Using the Star Tester

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Benjamin Lesley Hardy
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1 Page 1 of 12 Using the Star Tester 1. Turn the ignition key off. 2. Connect the color coded adapter cable to the STAR tester. 3. Connect the adapter cable leads to the proper Self-Test connectors(figure 1). 4. Connect the timing light. Figure 1. Figure 2. Using an Analog Volt/Ohm Meter (VOM)

2 Page 2 of Turn the ignition key off. 2. Set the VOM on a DC voltage range to read from 0 to 15 volts. 3. Connect the VOM from the battery positive post to the Self-Test Output pin of the large Self-Test connector (Figure 2). 4. Connect the timing light. Using the "Malfunction Indicator" Light (MIL) No special equipment hookup is required. STI is jumpered to SIG RTN at Self-Test connectors. Using the Message Center on Continental Applications Only No special equipment hookup is required. STI is jumpered to SIG RTN at Self-Test connectors. Using the Overdrive Cancel Indicator Light (OCIL) on 7.3L Diesel Engines Only No special equipment hookup is required. STI is jumpered to SIG RTN at Self-Test connectors. Key On Engine Off Self-Test Special Notes: It may be necessary to service non-eec-iv faults before running Quick Test. Refer to Section 2A. Continuous Memory Codes recorded in this step will be used for diagnosis in Step 5.0 after a PASS code 11 or 111 is received in both the Key On Engine Off and the Engine Running Self-Tests. Deviation from this procedure may cause the output of false codes. Refer to Quick Test Appendix for further information on how to read code output. On all vehicles equipped with a 4.9L ENGINE, the clutch must be depressed during the Key On Engine Off Self-Test. On all vehicles equipped with a 7.3L DIESEL ENGINE, the throttle must be depressed (WOT) during the entire Key On Engine Off Self-Test. How To Run The Key On Engine Off Self-Test

3 Page 3 of 12 DO Verify that the vehicle has been properly prepared according to QUICK TEST STEPS 1.0 and 2.0. Start engine and run until at operating temperature. Turn engine off and wait 10 seconds. Activate Self-Test. STAR Tester: Latch the center button in the down position. Analog VOM: Jumper STI to SIG RTN at the Self-Test connectors. Malfunction Indicator Light (MIL): Jumper STI to SIG RTN at the Self-Test connectors. Service Codes will be flashed on the Malfunction Indicator Light (MIL). Overdrive Cancel Indicator Light (OCIL) 7.3L Diesel only: Jumper STI to SIG RTN at the Self- Test connectors. Service Codes will be flashed on the Overdrive Cancel Indicator Light (OCIL). Message Center (Continental Applications Only). Refer to Self-Test with Message Center. Place ignition key in the ON position. For 7.3L Diesel vehicles only, depress the throttle. Record all service codes displayed. DON'T Depress throttle during Key On Engine Off Self-Test on gasoline engine applications. Engine Running Self-Test Special Notes: If the engine starts but stalls, or stalls during Self-Test, Go to Pinpoint Test Step S1. On vehicles equipped with the Brake On/Off Switch (BOO), the brake pedal MUST be depressed and released AFTER the ID code. On vehicles equipped with the Power Steering Pressure Switch (PSPS), within 1 to 2 seconds after the ID code, the steering wheel must be turned at least one-half turn and released. On vehicles equipped with E4OD transmission, the Overdrive Cancel Switch (OCS) must be cycled after the ID code. The Dynamic Response code is a single pulse (or a 10 code on the STAR Tester) that occurs 6-20 seconds after the engine running identification code. (See APPENDIX: Code Output Format.) When/if the Dynamic Response code occurs, perform a brief wide-open throttle. How To Run The Engine Running Self-Test DO Deactivate Self-Test. Start and run engine at 2,000 rpm for two minutes. This action warms up the HEGO sensor. Turn engine off, wait 10 seconds. Activate Self-Test. Start engine. After the ID code, depress and release the brake pedal if appropriate. See Special Note above. After the ID code, within 1 to 2 seconds, turn the steering wheel at least one-half turn and then

