttle body. If OK, GO to A1 .
DH16 CHECK MECHANICAL OPERATION OF TP SENSOR
Key on, engine off.
Access TP PID (TP V PID).
Slowly move throttle from closed throttle position to wide open throttle position.
Observe and record the TP PID (TP V PID).
While opening and closing the throttle, is there a change in the TP PID (TP V PID) between 9.85% and 93% (0.49 and 4.65 volts)?
Yes No
GO to DH17 . REPLACE TP sensor. VERIFY a symptom no longer exists.
DH17 CHECK TP SENSOR SIGNAL HIGH VERSUS THE ENGINE LOAD WHILE DRIVING VEHICLE
Key on, engine running.
Drive vehicle, exercising the throttle and TP sensor while accessing PIDS.
Access TP PID (TP V PID) and LOAD PID and record readings.
Is TP PID (TP V PID) greater than 49.02% (2.44 volts) and the LOAD PID reading less than 30%?
Yes No
LISTEN for air noise around MAF sensor and throttle body while engine is running. REPAIR if necessary. Otherwise, GO to HU1 for air restriction. If OK, REPLACE the TP sensor. GO to DH18 .
DH18 CHECK TP SENSOR SIGNAL LOW VERSUS THE ENGINE LOAD WHILE DRIVING VEHICLE
Note: If the vehicle is a no start, GO to A1 .
Drive vehicle exercising the throttle and TP sensor near higher gears (preferably overdrive) while accessing PIDS.
Access TP PID (TP V PID) and LOAD PID.
Is TP PID (TP V PID) reading less than 4.82% (0.24 volts) and the LOAD PID reading greater than 55%?
Yes No
TIGHTEN TP sensor to throttle body if necessary. CLEAR Continuous Memory DTCs. DRIVE vehicle exercising the throttle. If Continuous Memory P1121 is now present, REPLACE MAF sensor. Unable to identify the fault at this time. If vehicle is still a No Start, GO to A1 .
DH20 CONTINUOUS MEMORY DTCS P1120 OR P1125: CHECK FOR TP CIRCUIT INTERMITTENT SIGNAL
Start engine and bring to idle.
Run throttle up to 1500 rpm for 5 seconds.
Access TP PID (TP V PID) for a fault indication while completing the following:
Lightly tap on TP sensor and wiggle harness connector to simulate road shock.
Is TP PID (TP V PID) changing below the minimum 9.85% (0.49 volt) or above the maximum 93% (4.65 volts)?
Yes No
INSPECT the TP sensor connector. If OK, REPLACE the TP sensor. KEY OFF. GO to DH21 .
DH21 CHECK TP SENSOR HARNESS FOR INTERMITTENT OPENS OR SHORTS
Again access the TP PID (TP V PID).
Key on, engine off.
Complete the following:
Grasp the vehicle harness closest to the TP sensor connector.
Shake and bend a small section of the harness all the way to the dash panel.
Wiggle, shake and bend the harness from the dash panel to the PCM.
Is TP PID (TP V PID) reading changing below the minimum 9.85% (0.49 volt) or above the maximum 93% (4.65 volts)?
Yes No
ISOLATE and REPAIR as necessary. Unable to duplicate or identify fault at this time.GO to Z1
DH22 DTC P0121: ISOLATE BINDING OR STICKING CONCERN
Disconnect accelerator cable and speed control cable from throttle body linkage.
CAUTION: Do not attempt to clean the throttle bore and plate area. Cleaning will damage the throttle body assembly.
Note: Sticking or binding condition can either appear within cables or throttle body assembly.
Rotate throttle body linkage.
Does the throttle body rotate freely without a sticking, binding or grabbing condition?
Yes No
INSPECT cable(s). REPAIR as necessary. RERUN Quick Test. If the DTC P0121 is still present, GO to DH23 . REPLACE throttle body assembly.
DH23 CHECK FUNCTIONALITY OF THE THROTTLE POSITION SENSOR
Key on.
