Ford E-Series and F-Series

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1 Ford ESeries and FSeries Gen Propane Diagnostic Manual

2 0608 Ford ESeries and FSeries Products Liquid Propane Autogas Fuel System (th Generation) Includes: E50/E50 Custom Body F59 F50/550 F650/750 Revision History BA Initial Release 5/05 CA Revisions /07 DA Revisions 7/08 DIAGNOSTIC MANUAL P0B0DA

3 TABLE OF CONTENTS SAFETY INFORMATION Alert Messages Installation, Garaging and Training Purging and Venting (Tanks and Lines) DIAGNOSTIC TROUBLE CODES About Diagnostic Trouble Codes System and Diagnostic Terminology Diagnostic Trouble Code List Calibration Release OBD Summary Chart Diagnostic Codes EVAP System Flow Control Solenoid Bleed Solenoid Tank Solenoid Fuel Rail Pressure Control Module Supply Solenoid and Wiring SRM, CAN Bus Circuit Wiring Fuel System Heated Exhaust Gas Oxygen Sensor Electronic Fuel Pump Relay (A/B) Integrated Pressure Temperature Sensor Fuel Level Sender Fuel Level Indication Check DIAGNOSTIC TESTS AND PROCEDURES General Information Pinpoint Test A: No Fill Pinpoint Test B: Slow Fill Pinpoint Test C: Over Fill Pinpoint Test D: Engine Does Not Crank Pinpoint Test E: Engine Cranks, No Start Pinpoint Test F: Engine Stumble, Stall, Rough Idle Pinpoint Test G: Excess Flow Valve Check Pinpoint Test H: Maximum Pressure Check Pinpoint Test I: Fuel System Fails to Bleed Pinpoint Test J: Fuel Pressure Drop Pinpoint Test K: Tank Solenoid Electrical Check Pinpoint Test L: Return Valve Procedure Pinpoint Test M: Fuel Rail Pressure Control Module Electrical Check Pinpoint Test N: Injection Pressure Temperature Sensor Electrical Check Pinpoint Test O: Tank Pressure Temperature Sensor Electrical Check Pinpoint Test P: Fuel Pump Function/Electrical Test Procedure Pinpoint Test Q: Fuel Pump Control Module Electrical Continuity Test Pinpoint Test R: Smart Relay Module Electrical Test Pinpoint Test S: Fuel Level Sender Electrical Check Pinpoint Test T: Manual Solenoid Activation Procedure Pinpoint Test U: F650/F750 Dual Tank Transfer Pinpoint Test (P5B DTC) E50 GEN Wiring Harnesses and Connector Layout F59 Wiring Harnesses and Connector Layout E50 Roush Wiring Harnesses Page i

4 TABLE OF CONTENTS F59 Roush Wiring Harnesses E50 Electrical Schematic Underhood Harness E50 Electrical Schematic CAN Bus Harness E50 Electrical Schematic Rear Frame Harness E50 Electrical Schematic Tank Harness F59 F50 F550 Electrical Schematic Underhood Harness F59 F50 F550 Electrical Schematic CAN Bus Harness F59 F50 F550 Electrical Schematic Rear Frame Harness F59 F50 F550 Electrical Schematic Tank Harness F650 F750 Electrical Schematic Underhood Harness F650 F750 Electrical Schematic CAN Bus Harness F650 F750 Electrical Schematic Left Tank Harness F650 F750 Electrical Schematic Right Tank Harness F650 F750 Electrical Schematic Transfer Overlay Harness Page ii

5 INTRODUCTION INTRODUCTION Page

6 INTRODUCTION SAFETY INFORMATION The National Fire Protection Association (NFPA) publishes a code book of rules that apply to the storage, handling, transportation and use of liquefied petroleum gas (LPGas or LPG). The book is known as NFPA 58. It is revised as necessary and published every other year. This code is adopted as law in virtually every political subdivision in the United States. Check with your local authorities for regulations applicable to liquid propane. Alert Messages The following alert messages may appear from time to time in appropriate places in this manual. Ensure that all personnel read and adhere to these alert messages. Do NOT carry lighted smoking materials or smoke while working on fuel system components. Failure to heed this danger could result in severe personal injury or death. Disconnect the battery ground at the battery to ensure that the vehicle electrical system has no current. Failure to heed this danger could result in severe personal injury or death. Although propane is nontoxic, nonpoisonous, has the lowest flammability range of any alternative fuel and dissipates quickly when released into the atmosphere, propane vapor is heavier than air and seeks the lowest point. When the ratio of propane to air is between.% and 9.6%, propane will burn in the presence of an ignition source at 90 F (50 C) or hotter. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Failure to heed this danger may result in severe personal injury or death. The fuel supply lines remain pressurized after engine shutdown. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Do NOT enter storage areas or confined space unless they are adequately ventilated. Failure to heed this danger may result in severe personal injury or death. Propane is heavier than air and seeks the lowest available level when released to the atmosphere. Keep heat, sparks, flames, static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank. Failure to heed this danger can result in severe personal injury or property damage. Technicians working with, or around, fuel systems should be properly trained to utilize extreme care and caution at all times. Failure to exercise extreme caution and care may lead to serious accidents which can result in property damage, personal injury and/or death. Liquid propane is cold. The temperature of propane in its liquid state at atmospheric pressure is F ( C). Wear eye and ear protection during venting and repair operations. Keep moisture away from the valves. Failure to heed this warning can result in personal injury. Page

7 INTRODUCTION Installation, Garaging and Training Chapter of NFPA 58 applies to engine fuel systems using LPGas in internal combustion engines, including containers, container appurtenances, carburetion equipment, piping, hose and fittings and their installation. Additionally, this chapter applies to garaging of vehicles and to the training of personnel. Purging and Venting (Tanks and Lines) Venting of LPGas to the atmosphere is covered by paragraphs 7.., General, and 7.., Purging of NFPA 58, 008 edition. Refer to NFPA 58, Local Codes and Proper Training for specific information relating to safe venting of LPG. Paragraph. specifies that each person engaged in installing, repairing, filling or otherwise servicing an LPGas engine fuel system shall be trained and possess all local certifications to work on propanepowered vehicles. Contact the Propane Education and Research Council to learn more about your local propane technician requirements. Page

8 TROUBLESHOOTING Page

9 DIAGNOSTIC TROUBLE CODES About Diagnostic Trouble Codes All diagnostic trouble codes (DTCs) known to be affected by the liquid propane autogas (LPA) system are covered in this manual. For all other System and Diagnostic Terminology DTCs, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at Acronym or Abbreviation BS CAN DTC EFPR ERFS EVAP FCS FLS FP FPCM FRP FRPCM FTS GRD HEGO IPC IPTS KOEO KOER LPA MAF OEM OPD PCM PID PWR GND SIG RTN SRM SS TPTS TS VMV VPWR VREF WOT Bleed Solenoid Controller Area Network Diagnostic Trouble Code Electronic Fuel Pump Relay Electronic Returnless Fuel System Evaporative Flow Control Solenoid Fuel Level Sender Fuel Pump Fuel Pump Control Module Fuel Rail Pressure Fuel Rail Pressure Control Module Fuel Temperature Sensor Ground Heated Exhaust Gas Oxygen Instrument Panel Cluster Injection Pressure Temperature Sensor Key On Engine Off Key On Engine Running Liquid Propane Autogas Mass Air Flow Original Equipment Manufacturer Overfill Protection Device Powertrain Control Module Parameter Identification Power Ground Signal Return Smart Relay Module Supply Solenoid Tank Pressure Temperature Sensor Tank Solenoid Vapor Management Valve Voltage Power Voltage Reference Wide Open Throttle Page 5