4 Page 4 of 12 release it, if appropriate. See Special Note above. If a Dynamic Response Code occurs, perform a brief wide-open throttle (WOT). Record all service codes displayed. DON'T Depress the throttle unless a Dynamic Response Code is displayed. Continuous Memory Codes Special Notes: If Continuous Memory indicates a PASS Code 11 or 111 and a symptom is present, GO to Quick Test Step 8.0. Determining The Continuous Memory Codes To Be Serviced Refer to the Continuous Memory Codes recorded in Quick Test Step 3.0. The cause of some of the Continuous Memory Codes may have been eliminated during either Key On Engine Off or Engine Running Self-Test service. To address the remaining Continuous Memory codes, go to Quick Test Step 6.0 for 2-digit codes or 7.0 for 3-digit codes. If none, clear Continuous Memory. Self-Test Description The Self-Test is divided into three specialized tests: Key On Engine Off Self-Test, Engine Running Self-Test, and Continuous Self-Test. The Self-Test is not a conclusive test by itself, but is used as a part of the functional Quick-Test diagnostic procedure. The processor stores the Self-Test program in its permanent memory. When activated, it checks the EEC-IV system by testing its memory integrity and processing capability, and verifies that various sensors and actuators are connected and operating properly. The Key On Engine Off and Engine Running Self-Tests are functional tests which only detect faults present at the time of the Self-Test. Continuous Self-Test is performed during normal vehicle operation and stores any fault information in Keep Alive Memory (KAM) for retrieval at a later time. Key On Engine Off Self-Test At this time, a test of the EEC-IV system is conducted with power applied and engine at rest. For Self-Test to detect errors in the Key On Engine Off Self-Test mode, the fault must be present at the time of testing. For intermittents, refer to Continuous Memory Codes. Separator Pulse A single 1/2 second separator pulse is issued 6-9 seconds after the last Key On Engine Off Test code. Then, 6-9 seconds after the single 1/2 second separator pulse, the Continuous Memory Codes will be issued. Continuous Memory Codes Continuous Memory Codes are issued as a result of information stored during continuous Self-Test, while the vehicle was in normal operation. These codes are displayed only during Key On Engine Off testing and after the separator pulse. Intermittent faults that have not occured in the last 80 warm-up cycles (40 cycles

5 Page 5 of 12 on some applications) are erased from Continuous Memory and will not produce a Continuous Memory Code. Note: The separator pulse and Continuous Memory Codes follow Key On Engine Off Self-Test codes ONLY. Engine Running Self-Test At this time, a test of the EEC-IV system is conducted with the engine running. The sensors are checked under actual operating conditions and at normal operating temperatures. The actuators are exercised and checked for expected results. Engine Identification Codes (ID Codes) Engine ID codes are issued at the beginning of the Engine Running Self-Test and are one-digit numbers represented by the number of pulses sent out. For gasoline engines, the engine ID code is equal to one-half the number of engine cylinders (i.e. 2 pulses = 4 cylinders). For the 7.3L Diesel engine, the ID code = 5. These codes are used to verify the proper processor is installed and that the Self-Test has been entered. Dynamic Response Check The dynamic response check is used on some applications to verify operation of the TP, MAF, MAP and KS sensors during the brief Wide-Open Throttle (WOT) performed during the Engine Running Self-Test. The signal for the operator to perform the brief WOT is a single pulse or 10 code on the STAR Tester. Power Steering Pressure Switch Test On vehicles equipped with Power Steering Pressure Switch (PSPS), the steering wheel must be turned onehalf turn and released AFTER the ID Code has been displayed. This tests the ability of the EEC-IV system to detect a change of state in the Power Steering Pressure Switch. Brake On/Off Switch Test On vehicles equipped with Brake ON/OFF (BOO) input, the brake pedal MUST be depressed and released AFTER the ID Code has been displayed. This tests the ability of the EEC-IV system to detect a change of state in the Brakelamp Switch. Overdrive Cancel Switch Test On vehicles equipped with Overdrive Cancel Switch (OCS), the switch must be cycled after the ID code has been displayed. This tests the ability of the EEC-IV system to detect a change of state in the Overdrive Cancel Switch. Adaptive Fuel Self-Test Adaptive fuel logic is used in fuel injection systems primarily to account for normal variability in fuel system components. When, during steady state vehicle operation, the fuel system is detected to be "biased" rich or lean, Adaptive Fuel will make a corresponding shift in the fuel delivery calculations so an un-biased condition will exist. The adaptive fuel "shift" is stored in Keep Alive Memory (KAM), which is powered by the vehicle battery. This prevents Adaptive Fuel from being lost when the vehicle is turned off. MAF/TPS/Injector Pulsewidth In-Range Self-Test The In-Range Self-Test was designed to detect in-range failures of the MAF/TPS or fuel delivery systems.