Access TP V PID.
From closed throttle, slowly begin to press accelerator to wide open throttle.
Did the TP V PID display a smooth reading during accelerator movement?
Yes No
VERIFY a symptom no longer exists. KEY OFF. REPLACE TP sensor.
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hotcobra03
Active Member
UPDATE
DH5 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS TO TP SENSOR
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts? Yes, 4.9 volts
DH6 CHECK TP CIRCUIT FOR OPEN IN HARNESS
Disconnect PCM.
Measure resistance of TP circuit between PCM harness connector pin and TP harness connector.
Is resistance less than 5.0 ohms? Yes .5 ohms
DH7 CHECK TP SENSOR VOLTAGE TO PCM
Reconnect PCM and TP sensor.
Start engine and idle for 2 minutes.
Access TP PID (TP V PID).
Slowly open the throttle from closed position and observe PID(s).
Is TP PID (TP V PID) reading at any time between 3.42-9.85% (0.17-0.49 volt)?
Yes No Yes (.16v - 1.3volts linear) replaced TPS, made no difference, still get .16 volts
DH10 CHECK TP CIRCUIT FOR SHORT TO VREF OR VPWR IN HARNESS
Disconnect PCM.
Measure resistance between TP and VPWR circuits at the PCM harness connector.
Measure resistance between TP and VREF circuits at the PCM harness connector. (For 150 PIN PCM and 122 PCM PIN, measure to both VREF pins.)
Is each resistance greater than 10,000 ohms?
Yes No
NO - with ohm meter set on 2K
47(TP)-37 (VPWR)= 1 47(TP)-57VPWR)=1
47(TP)-26(VREF) = 1.24
Looks like a short in the (TP) (VPWR) circuit
DH14 CHECK TP CIRCUIT FOR SHORT TO PWR GND OR SIG RTN IN HARNESS
Disconnect PCM.
Disconnect scan tool from DLC.
Measure resistance between TP and PWR GND circuits at the PCM harness connector.
Measure resistance between TP and SIG RTN circuits at the PCM harness connector.
Are both resistances greater than 10,000 ohms?
Yes No
NO- With ohm meter set at 2k
47(TP)- 40(PWRGRD) =1
47(TP) - 60(PWRGRD) = 1
47(TP) - 46(SIGRTN)= .66
Looks like a short circuit in the (TP)(PWRGRD) circuit
DH21 CHECK TP SENSOR HARNESS FOR INTERMITTENT OPENS OR SHORTS
Again access the TP PID (TP V PID).
Key on, engine off.
Complete the following:
Grasp the vehicle harness closest to the TP sensor connector.
Shake and bend a small section of the harness all the way to the dash panel.
Wiggle, shake and bend the harness from the dash panel to the PCM.
Is TP PID (TP V PID) reading changing below the minimum 9.85% (0.49 volt) or above the maximum 93% (4.65 volts)?
Yes No
ISOLATE and REPAIR as necessary. Unable to duplicate or identify fault at this time.GO to Z1
NO- Voltage held steady at .16 despite wiggling and shaking harness
Looks like I might have 2 shorts. How do I chase these down without cutting up the harness???
DH5 CHECK VOLTAGE BETWEEN VREF AND SIG RTN CIRCUITS TO TP SENSOR
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF and SIG RTN circuits at the TP sensor harness connector.
Is voltage between 4.0 and 6.0 volts? Yes, 4.9 volts
DH6 CHECK TP CIRCUIT FOR OPEN IN HARNESS
Disconnect PCM.
Measure resistance of TP circuit between PCM harness connector pin and TP harness connector.
Is resistance less than 5.0 ohms? Yes .5 ohms
DH7 CHECK TP SENSOR VOLTAGE TO PCM
Reconnect PCM and TP sensor.
Start engine and idle for 2 minutes.
Access TP PID (TP V PID).