10 Diagnostic Trouble Code List Code P0005 Fuel Shutoff Valve A Control Circuit/Open P0090 Fuel Pressure Regulator Circuit/Open P009B Fuel Pressure Relief Control Circuit/Open P009E Fuel Pressure Relief Control Performance/Stuck Off P08 Fuel Delivery Error P07 System Too Lean (Bank ) P07 System Too Rich (Bank ) P07 System Too Lean (Bank ) P075 System Too Rich (Bank ) P08 Fuel Temperature Sensor A Circuit Range/Performance P08 Fuel Temperature Sensor A Circuit Low P08 Fuel Temperature Sensor A Circuit High P090 Fuel Rail Pressure Sensor Circuit (Bank ) P09 Fuel Rail Pressure Sensor Circuit Low (Bank ) P09 Fuel Rail Pressure Sensor Circuit High (Bank ) P0A0 Alternate Fuel Tank A Pressure Sensor Circuit Low P0A Alternate Fuel Tank A Pressure Sensor Circuit High P0A Alternative Fuel Tank "A" Pressure Sensor Circuit Intermittent/Erratic P0AC Alternate Fuel Tank Temperature Sensor Circuit Low P0AD Alternate Fuel Tank Temperature Sensor High P0AE Alternate Fuel Tank Temperature Sensor Circuit Intermittent/Erratic P05A Fuel Pump Module A Control Circuit/Open P05B Fuel Pump Module A Control Circuit Range/Performance P07B Fuel Pump Module B Control Circuit Range/Performance P0xx Misfire P0 EVAP System Leak Detected (small leak) P0 EVAP System Purge Control Valve "A" Circuit P06 EVAP System Vent Control Circuit P05 EVAP System Pressure Sensor/Switch Range/Performance P05 EVAP System Pressure Sensor/Switch Low P05 EVAP System Pressure Sensor/Switch High P05 EVAP System Pressure Sensor/Switch Intermittent P055 EVAP System Leak Detected (large leak) P056 EVAP System Leak Detected (very small leak) P06 Fuel Level Sender A Circuit Range/Performance P06 Fuel Level Sender A Circuit Low P06 Fuel Level Sender A Circuit High P067 Fuel Pump A Control Circuit Open P06A Fuel Pump Control Module A Page 6

11 P6E P5 P95 P97 P5B0 P5B P6 P665 P6B P6B5 P6EA U008 U009 U06C U0B U0C Code Fuel Pressure Relief Valve Actuated Fuel Tank Pressure Relief Valve Malfunction Heated Exhaust Gas Oxygen Sensor Stuck Heated Exhaust Gas Oxygen Sensor Stuck Fuel Level Sensor A Stuck Fuel Level Sensor B Stuck Fuel Pump B Control Circuit/Open Fuel Shutoff Valve B Control Circuit/Open Fuel Shutoff Valve A Control Circuit Performance/Stuck Off Fuel Shutoff Valve B Control Circuit Performance/Stuck Off Fuel Pump Control Module B Lost Communication with Alternative Fuel Control Module Lost Communication with Fuel Pump Control Module A Lost Communication with Fuel Pump Control Module B Lost Communication Between Fuel Pump Control Module A and Restraint Control Module Lost Communication Between Fuel Pump Control Module B and Restraint Control Module 0607 Calibration Release OBD Summary Chart 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code c05d7 N/A N/A nonmil P0005 Fuel Shutoff Valve "A" Control Circuit/Open nonmil nonmil nonmil P000 HOS Heater Control Circuit (Bank Sensor ) MIL MIL MIL P006 HOS Heater Control Circuit (Bank Sensor ) MIL MIL MIL P000 Oxygen Sensor Signals Swapped Bank Sensor /Bank Sensor nonmil nonmil nonmil P0050 HOS Heater Control Circuit (Bank Sensor ) MIL MIL MIL P0068 MAP/MAF Throttle Position Correlation MIL MIL MIL P0090 Fuel Pressure Regulator Control Circuit/Open nonmil nonmil nonmil P009B Fuel Pressure Relief Control Circuit/Open MIL MIL MIL P009E Fuel Pressure Relief Control Performance/Stuck Off MIL MIL MIL P000 Mass or Volume Air Flow Sensor "A" Circuit MIL MIL MIL P00 Mass or Volume Air Flow Sensor "A" Circuit Low MIL MIL MIL P00 Mass or Volume Air Flow Sensor "A" Circuit High MIL MIL MIL P00 Mass or Volume Air Flow Sensor "A" Circuit Intermittent MIL MIL MIL P0 Intake Air Temperature Sensor Circuit Range/Performance (Bank ) MIL MIL MIL P0 Intake Air Temperature Sensor Circuit Low (Bank ) MIL MIL MIL P0 Intake Air Temperature Sensor Circuit High (Bank ) MIL MIL MIL P06 Engine Coolant Temperature Sensor Circuit Range/Performance MIL MIL MIL P0 Throttle/Pedal Position Sensor "A" Circuit Low MIL MIL MIL P0 Throttle/Pedal Position Sensor "A" Circuit High MIL MIL MIL Page 7