6 Page 6 of 12 The EEC-IV processor will use information from these three systems to generate three independent values. The three independent values will be continuously monitored and if one of the values differs significantly from the others during normal vehicle operation a continuous memory code 121, 124, 125, 184, 185, 186 or 187 will be displayed. Code Output Format The EEC-IV system communicates service information through the Self-Test service codes. These service codes are two-digit or three-digit numbers representing the results of Self-Test. The service codes are transmitted on the Self-Test output (STO) line found in the vehicle Self-Test connector. They are in the form of timed pulses, and are read by the technician on a voltmeter, STAR tester, Malfunction Indicator Light (MIL), Overdrive Cancel Indicator Light (OCIL) or on the Continental message center. Self-Test Output Code Format Key On Engine Off and Continuous Memory Codes Figure 3: Key On Engine Off and Continuous Memory Code Format (2-digit codes shown, 3-digit codes similar) Self-Test Output Code Format Engine Running Codes Figure 4: Engine Running Self-Test Code Format (2-digit codes shown, 3-digit codes similar)

7 Page 7 of 12 Fast Codes/Slow Codes Fast codes are issued prior to slow service codes. These codes contain the identical information as the slow service codes but are transmitted at 100 times the normal rate. These codes are interpreted by special equipment at the end of the assembly line by the Body and Assembly Division as well as the Super STAR II tester. After Fast codes have been output, Self-Test should not be exited (remove jumper, unlatch button, etc.) until all the Slow codes have been output. Doing so will erase any Continuous Memory codes. Some meters in service detect these codes as a short burst of information (slight meter deflection). Continuous Self-Test The Continuous Memory service codes are separated from the Quick Test Key On Engine Off codes by a single separator pulse, Figure 3. Figure 5: Continuous Memory Code Format (2-digit codes shown, 3-digit codes similar) During this mode of testing the EEC-IV Processor continuously monitors inputs for opens and shorts. The Continuous Memory Codes must be retrieved within* 80 engine temperature warm up cycles. On the 81st or 41st Engine Temperature cycle, the service code will be automatically erased. The Continuous Memory Codes can also be erased by deactivating Self-Test while the service codes are being outputted. *40 engine temperature warm up cycles for some applications. Self-Test with Self-Test Automatic Readout (STAR) Tester Note: The STAR tester cannot be used to read 3-digit service codes. If the STAR tester is used on a 3-digit service code application, the display will be blank. After hooking up the STAR tester and turning on its power switch, the tester will run a display check and the numerals 88 will begin to flash in the display window (Figure 6). A steady 00 will then appear, indicating that the STAR tester is ready. To receive the service codes, press the push button at the front of the STAR tester. The button will latch down, and a colon will appear in the display window in front of the 00 numerals. The colon must be displayed to receive the service codes. If, for any reason, the technician wishes to clear the display window during the Self-Test, he must turn off the vehicle's engine, press the tester's push button once to unlatch it (colon will disappear), then press the

8 Page 8 of 12 button again to latch down the button (colon will appear again). The STAR tester will display the last service code received, even after disconnecting it from the vehicle. It will hold the service code on the display until the power is turned off or the push button is unlatched and relatched. For a detailed description of the STAR tester and the variety of tests that can be run, refer to the instruction manual provided with the tester. Figure 6: Star Tester Output Code Format Self-Test with SUPER STAR II Tester The SUPER STAR II Tester (Figure 7) can read fast codes as well as slow codes, and can be used on Ford EEC-IV as well as MCU and MECS systems. A built-in Self-Test memory will retain the codes as they are received. The SUPER STAR II tester also contains a beeper for running wiggle tests. After hooking up the SUPER STAR II tester and turning it on, the SUPER STAR II will briefly display 888. It will also light all the prompts on the left side of the display and the speaker will beep. When the tester is ready, both the STI-LO and STO-LO will be on, but the readout will be blank if the vehicle key is off. Key On Engine Off (KOEO) Self-Test 1. Plug in both connectors of the tester to the mating connectors of the vehicle. 2. Determine the type of system you have (EEC-IV or MECS) and set the switch to the proper type. 3. Select fast code mode or slow code mode with the mode selector switch. Note: The SUPER STAR II tester will only display 3-digit service codes in fast code mode. If slow code mode is used on 3-digit service code applications, the display will be blank. 4. Turn on the power to the tester. 5. Depress the test button on the tester to the test position. 6. Turn on the vehicle ignition key.

Page 9 of 12 The tester will now read any Self-Test codes in this mode. Key On Engine Running (KOER) Self-Test 1. Start and warm up the engine until it is at a normal running temperature. 2.