Slowly open the throttle from closed position and observe PID(s).
Is TP PID (TP V PID) reading at any time between 3.42-9.85% (0.17-0.49 volt)?
Yes No Yes (.16v - 1.3volts linear) replaced TPS, made no difference, still get .16 volts
DH10 CHECK TP CIRCUIT FOR SHORT TO VREF OR VPWR IN HARNESS
Disconnect PCM.
Measure resistance between TP and VPWR circuits at the PCM harness connector.
Measure resistance between TP and VREF circuits at the PCM harness connector. (For 150 PIN PCM and 122 PCM PIN, measure to both VREF pins.)
Is each resistance greater than 10,000 ohms?
Yes No
NO - with ohm meter set on 2K
47(TP)-37 (VPWR)= 1 47(TP)-57VPWR)=1
47(TP)-26(VREF) = 1.24
Looks like a short in the (TP) (VPWR) circuit
DH14 CHECK TP CIRCUIT FOR SHORT TO PWR GND OR SIG RTN IN HARNESS
Disconnect PCM.
Disconnect scan tool from DLC.
Measure resistance between TP and PWR GND circuits at the PCM harness connector.
Measure resistance between TP and SIG RTN circuits at the PCM harness connector.
Are both resistances greater than 10,000 ohms?
Yes No
NO- With ohm meter set at 2k
47(TP)- 40(PWRGRD) =1
47(TP) - 60(PWRGRD) = 1
47(TP) - 46(SIGRTN)= .66
Looks like a short circuit in the (TP)(PWRGRD) circuit
DH21 CHECK TP SENSOR HARNESS FOR INTERMITTENT OPENS OR SHORTS
Again access the TP PID (TP V PID).
Key on, engine off.
Complete the following:
Grasp the vehicle harness closest to the TP sensor connector.
Shake and bend a small section of the harness all the way to the dash panel.
Wiggle, shake and bend the harness from the dash panel to the PCM.
Is TP PID (TP V PID) reading changing below the minimum 9.85% (0.49 volt) or above the maximum 93% (4.65 volts)?
Yes No
ISOLATE and REPAIR as necessary. Unable to duplicate or identify fault at this time.GO to Z1
NO- Voltage held steady at .16 despite wiggling and shaking harness
Looks like I might have 2 shorts. How do I chase these down without cutting up the harness???
hotcobra03
Active Member
im learning right with you,,,,,,,,let me read this over real good ...hission50 should comment and that will be very helpfull .....tell me more about any other codes ,,,fords book has many foot notes about code repair and what to fix first...thier could be another cause that is causing your problem or worse case changing the whole harness.
hotcobra03
Active Member
codes
here is were it gets harder...pin tests go with codes and not all pin tests are done.. go back to the first thing i said to you? ck pin 46 to 26 and you failed that ....lets stop and review ,,,,,,,,,,i have to type this and hate spelling,,,,,,,in book for your car it was DH4 pin test if yes change tps,,,,,,,,,if no go to pin test C....... C1..CHECK VECHICLE BATTERY POWER CIRCUIT. WITH KOEO DVOM on 20 volt scale,,,,,,measure voltage between pin 37 on 60 pin connector to signal return on the self-test connector....is voltage greater than 10.5 volts?,,,,,,,,yes goto c2,,,,,no goto B1 C2CHECK VREF VOLTAGE koeo dvom set to 20 volt scale ,,,measure voltage between pin 26 and pin 46 at 60pin connector...WHAT IS THE VOLTAGE??? these test are done with a break-out box ,,not sure what you are using but pcm is connected during tests.......when you are doing the test to the self-test connector that circuit goes through the eec power relay,,,
here is were it gets harder...pin tests go with codes and not all pin tests are done.. go back to the first thing i said to you? ck pin 46 to 26 and you failed that ....lets stop and review ,,,,,,,,,,i have to type this and hate spelling,,,,,,,in book for your car it was DH4 pin test if yes change tps,,,,,,,,,if no go to pin test C....... C1..CHECK VECHICLE BATTERY POWER CIRCUIT. WITH KOEO DVOM on 20 volt scale,,,,,,measure voltage between pin 37 on 60 pin connector to signal return on the self-test connector....is voltage greater than 10.5 volts?,,,,,,,,yes goto c2,,,,,no goto B1 C2CHECK VREF VOLTAGE koeo dvom set to 20 volt scale ,,,measure voltage between pin 26 and pin 46 at 60pin connector...WHAT IS THE VOLTAGE??? these test are done with a break-out box ,,not sure what you are using but pcm is connected during tests.......when you are doing the test to the self-test connector that circuit goes through the eec power relay,,,
Ok, I will try those tests. I appreciate the help!