12 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P05 Insufficient Coolant Temp For Closed Loop Fuel Control MIL MIL MIL P0 O Sensor Circuit Low Voltage (Bank Sensor ) MIL MIL MIL P0 O Sensor Circuit High Voltage (Bank Sensor ) MIL MIL MIL P05 O Sensor Heater Circuit (Bank Sensor ) MIL MIL MIL P07 O Sensor Circuit Low Voltage (Bank Sensor ) MIL MIL MIL P08 O Sensor Circuit High Voltage (Bank Sensor ) MIL MIL MIL P0 O Sensor Heater Circuit (Bank Sensor ) MIL MIL MIL P08 Fuel Delivery Error nonmil nonmil nonmil P05 O Sensor Circuit Low Voltage (Bank Sensor ) MIL MIL MIL P05 O Sensor Circuit High Voltage (Bank Sensor ) MIL MIL MIL P055 O Sensor Heater Circuit (Bank Sensor ) MIL MIL MIL P07 System Too Lean (Bank ) MIL MIL MIL P07 System Too Rich (Bank ) MIL MIL MIL P07 System Too Lean (Bank ) MIL MIL MIL P075 System Too Rich (Bank ) MIL MIL MIL P08 Fuel Temperature Sensor A Circuit Range/Performance nonmil nonmil nonmil P08 Fuel Temperature Sensor A Circuit Low MIL MIL MIL P08 Fuel Temperature Sensor A Circuit High MIL MIL MIL P090 Fuel Rail Pressure Sensor Circuit (Bank ) MIL MIL MIL P09 Fuel Rail Pressure Sensor Circuit Low (Bank ) MIL MIL MIL P09 Fuel Rail Pressure Sensor Circuit High (Bank ) MIL MIL MIL P0A0 Alternate Fuel Tank A Pressure Sensor Circuit Low nonmil nonmil nonmil P0A Alternate Fuel Tank A Pressure Sensor Circuit High nonmil nonmil nonmil P0A Alternative Fuel Tank "A" Pressure Sensor Circuit Intermittent/ Erratic nonmil nonmil nonmil P0AC Alternate Fuel Tank Temperature Sensor Circuit Low nonmil nonmil nonmil P0AD Alternate Fuel Tank Temperature Sensor High nonmil nonmil nonmil P0AE Alternate Fuel Tank Temperature Sensor Circuit Intermittent/Erratic nonmil nonmil nonmil P00 Cylinder Injector "A" Circuit/Open MIL MIL MIL P00 Cylinder Injector "A" Circuit/Open MIL MIL MIL P00 Cylinder Injector "A" Circuit/Open MIL MIL MIL P00 Cylinder Injector "A" Circuit/Open MIL MIL MIL P005 Cylinder 5 Injector "A" Circuit/Open MIL MIL MIL P006 Cylinder 6 Injector "A" Circuit/Open MIL MIL MIL P007 Cylinder 7 Injector "A" Circuit/Open MIL MIL MIL P008 Cylinder 8 Injector "A" Circuit/Open MIL MIL MIL P009 Cylinder 9 Injector "A" Circuit/Open MIL MIL MIL P00 Cylinder 0 Injector "A" Circuit/Open MIL MIL MIL P07 Engine Coolant Over Temperature Condition nonmil nonmil nonmil Page 8

13 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P08 Transmission Fluid Temperature Sensor "A" Over Temperature nonmil nonmil nonmil Condition P09 Engine Overspeed Condition nonmil nonmil nonmil P0 Throttle/Pedal Position Sensor/Switch "B" Circuit Low MIL MIL MIL P0 Throttle/Pedal Position Sensor/Switch "B" Circuit High MIL MIL MIL P05A Fuel Pump Module A Control Circuit/Open nonmil nonmil nonmil P05B Fuel Pump Module A Control Circuit Range/Performance nonmil nonmil nonmil P07B Fuel Pump Module B Control Circuit Range/Performance nonmil nonmil N/A P097 Vehicle Overspeed Condition nonmil nonmil nonmil P098 Engine Oil Over Temperature Condition nonmil nonmil nonmil P0xx Misfire nonmil nonmil nonmil P09 Crankshaft Position Sensor "A" Circuit Intermittent MIL MIL MIL P00 Camshaft Position Sensor "A" Circuit (Bank or single sensor) MIL MIL MIL P05 Ignition Coil "A" Primary Control Circuit/Open MIL MIL MIL P05 Ignition Coil "B" Primary Control Circuit/Open MIL MIL MIL P05 Ignition Coil "C" Primary Control Circuit/Open MIL MIL MIL P05 Ignition Coil "D" Primary Control Circuit/Open MIL MIL MIL P055 Ignition Coil "E" Primary Control Circuit/Open MIL MIL MIL P056 Ignition Coil "F" Primary Control Circuit/Open MIL MIL MIL P057 Ignition Coil "G" Primary Control Circuit/Open MIL MIL MIL P058 Ignition Coil "H" Primary Control Circuit/Open MIL MIL MIL P059 Ignition Coil "I" Primary Control Circuit/Open MIL MIL MIL P060 Ignition Coil "J" Primary Control Circuit/Open MIL MIL MIL P0xx Misfire nonmil nonmil nonmil P0 EVAP System Purge Control Valve "A" Circuit MIL MIL MIL P060 Fuel Level Sensor "A" Circuit N/A nonmil N/A P06 Fuel Level Sensor A Circuit Range/Performance nonmil nonmil nonmil P06 Fuel Level Sensor A Circuit Low nonmil nonmil nonmil P06 Fuel Level Sensor A Circuit High nonmil nonmil nonmil P050 Brake Switch "A"/"B" Correlation nonmil nonmil nonmil P0505 Idle Control System nonmil nonmil nonmil P0506 Idle Control System RPM Lower Than Expected MIL MIL MIL P0507 Idle Control System RPM Higher Than Expected MIL MIL MIL P05 A/C Refrigerant Pressure Sensor "A" Circuit Low nonmil nonmil nonmil P05 A/C Refrigerant Pressure Sensor "A" Circuit High nonmil nonmil nonmil P056 System Voltage Low nonmil nonmil nonmil P056 System Voltage High nonmil nonmil nonmil P057 Brake Switch "A" Circuit Low nonmil nonmil nonmil P057 Brake Switch "A" Circuit High nonmil nonmil nonmil P0579 Cruise Control MultiFunction Input "A" Circuit Range/Performance nonmil N/A nonmil Page 9

14 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P058 Cruise Control MultiFunction Input "A" Circuit High nonmil N/A nonmil P0600 Serial Communication Link MIL MIL MIL P060 Powertrain Control Module Programming Error MIL MIL MIL P060 Internal Control Module Random Access Memory (RAM) Error MIL MIL MIL P0605 Internal Control Module Read Only Memory (ROM) Error MIL MIL MIL P0607 Control Module Performance MIL MIL MIL P060A Internal Control Module Monitoring Processor Performance MIL MIL MIL P060B Internal Control Module A/D Processing Performance MIL MIL MIL P060C Internal Control Module Main Processor Performance MIL MIL MIL P060D Internal Control Module Accelerator Pedal Position Performance nonmil nonmil nonmil P060 Control Module Vehicle Options Error MIL MIL MIL P06A Internal Control Module Torque Performance nonmil nonmil nonmil P06B Internal Control Module Torque Calculation Performance MIL MIL MIL P06C Internal Control Module Engine RPM Performance MIL MIL MIL P06D Internal Control Module Engine Air Mass Performance MIL MIL MIL P060 Generator Control Circuit nonmil nonmil nonmil P065 Generator Field/F Terminal Circuit Low nonmil nonmil nonmil P066 Generator Field/F Terminal Circuit High nonmil nonmil nonmil P067 Fuel Pump A" Control Circuit Open nonmil nonmil nonmil P06F Internal Control Module EEPROM Error N/A nonmil N/A P060 VIN Not Programmed or Incompatible ECM/PCM N/A nonmil N/A P06 Sensor Reference Voltage "A" Circuit Low MIL MIL MIL P06 Sensor Reference Voltage "A" Circuit High MIL MIL MIL P065 A/C Clutch Relay Control Circuit nonmil nonmil nonmil P06A Fuel Pump Control Module A nonmil nonmil N/A P06D Internal Control Module O Sensor Processor Performance (Bank ) MIL MIL MIL P06E Internal Control Module O Sensor Processor Performance (Bank ) MIL MIL MIL P0657 Actuator Supply Voltage "A" Circuit/Open MIL MIL MIL P065B Generator Control Circuit Range/Performance nonmil nonmil nonmil P06B8 Internal Control Module NonVolatile Random Access Memory (NVRAM) Error MIL MIL MIL P06E Control Module Wakeup Circuit Performance N/A nonmil N/A P06E9 Engine Starter Performance nonmil nonmil nonmil P070 Transmission Control System Range/Performance nonmil nonmil nonmil P070 Transmission Control System Electrical nonmil nonmil nonmil P0706 Transmission Range Sensor "A" Circuit Range/Performance MIL MIL MIL P0707 Transmission Range Sensor "A" Circuit Low MIL MIL MIL P0708 Transmission Range Sensor "A" Circuit High MIL MIL MIL P070 Transmission Fluid Temperature Sensor "A" Circuit nonmil nonmil nonmil Page 0