9 Page 9 of 12 The tester will now read any Self-Test codes in this mode. Key On Engine Running (KOER) Self-Test 1. Start and warm up the engine until it is at a normal running temperature. 2. Turn the engine off. 3. Depress the test button to the test position, then restart the engine. On applications with 2-digit service codes, the tester will now display an engine I.D. code, and on certain vehicles, a Dynamic Response code. Then, service codes will be displayed. For 3-digit code applications, no engine ID code will be displayed. The Dynamic Response indicator will light but no Dynamic Response code will be displayed. Service Codes will then be displayed. For a detailed description of the variety of tests that can be run with the SUPER STAR II, refer to the instruction manual provided with the tester. Figure 7: SUPER STAR II Tester Self-Test with Analog Voltmeter Service codes will be represented by pulsing or sweeping movements of the voltmeter's needle across the dial face of the voltmeter (Figure 6). Therefore, a single-digit number of three will be reported by three needle pulses (sweeps). However, a service code is represented by a two-digit or 3-digit number, such as 2-3. As a result, the Self-Tests service code of 2-3 will appear on the voltmeter as two needle pulses (sweeps), then, after a two-second pause, the needle will pulse (sweep) three times. The Continuous Memory Codes are separated from the Key On Engine Off codes by a six-second delay, a single half-second sweep, and another six-second delay.

Page 10 of 12 Figure 8: Analog Voltmeter Output Code Format (2-digit codes shown, 3-digit codes similar) Self-Test with Malfunction Indicator Light (MIL) During Self-Test a service code is reported

10 Page 10 of 12 Figure 8: Analog Voltmeter Output Code Format (2-digit codes shown, 3-digit codes similar) Self-Test with Malfunction Indicator Light (MIL) During Self-Test a service code is reported by the Malfunction Indicator Light (MIL). It will represent itself as a flash on the "CHECK ENGINE" or "SERVICE ENGINE SOON" light on the dash panel (Figure 9). A singledigit number of three will be reported by three flashes. However, a service code is represented by a two-digit or three-digit number, such as 2-3 or three digit. As a result, the Self-Test service code of 2-3 will appear on the MIL light as two flashes, then, after a two-second pause, the light will flash three times. The Continuous Memory Codes are separated from the Key On Engine Off codes by a six-second delay, a single half-second flash, and another six-second delay.

11 Page 11 of 12 Figure 9: Malfunction Indicator Light (MIL) Output Code Format (2-digit codes shown, 3-digit codes similar) Self-Test with Message Center (Continental Only) 1. On the Electronic Instrument Cluster, hold in all three buttons (Gauge Select, English Metric and Speed Alarm) at the same time. a. Key On Engine Off Self-Test While holding in all three buttons, place ignition switch in the ON position. Release buttons. b. Key On Engine Running Self-Test While holding in all three buttons, start engine. Release buttons. 2. Press the Gauge Select button three times, until cluster mode "dealer 4" is displayed. 3. To initiate Self-Test, jumper STI to SIG RTN at the Self-Test connectors, or use a STAR Tester and latch the center button in the down position. 4. Service code output will be displayed on the message center. 5. To exit Self-Test, turn ignition switch to OFF and remove jumper or unlatch STAR Tester.

12 Page 12 of 12 Figure 10: Electronic Instrument Cluster Center in Self-Test Mode Self-Test With Overdrive Cancel Indicator Light (OCIL) The OCIL serves a dual purpose on the 7.3L Diesel vehicle with E40D transmissions. The light stays OFF when the Overdrive Cancel Switch (OSC) is toggled once on the instrument panel indicating that the vehicle can attain the overdrive gear position. The light stays ON when the Overdrive Cancel Switch (OSC) is toggled again on the instrument panel indicating that the vehicle is prevented from shifting into the overdrive gear position. If the light flashes, then perform Key On Engine Off Self-Test. The light under this condition serves a Transmission Malfunction Indicator Light. Refer to Self-Test with Malfunction Indicator Light (MIL) to perform Self-Test.

E150/ L PFI Bronco & "F" Series E250/350, F250/350 & "F" Super Duty

E150/ L PFI Bronco & F Series E250/350, F250/350 & F Super Duty 1 of 57 12/12/2014 11:46 AM E4OD ELECTRONIC CONTROLS 1992 Ford Pickup 7.3L Eng F350 APPLICATION E4OD APPLICATIONS Models Engine E150/250 4.9L PFI Bronco & "F" Series "E" Series Bronco & "F" Series E250/350,