What is a "breakout box"? I am using one of those standard digital volt/ohm meters.
What is a "breakout box"? I am using one of those standard digital volt/ohm meters.
hotcobra03
Active Member
it would be a tool/scanner,,, it goes in between harness and pcm,its used for pin testing instead of probing on the wires.it has other functions, like a hand held scanner just plugs into self-test connector,or you probe with jumper wire to count blinks....just makes things alot easier.........
hotcobra03
Active Member
read
2003 PCED OBD Introduction
Procedure revision date: 10/22/2002
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Introduction
Note: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.
Important Safety Notice
Appropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This manual provides general directions for performing service with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
Notes, Cautions, and Warnings
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4" x 4" or larger) against the front and rear surfaces of the tires to help prevent the vehicle from moving.
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning.
Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, three-way catalytic converter, and muffler.
Do not smoke while working on a vehicle.
To avoid injury,always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades!
Preface
This manual provides a step-by-step approach for diagnosing driveability, emission and powertrain control system symptoms. Before beginning diagnosis, it may be helpful to reference any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available.
Note: For 6.0L diesel, 7.3L diesel and Bi-Fuel, go to the 6.0L DIESEL, 7.3L DIESEL or BI-FUEL tab in this manual.
This manual is used in conjunction with the Body, Chassis, Electrical, Powertrain Workshop Manuals, and the Wiring Diagram Manuals. The Workshop Manuals are used to provide additional diagnostics when directed by this manual. The Workshop Manuals are also used for component removal and replacement information. Refer to the Wiring Diagram Manuals for vehicle specific wiring information and component, connector and splice location.
The following is a description of the information contained in each section of this manual.
Section 1: Description And Operation
This section contains description and operation information on powertrain control systems and components. This section is designed to give the technician a general knowledge of the powertrain control system. It should be used when general information about the powertrain control system is desired, and is rarely referenced from other sections of the manual.
Section 2: Diagnostic Methods
The Diagnostic Methods section contains information on specific diagnostic tasks that are used during diagnosis. Descriptions of specific diagnostic methods are included, as well as detailed instructions on how to access or perform the tasks. This section provides the technician with step-by-step instructions for performing routine diagnostic tasks.
Section 3: Symptom Charts
All diagnosis begins in Section 3 with Step 1: PCM Quick Test. If the PCM Quick Test is completed and no DTCs are received, the technician may be directed to Step 2: No DTCs Present Symptom Chart Index (refer to Section 3 for details). The No DTCs Present Symptom Chart Index contains the list of symptoms addressed in this manual, and will send the technician to the appropriate Step 3: No DTCs Present Symptom Chart. If no PCM DTCs are present and the vehicle symptom is not listed in the Step 2: No DTCs Present Symptom Chart Index, the technician should go the appropriate Workshop Manual to continue diagnosis.
Section 4: Powertrain DTC Charts and Description
Section 4 contains the Powertrain Diagnostic Trouble Code (DTC) "Go To" Charts. These charts will be referenced if a DTC is received in Section 3. Also included in this section are the Powertrain DTC descriptions and list of possible causes.