15 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P07 Transmission Fluid Temperature Sensor "A" Circuit Range/ Performance MIL MIL MIL P07 Transmission Fluid Temperature Sensor "A" Circuit Low MIL MIL MIL P07 Transmission Fluid Temperature Sensor "A" Circuit High MIL MIL MIL P075 Input/Turbine Shaft Speed Sensor "A" Circuit MIL MIL MIL P077 Input/Turbine Shaft Speed Sensor "A" Circuit No Signal nonmil nonmil nonmil P078 Input/Turbine Shaft Speed Sensor "A" Circuit Intermittent MIL MIL MIL P070 Output Shaft Speed Sensor Circuit MIL MIL MIL P07 Output Shaft Speed Sensor Circuit No Signal nonmil nonmil nonmil P079 Gear 6 Incorrect Ratio nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil P075 Gear 5 Incorrect Ratio nonmil nonmil nonmil P070 Torque Converter Clutch Solenoid Circuit/Open MIL MIL MIL P07 Torque Converter Clutch Solenoid Circuit Performance/Stuck Off MIL MIL MIL P07 Torque Converter Clutch Solenoid Circuit Stuck On MIL MIL MIL P07 Torque Converter Clutch Solenoid Circuit Electrical nonmil nonmil nonmil P07 Torque Converter Clutch Solenoid Circuit Intermittent MIL MIL MIL P078 Pressure Control Solenoid "A" Electrical nonmil nonmil nonmil P0750 Shift Solenoid "A" MIL MIL MIL P075 Shift Solenoid "A" Performance/Stuck Off MIL MIL MIL P075 Shift Solenoid "A" Stuck On MIL MIL MIL P075 Shift Solenoid "A" Electrical nonmil nonmil nonmil P075 Shift Solenoid "A" Intermittent MIL MIL MIL P0755 Shift Solenoid "B" MIL MIL MIL P0756 Shift Solenoid "B" Performance/Stuck Off MIL MIL MIL P0757 Shift Solenoid "B" Stuck On MIL MIL MIL P0758 Shift Solenoid "B" Electrical nonmil nonmil nonmil P0759 Shift Solenoid "B" Intermittent MIL MIL MIL P0760 Shift Solenoid "C" MIL MIL MIL P076 Shift Solenoid "C" Performance/Stuck Off MIL MIL MIL P076 Shift Solenoid "C" Stuck On MIL MIL MIL P076 Shift Solenoid "C" Electrical nonmil nonmil nonmil P076 Shift Solenoid "C" Intermittent MIL MIL MIL P0765 Shift Solenoid "D" MIL MIL MIL P0766 Shift Solenoid "D" Performance/Stuck Off MIL MIL MIL P0767 Shift Solenoid "D" Stuck On MIL MIL MIL P0768 Shift Solenoid "D" Electrical nonmil nonmil nonmil Page

16 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P0769 Shift Solenoid "D" Intermittent MIL MIL MIL P0770 Shift Solenoid "E" MIL MIL MIL P077 Shift Solenoid "E" Performance/Stuck Off MIL MIL MIL P077 Shift Solenoid "E" Stuck On MIL MIL MIL P077 Shift Solenoid "E" Electrical nonmil nonmil nonmil P077 Shift Solenoid "E" Intermittent MIL MIL MIL P088 TCM Power Input Signal Low MIL MIL MIL P088 TCM Power Input Signal High MIL MIL MIL P0885 TCM Power Relay Control Circuit /Open nonmil nonmil nonmil P0960 Pressure Control Solenoid "A" Control Circuit/Open MIL MIL MIL P096 Pressure Control Solenoid "A" Control Circuit Range/Performance MIL MIL MIL P096 Pressure Control Solenoid "A" Control Circuit Low MIL MIL MIL P096 Pressure Control Solenoid "A" Control Circuit High MIL MIL MIL P097 Shift Solenoid "A" Control Circuit Low MIL MIL MIL P097 Shift Solenoid "A" Control Circuit High MIL MIL MIL P0976 Shift Solenoid "B" Control Circuit Low MIL MIL MIL P0977 Shift Solenoid "B" Control Circuit High MIL MIL MIL P0979 Shift Solenoid "C" Control Circuit Low MIL MIL MIL P0980 Shift Solenoid "C" Control Circuit High MIL MIL MIL P098 Shift Solenoid "D" Control Circuit Low MIL MIL MIL P098 Shift Solenoid "D" Control Circuit High MIL MIL MIL P0985 Shift Solenoid "E" Control Circuit Low MIL MIL MIL P0986 Shift Solenoid "E" Control Circuit High MIL MIL MIL P00 KOER Not Able to Complete, KOER Aborted nonmil nonmil nonmil P00 KOER Not Able to Complete, KOER Aborted nonmil N/A nonmil P0 Mass Air Flow Sensor Out Of Self Test Range nonmil nonmil nonmil P Throttle Position Sensor "A" Out Of Self Test Range nonmil nonmil nonmil P7 Exhaust Temperature Out of Range, O Sensor Tests Not Completed nonmil nonmil nonmil P5E Throttle Actuator Control Throttle Body Air Flow Trim at Max Limit nonmil nonmil nonmil P6E Fuel Pressure Relief Valve Actuated nonmil nonmil nonmil P60 Theft Detected, Vehicle Immobilized nonmil N/A N/A P85 Cylinder Head Over Temperature Condition nonmil nonmil nonmil P88 Cylinder Head Temperature Sensor Out Of Self Test Range nonmil nonmil nonmil P89 Cylinder Head Temperature Sensor Circuit High MIL MIL MIL P90 Cylinder Head Temperature Sensor Circuit Low MIL MIL MIL P6 Crankshaft/Camshaft Sensor Range/Performance nonmil nonmil nonmil P97 System Voltage Out Of Self Test Range nonmil nonmil nonmil P5 Fuel Tank Pressure Relief Valve Malfunction nonmil nonmil nonmil P6 A/C Demand Out Of Self Test Range nonmil nonmil nonmil Page