Section 5: Pinpoint Tests
All pinpoint tests are included in Section 5. Never enter a Pinpoint Test unless directed there. When directed to a Pinpoint Test, always read the information and look at the schematic included at the beginning of the Pinpoint Test.
Section 6: Reference Values
Section 6 contains the "Typical Diagnostic Reference Values" charts. The technician will be directed to these charts from Pinpoint Test Z in Section 5.
How To Use The Diagnostic Procedures
Use the information about the vehicle driveability or emission concern to attempt to verify/re-create the symptom. Look for any vehicle modifications or aftermarket items that may contribute to the symptom. A check of any applicable TSBs or OASIS messages may be useful, if this information is available.
Go to Section 3, Step 1: PCM Quick Test. Perform the PCM Quick Test step(s). Follow any notes as directed.
If PCM Quick Test is completed, no DTCs were received and no special notes applied, go to Step 2: No DTCs Present Symptom Chart Index.
Select the symptom that best describes the vehicle symptom (for multiple symptoms select the one that is most noticeable). Go to the Step 3: No DTCs Present Symptom Chart that is indicated. If no PCM DTCs are present and the vehicle's symptom is not listed in the No DTCs Present Symptom Chart Index, go to the appropriate Workshop Manual to continue diagnosis.
The No DTCs Present Symptom Chart contains areas to be tested for diagnosis of the vehicle's symptom. The chart is arranged to place the higher probability, or easiest to test items toward the top of the chart. The technician, however, is not required to follow this order due to reasons such as variations in vehicle type, vehicle repair history or technician experience.
The System/Component column indicates the areas that will be tested. This column may also contain a quick system/component test.
The Reference column indicates where to go for the System/Component testing. All references are to pinpoint test steps in Section 5 of this manual unless noted otherwise. If referenced to a Pinpoint Test Step in this manual or a Workshop Manual section, go to the procedures. Follow the directions given in those procedures, including directions to other tests or sections. If a damaged part is found, repair/replace as directed. If no fault is found, and diagnosis in that area is complete, return to the No DTCs Present Symptom chart and continue to the next item.
If a quick system/component test is in the System/Component column, the reference column will indicate where to go if the test failed.
During diagnosis, if directed to test a system/component that is not contained on that vehicle, proceed to the next step.
If the No DTCs Present Symptom Chart for the vehicle symptom is completed and no fault is found, return to Step 2: No DTCs Present Symptom Chart Index to address the next most prominent symptom. If all diagnosis is complete and no fault is found, it may be helpful to go to Section 5, Pinpoint Test Step Z1, for further diagnosis.
After service, restore vehicle by reconnecting any components, removing test equipment, etc. Verify that the vehicle is operating properly and the original complaint is eliminated. If a DTC was present, rerun Quick Test to verify repair and complete a PCM Reset to clear any Continuous Memory DTCs.
Note: If a symptom is determined to be intermittent, careful visual and physical underhood inspection of connectors, wiring harnesses, vacuum lines, components, etc. is required. The Customer Information Worksheet may contain more detailed symptom information. Before an in-depth diagnosis begins, start the engine and wiggle wires, tap on components, etc., while listening for an indication of a concern (such as rpm change or relay clicking).
Information about engine conditions is stored when a Diagnostic Trouble Code (DTC) that lights the Malfunction Indicator Lamp (MIL) is set. This information is called Freeze Frame Data and may be helpful in diagnosing intermittents. (Refer to Section 2, Freeze Frame Data, for more information.)
What's New In This Manual
The following is a list of changes to this manual for 2003:
New Components/Systems (see Section 1 for description):
Electronic Throttle Control (ETC) (LS and Thunderbird)
EGR system module (ESM)
Variable speed electric cooling fan (introduced on Crown Victoria/Grand Marquis, Thunderbird, LS6/LS8 and Town Car)
New Vehicles:
Mercury Marauder (4.6L 4V) (unless specifically called out, follow Grand Marquis direction in this manual for the Marauder)
Mustang Mach I with 4.6L 4V
Lincoln Aviator (with 4.6L 4v and 150 pin PCM)
Deleted Vehicles:
Cougar
Continental
Villager (was covered under separate tab in this manual)
Other Changes
3.0L Escape mid-year engine cooling fan change from three speed to two speed fan.
Mustang Cobra with 4.6L 4V SC
Focus with 2.3L
122 pin PCM introduced on Expedition and Navigator.
New SAE DTCs included. For 2003, some manufacturer specific DTCs (P1xxx) are being changed to SAE defined DTCs (P0xx). The PCM software that sets the DTC remains the same.
Electronic Throttle Control (ETC) pinpoint tests DK and DV added. ETC description added to section 1.
EGR System Module (ESM) pinpoint test HH added to section 5.
Variable Speed Electric Cooling Fan pinpoint test KN added to section 5.
Link/reference to section 1 PCM connector view included from each section 5 pinpoint test cover page. This link/reference was included because of multiple PCM connector designs.
Section 6 has included PCM connector views for each application.
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2003 PCED OBD Introduction
Procedure revision date: 10/22/2002
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Introduction
Note: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.
Important Safety Notice
Appropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This manual provides general directions for performing service with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
Notes, Cautions, and Warnings
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4" x 4" or larger) against the front and rear surfaces of the tires to help prevent the vehicle from moving.
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning.
Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, three-way catalytic converter, and muffler.
Do not smoke while working on a vehicle.
To avoid injury,always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades!
Preface
This manual provides a step-by-step approach for diagnosing driveability, emission and powertrain control system symptoms. Before beginning diagnosis, it may be helpful to reference any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available.
Note: For 6.0L diesel, 7.3L diesel and Bi-Fuel, go to the 6.0L DIESEL, 7.3L DIESEL or BI-FUEL tab in this manual.
This manual is used in conjunction with the Body, Chassis, Electrical, Powertrain Workshop Manuals, and the Wiring Diagram Manuals. The Workshop Manuals are used to provide additional diagnostics when directed by this manual. The Workshop Manuals are also used for component removal and replacement information. Refer to the Wiring Diagram Manuals for vehicle specific wiring information and component, connector and splice location.
The following is a description of the information contained in each section of this manual.
Section 1: Description And Operation
This section contains description and operation information on powertrain control systems and components. This section is designed to give the technician a general knowledge of the powertrain control system. It should be used when general information about the powertrain control system is desired, and is rarely referenced from other sections of the manual.
Section 2: Diagnostic Methods
The Diagnostic Methods section contains information on specific diagnostic tasks that are used during diagnosis. Descriptions of specific diagnostic methods are included, as well as detailed instructions on how to access or perform the tasks. This section provides the technician with step-by-step instructions for performing routine diagnostic tasks.
Section 3: Symptom Charts
All diagnosis begins in Section 3 with Step 1: PCM Quick Test. If the PCM Quick Test is completed and no DTCs are received, the technician may be directed to Step 2: No DTCs Present Symptom Chart Index (refer to Section 3 for details). The No DTCs Present Symptom Chart Index contains the list of symptoms addressed in this manual, and will send the technician to the appropriate Step 3: No DTCs Present Symptom Chart. If no PCM DTCs are present and the vehicle symptom is not listed in the Step 2: No DTCs Present Symptom Chart Index, the technician should go the appropriate Workshop Manual to continue diagnosis.
Section 4: Powertrain DTC Charts and Description
Section 4 contains the Powertrain Diagnostic Trouble Code (DTC) "Go To" Charts. These charts will be referenced if a DTC is received in Section 3. Also included in this section are the Powertrain DTC descriptions and list of possible causes.
Section 5: Pinpoint Tests
All pinpoint tests are included in Section 5. Never enter a Pinpoint Test unless directed there. When directed to a Pinpoint Test, always read the information and look at the schematic included at the beginning of the Pinpoint Test.