17 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P50 Vehicle Speed Sensor Out Of Self Test Range nonmil nonmil nonmil P56 Brake Line Pressure Sensor Circuit nonmil N/A nonmil P575 Pedal Position Out Of Self Test Range nonmil nonmil nonmil P59 Forced Engine Shutdown Remote Start System Fault, No Unattended Vehicle Timeout N/A nonmil nonmil P595 Forced Engine Shutdown Remote Start System Fault, Transmission Range Not In Park Position N/A nonmil nonmil P60 Immobilizer/ECM Communication Error nonmil N/A N/A P60A Control Module Vehicle Options Reconfiguration Error N/A nonmil N/A P6A Incorrect Response from Immobilizer Control Module N/A nonmil N/A P6 Immobilizer ID Does Not Match nonmil N/A N/A P6E Internal Control Module PTO Control Performance nonmil nonmil nonmil P6F Starter Motor Disabled Engine Crank Time Too Long nonmil nonmil nonmil P6 Keep Alive Power Voltage Too Low nonmil N/A nonmil P65 Tire/Axle Out of Acceptable Range nonmil N/A nonmil P66 Inductive Signature Chip Communication Error MIL MIL MIL P69 Vehicle ID Block Corrupted, Not Programmed N/A nonmil N/A P66 Linear O Sensor Control Chip (Bank ) MIL MIL MIL P67 Linear O Sensor Control Chip (Bank ) MIL MIL MIL P67 Control Module Software Corrupted MIL MIL MIL P70 Transmission Range Sensor Circuit Intermittent nonmil nonmil nonmil P70 Brake Switch Out Of Self Test Range nonmil nonmil nonmil P705 Transmission Range Circuit Not Indicating Park/Neutral During Self Test nonmil nonmil nonmil P7 Transmission Fluid Temperature Sensor Out Of Self Test Range nonmil nonmil nonmil P7 Torque Converter Clutch Solenoid Circuit Performance nonmil nonmil nonmil P77F Unable To Fully Engage Neutral nonmil nonmil nonmil P780 Transmission Control Switch (O/D Cancel) Circuit Out Of Self Test Range nonmil N/A nonmil P78 Transmission Overtemperature Condition nonmil nonmil nonmil P9 Transmission Range Signal nonmil nonmil nonmil P9 Vehicle Speed Signal N/A MIL N/A P9E A/C Clutch Request Signal N/A nonmil N/A P067 Fuel Level Sensor "B" Circuit Low N/A nonmil N/A P068 Fuel Level Sensor "B" Circuit High N/A nonmil N/A P096 Post Catalyst Fuel Trim System Too Lean (Bank ) MIL MIL MIL P097 Post Catalyst Fuel Trim System Too Rich (Bank ) MIL MIL MIL P098 Post Catalyst Fuel Trim System Too Lean (Bank ) MIL MIL MIL P099 Post Catalyst Fuel Trim System Too Rich (Bank ) MIL MIL MIL P0 Throttle Actuator "A" Control Motor Circuit Range/Performance MIL MIL MIL P07 Throttle Actuator "A" Control Module Processor MIL MIL MIL Page

18 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code P Throttle Actuator "A" Control System Stuck Open MIL MIL MIL P Throttle Actuator "A" Control System Stuck Closed MIL MIL MIL P Throttle/Pedal Position Sensor/Switch "D" Circuit Low nonmil nonmil nonmil P Throttle/Pedal Position Sensor/Switch "D" Circuit High nonmil nonmil nonmil P7 Throttle/Pedal Position Sensor/Switch "E" Circuit Low nonmil nonmil nonmil P8 Throttle/Pedal Position Sensor/Switch "E" Circuit High nonmil nonmil nonmil P5 Throttle/Pedal Position Sensor/Switch "A"/"B" Voltage Correlation MIL MIL MIL P8 Throttle/Pedal Position Sensor/Switch "D"/"E" Voltage Correlation nonmil nonmil nonmil P95 Heated Exhaust Gas Oxygen Sensor Stuck MIL MIL MIL P96 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) MIL MIL P97 Heated Exhaust Gas Oxygen Sensor Stuck MIL MIL P98 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) MIL MIL P9A Bank AirFuel Ratio Imbalance N/A MIL MIL P9B Bank AirFuel Ratio Imbalance N/A MIL MIL P7 O Sensor Positive Current Control Circuit/Open (Bank Sensor ) MIL MIL MIL P0 O Sensor Positive Current Control Circuit/Open (Bank Sensor ) MIL MIL MIL P O Sensor Reference Voltage Circuit/Open (Bank Sensor ) MIL MIL MIL P7 O Sensor Reference Voltage Circuit/Open (Bank Sensor ) MIL MIL MIL P5 O Sensor Negative Current Control Circuit/Open (Bank Sensor ) MIL MIL MIL P5 O Sensor Negative Current Control Circuit/Open (Bank Sensor ) MIL MIL MIL P55 Ignition Switch Run/Start Position Circuit High nonmil nonmil nonmil P5B0 Fuel Level Sensor A Stuck nonmil nonmil nonmil P5B Fuel Level Sensor "B" Stuck N/A nonmil N/A P60 ECM/PCM Engine Off Timer Performance MIL MIL MIL P6 Fuel Pump B Control Circuit/Open nonmil nonmil N/A P6F Engine Serial Number Not Programmed or Incompatible MIL MIL MIL P665 Fuel Shutoff Valve "B" Control Circuit/Open nonmil nonmil nonmil P669 Actuator Supply Voltage "B" Circuit/Open MIL MIL MIL P6B Fuel Shutoff Valve A Control Circuit Performance/Stuck Off nonmil nonmil nonmil P6B5 Fuel Shutoff Valve "B" Control Circuit Performance/Stuck Off nonmil nonmil nonmil P6EA Fuel Pump Control Module B nonmil nonmil N/A P700 Transmission Friction Element "A" Apply Time Range/Performance nonmil nonmil nonmil P70 Transmission Friction Element "B" Apply Time Range/Performance nonmil nonmil nonmil P70 Transmission Friction Element "C" Apply Time Range/Performance nonmil nonmil nonmil P70 Transmission Friction Element "D" Apply Time Range/Performance nonmil nonmil nonmil P70 Transmission Friction Element "E" Apply Time Range/Performance nonmil nonmil nonmil P705 Transmission Friction Element "F" Apply Time Range/Performance nonmil nonmil nonmil P758 Torque Converter Clutch Pressure Control Solenoid Stuck On MIL MIL MIL P760 Torque Converter Clutch Pressure Control Solenoid Intermittent MIL MIL MIL Page