Section 6: Reference Values
Section 6 contains the "Typical Diagnostic Reference Values" charts. The technician will be directed to these charts from Pinpoint Test Z in Section 5.
How To Use The Diagnostic Procedures
Use the information about the vehicle driveability or emission concern to attempt to verify/re-create the symptom. Look for any vehicle modifications or aftermarket items that may contribute to the symptom. A check of any applicable TSBs or OASIS messages may be useful, if this information is available.
Go to Section 3, Step 1: PCM Quick Test. Perform the PCM Quick Test step(s). Follow any notes as directed.
If PCM Quick Test is completed, no DTCs were received and no special notes applied, go to Step 2: No DTCs Present Symptom Chart Index.
Select the symptom that best describes the vehicle symptom (for multiple symptoms select the one that is most noticeable). Go to the Step 3: No DTCs Present Symptom Chart that is indicated. If no PCM DTCs are present and the vehicle's symptom is not listed in the No DTCs Present Symptom Chart Index, go to the appropriate Workshop Manual to continue diagnosis.
The No DTCs Present Symptom Chart contains areas to be tested for diagnosis of the vehicle's symptom. The chart is arranged to place the higher probability, or easiest to test items toward the top of the chart. The technician, however, is not required to follow this order due to reasons such as variations in vehicle type, vehicle repair history or technician experience.
The System/Component column indicates the areas that will be tested. This column may also contain a quick system/component test.
The Reference column indicates where to go for the System/Component testing. All references are to pinpoint test steps in Section 5 of this manual unless noted otherwise. If referenced to a Pinpoint Test Step in this manual or a Workshop Manual section, go to the procedures. Follow the directions given in those procedures, including directions to other tests or sections. If a damaged part is found, repair/replace as directed. If no fault is found, and diagnosis in that area is complete, return to the No DTCs Present Symptom chart and continue to the next item.
If a quick system/component test is in the System/Component column, the reference column will indicate where to go if the test failed.
During diagnosis, if directed to test a system/component that is not contained on that vehicle, proceed to the next step.
If the No DTCs Present Symptom Chart for the vehicle symptom is completed and no fault is found, return to Step 2: No DTCs Present Symptom Chart Index to address the next most prominent symptom. If all diagnosis is complete and no fault is found, it may be helpful to go to Section 5, Pinpoint Test Step Z1, for further diagnosis.
After service, restore vehicle by reconnecting any components, removing test equipment, etc. Verify that the vehicle is operating properly and the original complaint is eliminated. If a DTC was present, rerun Quick Test to verify repair and complete a PCM Reset to clear any Continuous Memory DTCs.
Note: If a symptom is determined to be intermittent, careful visual and physical underhood inspection of connectors, wiring harnesses, vacuum lines, components, etc. is required. The Customer Information Worksheet may contain more detailed symptom information. Before an in-depth diagnosis begins, start the engine and wiggle wires, tap on components, etc., while listening for an indication of a concern (such as rpm change or relay clicking).
Information about engine conditions is stored when a Diagnostic Trouble Code (DTC) that lights the Malfunction Indicator Lamp (MIL) is set. This information is called Freeze Frame Data and may be helpful in diagnosing intermittents. (Refer to Section 2, Freeze Frame Data, for more information.)
What's New In This Manual
The following is a list of changes to this manual for 2003:
New Components/Systems (see Section 1 for description):
Electronic Throttle Control (ETC) (LS and Thunderbird)
EGR system module (ESM)
Variable speed electric cooling fan (introduced on Crown Victoria/Grand Marquis, Thunderbird, LS6/LS8 and Town Car)
New Vehicles:
Mercury Marauder (4.6L 4V) (unless specifically called out, follow Grand Marquis direction in this manual for the Marauder)
Mustang Mach I with 4.6L 4V
Lincoln Aviator (with 4.6L 4v and 150 pin PCM)
Deleted Vehicles:
Cougar
Continental
Villager (was covered under separate tab in this manual)
Other Changes
3.0L Escape mid-year engine cooling fan change from three speed to two speed fan.