19 6.8L V LPG E50 Custom Body 6.8L V LPG F650 (dual tank) 6.8L V LPG F5 (Motorhome) F59 (Step Van) Code U008 Lost Communication with Alternative Fuel Control Module MIL MIL MIL U009 Loss of Communication on Fuel Pump Control Module A nonmil nonmil nonmil U0 Lost Communication With AntiLock Brake System (ABS) Control Module nonmil nonmil nonmil U00 Lost Communication With Body Control Module N/A nonmil N/A U06C Loss of Communication on Fuel Pump Control Module B nonmil nonmil N/A U0 Lost Communication With Steering Column Control Module N/A nonmil N/A U000 Internal Control Module Software Incompatibility MIL MIL MIL U05 Invalid Data Received from AntiLock Brake System (ABS) Control Module N/A nonmil N/A U0 Invalid Data Received from Body Control Module N/A nonmil N/A U0B U0C Lost Communication Between Fuel Pump Control Module A and Restraint Control Module Lost Communication Between Fuel Pump Control Module B and Restraint Control Module nonmil N/A N/A nonmil N/A N/A N/A nonmil MIL Code not present DTC non MIL DTC MIL (two trips) NOTE: For any DTCs not specific to the ROUSH CleanTech fuel system, please reference the Ford PC/ED manual. 08 Diagnostic Codes Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) B ECU is Faulted nonmil nonmil N/A OFF N/A OFF C05D7 N/A N/A N/A nonmil N/A OFF P0005 Fuel Shutoff Valve "A" Control Circuit/Open nonmil nonmil nonmil nonmil nonmil nonmil P000 HOS Heater Control Circuit (Bank Sensor ) P006 HOS Heater Control Circuit (Bank Sensor ) P000 Oxygen Sensor Signals Swapped Bank Sensor /Bank Sensor nonmil nonmil nonmil nonmil nonmil nonmil P00 Oxygen Sensor Signals Swapped Bank Sensor / Bank Sensor nonmil OFF OFF OFF OFF OFF P0050 HOS Heater Control Circuit (Bank Sensor ) P0056 HOS Heater Control Circuit (Bank Sensor ) MIL OFF OFF OFF OFF OFF P0068 MAP/MAF Throttle Position Correlation Page 5

20 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P007 Ambient Air Temperature Sensor Circuit "A" Range/Performance N/A N/A MIL N/A N/A N/A P007 Ambient Air Temperature Sensor Circuit "A" Low N/A N/A MIL N/A N/A N/A P007 Ambient Air Temperature Sensor Circuit "A" High N/A N/A MIL N/A N/A N/A P0090 Fuel Pressure Regulator Control Circuit/Open P009B Fuel Pressure Relief Control Circuit/Open P009E Fuel Pressure Relief Control Performance/Stuck Off P009F Fuel Pressure Relief Control Performance/Stuck On P000 Mass or Volume Air Flow Sensor "A" Circuit P00 P00 P00 P0 P0 P0 P06 P0 P0 P05 P08 P0 P0 Mass or Volume Air Flow Sensor "A" Circuit Low Mass or Volume Air Flow Sensor "A" Circuit High Mass or Volume Air Flow Sensor "A" Circuit Intermittent Intake Air Temperature Sensor Circuit Range/Performance (Bank ) Intake Air Temperature Sensor Circuit Low (Bank ) Intake Air Temperature Sensor Circuit High (Bank ) Engine Coolant Temperature Sensor Circuit Range/Performance Throttle/Pedal Position Sensor "A" Circuit Low Throttle/Pedal Position Sensor "A" Circuit High Insufficient Coolant Temp For Closed Loop Fuel Control Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature) O Sensor Circuit Low Voltage (Bank Sensor ) O Sensor Circuit High Voltage (Bank Sensor ) nonmil nonmil MIL MIL MIL MIL P0 O Sensor Circuit Slow Response (Bank Sensor ) P05 O Sensor Heater Circuit (Bank Sensor ) P07 P08 P0A O Sensor Circuit Low Voltage (Bank Sensor ) O Sensor Circuit High Voltage (Bank Sensor ) O Sensor Slow Response Rich to Lean (Bank Sensor ) Page 6

21 Code P0C O Sensor Slow Response Rich to Lean (Bank Sensor ) 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) MIL OFF OFF OFF OFF OFF P0E O Sensor Delayed Response Rich to Lean (Bank Sensor ) P0 O Sensor Heater Circuit (Bank Sensor ) P08 Fuel Delivery Error nonmil nonmil nonmil nonmil nonmil nonmil P0A P05 P05 O Sensor Delayed Response Rich to Lean (Bank Sensor ) O Sensor Circuit Low Voltage (Bank Sensor ) O Sensor Circuit High Voltage (Bank Sensor ) MIL OFF OFF OFF OFF OFF P05 O Sensor Circuit Slow Response (Bank Sensor ) P055 O Sensor Heater Circuit (Bank Sensor ) P057 O Sensor Circuit Low Voltage (Bank Sensor ) MIL OFF OFF OFF OFF OFF P058 O Sensor Circuit High Voltage (Bank Sensor ) MIL OFF OFF OFF OFF OFF P06 O Sensor Heater Circuit (Bank Sensor ) MIL OFF OFF OFF OFF OFF P07 System Too Lean (Bank ) P07 System Too Rich (Bank ) P07 System Too Lean (Bank ) P075 System Too Rich (Bank ) P08 Fuel Temperature Sensor A Circuit Range/Performance P08 Fuel Temperature Sensor A Circuit Low P08 Fuel Temperature Sensor A Circuit High P09 P09 P09F P0A0 P0A P0A P0A9 P0AC P0AD P0AE Fuel Rail Pressure Sensor Circuit Low (Bank ) Fuel Rail Pressure Sensor Circuit High (Bank ) Alternative Fuel Tank "A" Pressure Sensor Range/Performance Alternate Fuel Tank A Pressure Sensor Circuit Low Alternate Fuel Tank A Pressure Sensor Circuit High Alternative Fuel Tank "A" Pressure Sensor Circuit Intermittent/ Erratic Alternative Fuel Rail/System Pressure Too High Alternate Fuel Tank Temperature Sensor Circuit Low Alternate Fuel Tank Temperature Sensor High Alternate Fuel Tank Temperature Sensor Circuit Intermittent/Erratic Page 7

22 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P00 Cylinder Injector "A" Circuit/Open P00 Cylinder Injector "A" Circuit/Open P00 Cylinder Injector "A" Circuit/Open P00 Cylinder Injector "A" Circuit/Open P005 Cylinder 5 Injector "A" Circuit/Open P006 Cylinder 6 Injector "A" Circuit/Open P007 Cylinder 7 Injector "A" Circuit/Open P008 Cylinder 8 Injector "A" Circuit/Open P009 Cylinder 9 Injector "A" Circuit/Open P00 Cylinder 0 Injector "A" Circuit/Open P07 Engine Coolant Over Temperature Condition nonmil nonmil nonmil nonmil nonmil nonmil P08 Transmission Fluid Temperature Sensor "A" Over Temperature Condition nonmil nonmil nonmil nonmil nonmil nonmil P09 Engine Overspeed Condition nonmil nonmil nonmil nonmil nonmil nonmil P0 Throttle/Pedal Position Sensor/Switch "B" Circuit Low P0 Throttle/Pedal Position Sensor/Switch "B" Circuit High P05A Fuel Pump Module A Control Circuit/Open P05B Fuel Pump Module A Control Circuit Range/Performance P07B Fuel Pump Module B Control Circuit Range/Performance P097 Vehicle Overspeed Condition nonmil nonmil nonmil nonmil nonmil nonmil P098 Engine Oil Over Temperature Condition nonmil nonmil nonmil nonmil nonmil nonmil P000 Random Misfire Detected P00 Cylinder Misfire Detected P00 Cylinder Misfire Detected P00 Cylinder Misfire Detected P00 Cylinder Misfire Detected P005 Cylinder 5 Misfire Detected P006 Cylinder 6 Misfire Detected P007 Cylinder 7 Misfire Detected P008 Cylinder 8 Misfire Detected P009 Cylinder 9 Misfire Detected P00 Cylinder 0 Misfire Detected P0 Misfire Detected With Low Fuel nonmil nonmil nonmil nonmil nonmil nonmil P05 P06 P09 P00 Crankshaft Position System Variation Not Learned Misfire Detected On Startup (First 000 Revolutions) Crankshaft Position Sensor "A" Circuit Intermittent Camshaft Position Sensor "A" Circuit (Bank or single sensor) nonmil nonmil nonmil nonmil nonmil nonmil Page 8

23 Code P05 P05 P05 P05 P055 P056 P057 Ignition Coil "A" Primary Control Circuit/Open Ignition Coil "B" Primary Control Circuit/Open Ignition Coil "C" Primary Control Circuit/Open Ignition Coil "D" Primary Control Circuit/Open Ignition Coil "E" Primary Control Circuit/Open Ignition Coil "F" Primary Control Circuit/Open Ignition Coil "G" Primary Control Circuit/Open 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P058 Ignition Coil "H" Primary Control Circuit/Open P059 Ignition Coil "I" Primary Control Circuit/Open P060 P00 Ignition Coil "J" Primary Control Circuit/Open Catalyst System Efficiency Below Threshold (Bank ) P00 Catalyst System Efficiency Below Threshold (Bank ) MIL OFF OFF OFF OFF OFF P0 EVAP System Leak Detected (small leak) OFF MIL MIL MIL MIL MIL P0 EVAP System Purge Control Valve "A" Circuit P06 EVAP System Vent Control Circuit P05 EVAP System Pressure Sensor/Switch Range/Performance P05 EVAP System Pressure Sensor/Switch Low P05 EVAP System Pressure Sensor/Switch High P05 EVAP System Pressure Sensor/Switch Intermittent P055 EVAP System Leak Detected (large leak) P056 EVAP System Leak Detected (very small leak) MIL OFF OFF OFF OFF OFF P060 Fuel Level Sensor "A" Circuit N/A N/A N/A N/A nonmil N/A P06 Fuel Level Sensor A Circuit Range/Performance MIL OFF OFF OFF OFF OFF P06 Fuel Level Sensor A Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P06 Fuel Level Sensor A Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P096 EVAP System High Purge Flow MIL N/A N/A N/A N/A N/A P050 Brake Switch "A"/"B" Correlation nonmil nonmil nonmil nonmil nonmil nonmil P0505 Idle Control System nonmil nonmil nonmil nonmil nonmil nonmil P0506 P0507 Idle Control System RPM Lower Than Expected Idle Control System RPM Higher Than Expected Page 9

24 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P050A Cold Start Idle Control System Performance P050B Cold Start Ignition Timing Performance P050E P05 Cold Start Engine Exhaust Temperature Too Low A/C Refrigerant Pressure Sensor "A" Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P05 A/C Refrigerant Pressure Sensor "A" Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P056 System Voltage Low nonmil nonmil nonmil nonmil nonmil nonmil P056 System Voltage High nonmil nonmil nonmil nonmil nonmil nonmil P057 Brake Switch "A" Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P057 Brake Switch "A" Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P0579 Cruise Control MultiFunction Input "A" Circuit Range/Performance nonmil nonmil N/A nonmil N/A nonmil P058 Cruise Control MultiFunction Input "A" Circuit High nonmil nonmil N/A nonmil N/A OFF P0600 Serial Communication Link P060 Powertrain Control Module Programming Error P060 Internal Control Module Random Access Memory (RAM) Error P0605 Internal Control Module Read Only Memory (ROM) Error P0607 Control Module Performance P060A P060B P060C Internal Control Module Monitoring Processor Performance Internal Control Module A/D Processing Performance Internal Control Module Main Processor Performance P060D Internal Control Module Accelerator Pedal Position Performance nonmil nonmil nonmil nonmil nonmil nonmil P060 Control Module Vehicle Options Error P06A Internal Control Module Torque Performance nonmil nonmil nonmil nonmil nonmil nonmil P06B P06C Internal Control Module Torque Calculation Performance Internal Control Module Engine RPM Performance P06D Internal Control Module Engine Air Mass Performance P060 Generator Control Circuit nonmil nonmil nonmil nonmil nonmil OFF P065 Generator Field/F Terminal Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P066 Generator Field/F Terminal Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P067 Fuel Pump A" Control Circuit Open P06C Internal Control Module Vehicle Speed Performance OFF OFF nonmil OFF OFF OFF P06F Internal Control Module EEPROM Error N/A N/A nonmil N/A nonmil N/A Page 0

25 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P060 VIN Not Programmed or Incompatible ECM/PCM N/A N/A nonmil N/A nonmil N/A P06 Sensor Reference Voltage "A" Circuit Low P06 Sensor Reference Voltage "A" Circuit High P065 A/C Clutch Relay Control Circuit nonmil nonmil nonmil nonmil nonmil nonmil P06A Fuel Pump Control Module A P06D Internal Control Module O Sensor Processor Performance (Bank ) P06E Internal Control Module O Sensor Processor Performance (Bank ) P0657 Actuator Supply Voltage "A" Circuit/Open P065B P068A P06B8 Generator Control Circuit Range/ Performance ECM/PCM Power Relay DeEnergized Too Early Internal Control Module NonVolatile Random Access Memory (NVRAM) Error nonmil nonmil nonmil nonmil nonmil OFF P06E Control Module Wakeup Circuit Performance OFF OFF nonmil OFF nonmil OFF P06E9 Engine Starter Performance nonmil nonmil nonmil nonmil nonmil nonmil P070 Transmission Control System Range/ Performance nonmil nonmil nonmil nonmil nonmil nonmil P070 Transmission Control System Electrical nonmil nonmil nonmil nonmil nonmil nonmil P0706 Transmission Range Sensor "A" Circuit Range/Performance P0707 Transmission Range Sensor "A" Circuit Low P0708 Transmission Range Sensor "A" Circuit High P070 P07 P07 P07 P075 P077 Transmission Fluid Temperature Sensor "A" Circuit Transmission Fluid Temperature Sensor "A" Circuit Range/ Performance Transmission Fluid Temperature Sensor "A" Circuit Low Transmission Fluid Temperature Sensor "A" Circuit High Input/Turbine Shaft Speed Sensor "A" Circuit Input/Turbine Shaft Speed Sensor "A" Circuit No Signal nonmil nonmil nonmil nonmil nonmil nonmil nonmil nonmil nonmil nonmil nonmil nonmil P078 Input/Turbine Shaft Speed Sensor "A" Circuit Intermittent P070 Output Shaft Speed Sensor Circuit P07 Output Shaft Speed Sensor Circuit Range/Performance OFF OFF MIL OFF OFF OFF P07 Output Shaft Speed Sensor Circuit No Signal nonmil nonmil nonmil nonmil nonmil nonmil P079 Gear 6 Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil Page