Mustang Cobra with 4.6L 4V SC
Focus with 2.3L
122 pin PCM introduced on Expedition and Navigator.
New SAE DTCs included. For 2003, some manufacturer specific DTCs (P1xxx) are being changed to SAE defined DTCs (P0xx). The PCM software that sets the DTC remains the same.
Electronic Throttle Control (ETC) pinpoint tests DK and DV added. ETC description added to section 1.
EGR System Module (ESM) pinpoint test HH added to section 5.
Variable Speed Electric Cooling Fan pinpoint test KN added to section 5.
Link/reference to section 1 PCM connector view included from each section 5 pinpoint test cover page. This link/reference was included because of multiple PCM connector designs.
Section 6 has included PCM connector views for each application.
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UPDATE
C1 -Check vehicle battery power circuit- measure voltage between pin 37 and SIGRTN on self-test connector- Is voltage greater than 10.5 volts?? - NO 6.53 volts
C2- Check VREF voltage between pin 26 and pin 46 - 4.89 volts
Just for the heck of it, I pulled codes and got the following-
21- ECT out of self test range
24- MAP sensor out of self test range
81- TAD circuit failure
82 - TAB circuit failure
84- EGR vacuum circuit failure
87- fuel pump primary circuit failure
81,82,84 are smog related. I have removed the smog pump and hoses but EGR is still in place.
Last time I pulled KOEO, it was clean - code 11. What the heck is going on here???
C1 -Check vehicle battery power circuit- measure voltage between pin 37 and SIGRTN on self-test connector- Is voltage greater than 10.5 volts?? - NO 6.53 volts
C2- Check VREF voltage between pin 26 and pin 46 - 4.89 volts
Just for the heck of it, I pulled codes and got the following-
21- ECT out of self test range
24- MAP sensor out of self test range
81- TAD circuit failure
82 - TAB circuit failure
84- EGR vacuum circuit failure
87- fuel pump primary circuit failure
81,82,84 are smog related. I have removed the smog pump and hoses but EGR is still in place.
Last time I pulled KOEO, it was clean - code 11. What the heck is going on here???
hotcobra03
Active Member
relay??????????
any way maybe try 2 new relays fuel pump and eec...than go from thier.
codes come back to 21,24,84 are all on signal return pin 46... than code 87 and pin test C1 both use eec relay, still hate to guess but its sounding like the relay that other guy ripped me on and said i was stupid......might be faulty...... ,code 24,I got ACT,not map
any way maybe try 2 new relays fuel pump and eec...than go from thier.
hotcobra03
Active Member
pin test C
test c1 if no go to B1,,,,,,BATTERY VOLTAGE...is voltage more than 10.5 if yes go to b2......B2 CHECK EEC GROUND TO BATTERY GROUND...key off ,dvom set to 200ohm scale,At 60 pin plug measure resistance between pin 40 and negative battery post and, pin 60 and negative battery post.Are both less than 5.0 ohms??? buy this time you should have located the problem,,steps do continue if needed
test c1 if no go to B1,,,,,,BATTERY VOLTAGE...is voltage more than 10.5 if yes go to b2......B2 CHECK EEC GROUND TO BATTERY GROUND...key off ,dvom set to 200ohm scale,At 60 pin plug measure resistance between pin 40 and negative battery post and, pin 60 and negative battery post.Are both less than 5.0 ohms??? buy this time you should have located the problem,,steps do continue if needed
joel5.0
Member
Q here....... if the TPS signal is below .49 vdc, why isn't a code 63 showing in a KOEO? Code 21 and 24 are usually "engine too cold for a KOEO" condition codes.
Suggest to plug everything back, clear ECM memory, start engine and let it reach op temp, rerun a KOEO and KOER and LUK.
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