26 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P07 Gear Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil P07 Gear Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil P075 Gear 5 Incorrect Ratio nonmil nonmil nonmil nonmil nonmil nonmil P070 Torque Converter Clutch Solenoid Circuit/Open P07 Torque Converter Clutch Solenoid Circuit Performance/Stuck Off P07 Torque Converter Clutch Solenoid Circuit Stuck On P07 Torque Converter Clutch Solenoid Circuit Electrical nonmil nonmil nonmil nonmil nonmil nonmil P07 Torque Converter Clutch Solenoid Circuit Intermittent P078 Pressure Control Solenoid "A" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P0750 Shift Solenoid "A" P075 Shift Solenoid "A" Performance/Stuck Off P075 Shift Solenoid "A" Stuck On P075 Shift Solenoid "A" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P075 Shift Solenoid "A" Intermittent P0755 Shift Solenoid "B" P0756 Shift Solenoid "B" Performance/Stuck Off P0757 Shift Solenoid "B" Stuck On P0758 Shift Solenoid "B" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P0759 Shift Solenoid "B" Intermittent P0760 Shift Solenoid "C" P076 Shift Solenoid "C" Performance/Stuck Off P076 Shift Solenoid "C" Stuck On P076 Shift Solenoid "C" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P076 Shift Solenoid "C" Intermittent P0765 Shift Solenoid "D" P0766 Shift Solenoid "D" Performance/Stuck Off P0767 Shift Solenoid "D" Stuck On P0768 Shift Solenoid "D" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P0769 Shift Solenoid "D" Intermittent P0770 Shift Solenoid "E" P077 Shift Solenoid "E" Performance/Stuck Off P077 Shift Solenoid "E" Stuck On P077 Shift Solenoid "E" Electrical nonmil nonmil nonmil nonmil nonmil nonmil P077 Shift Solenoid "E" Intermittent P088 TCM Power Input Signal Low P088 TCM Power Input Signal High P0885 TCM Power Relay Control Circuit /Open nonmil nonmil nonmil nonmil nonmil nonmil Page

27 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P0960 Pressure Control Solenoid "A" Control Circuit/Open P096 Pressure Control Solenoid "A" Control Circuit Range/Performance P096 Pressure Control Solenoid "A" Control Circuit Low P096 Pressure Control Solenoid "A" Control Circuit High P097 Shift Solenoid "A" Control Circuit Low P097 Shift Solenoid "A" Control Circuit High P0976 Shift Solenoid "B" Control Circuit Low P0977 Shift Solenoid "B" Control Circuit High P0979 Shift Solenoid "C" Control Circuit Low P0980 Shift Solenoid "C" Control Circuit High P098 Shift Solenoid "D" Control Circuit Low P098 Shift Solenoid "D" Control Circuit High P0985 Shift Solenoid "E" Control Circuit Low P0986 Shift Solenoid "E" Control Circuit High P00 KOER Not Able to Complete, KOER Aborted nonmil nonmil nonmil nonmil nonmil nonmil P00 Fuel Shutoff Valve "C" Control Circuit/Open OFF OFF OFF OFF nonmil OFF P070 nonmil nonmil nonmil nonmil nonmil nonmil P0 Mass Air Flow Sensor Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P Throttle Position Sensor "A" Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P7 Exhaust Temperature Out of Range, O Sensor Tests Not Completed nonmil nonmil nonmil nonmil nonmil nonmil P5E Throttle Actuator Control Throttle Body Air Flow Trim at Max Limit nonmil nonmil nonmil nonmil nonmil nonmil P6E Fuel Pressure Relief Valve Actuated nonmil nonmil nonmil nonmil nonmil nonmil P60 Theft Detected, Vehicle Immobilized nonmil nonmil N/A OFF N/A OFF P85 Cylinder Head Over Temperature Condition nonmil nonmil nonmil nonmil nonmil nonmil P88 Cylinder Head Temperature Sensor Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P89 Cylinder Head Temperature Sensor Circuit High P90 Cylinder Head Temperature Sensor Circuit Low P99 Cylinder Head Over Temperature Protection Active P6 Crankshaft/Camshaft Sensor Range/Performance P97 System Voltage Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil PD A/C Clutch Relay Control "B" Circuit nonmil nonmil nonmil nonmil nonmil nonmil P50 Unable to Bleed Up Fuel Tank Vacuum N/A MIL MIL MIL MIL MIL P5 Fuel Tank Pressure Relief Valve Malfunction nonmil nonmil nonmil nonmil nonmil nonmil Page

28 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P56 Fuel Tank Temperature Sensor Circuit P6 A/C Demand Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P50 Vehicle Speed Sensor Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P56 Brake Line Pressure Sensor Circuit nonmil nonmil N/A nonmil N/A nonmil P575 Pedal Position Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P59 Forced Engine Shutdown Remote Start System Fault, No Unattended Vehicle OFF OFF OFF OFF OFF nonmil Timeout P595 Forced Engine Shutdown Remote Start System Fault, Transmission Range Not In OFF OFF nonmil nonmil nonmil nonmil Park Position P60 Immobilizer/ECM Communication Error nonmil nonmil N/A OFF N/A OFF P60A Control Module Vehicle Options Reconfiguration Error N/A N/A nonmil N/A nonmil N/A P6A Incorrect Response from Immobilizer Control Module N/A N/A nonmil N/A nonmil N/A P6 Immobilizer ID Does Not Match nonmil nonmil N/A OFF N/A OFF P6E Internal Control Module PTO Control Performance nonmil nonmil nonmil nonmil nonmil nonmil P6F Starter Motor Disabled Engine Crank Time Too Long nonmil nonmil nonmil nonmil nonmil nonmil P6 Keep Alive Power Voltage Too Low nonmil nonmil OFF nonmil OFF nonmil P65 Tire/Axle Out of Acceptable Range nonmil nonmil N/A nonmil N/A nonmil P66 Inductive Signature Chip Communication Error P69 Vehicle ID Block Corrupted, Not Programmed MIL MIL nonmil MIL nonmil MIL P6E Transmission Control Module Programming Error P6F Transmission ID Block Corrupted, Not Programmed P66 Linear O Sensor Control Chip (Bank ) P67 Linear O Sensor Control Chip (Bank ) P66A Restraints Deployment Communication Circuit N/A N/A nonmil N/A N/A N/A P67 Control Module Software Corrupted P70 Transmission Range Sensor Circuit Intermittent nonmil nonmil nonmil nonmil nonmil nonmil P70 Brake Switch Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P705 Transmission Range Circuit Not Indicating Park/Neutral During Self Test nonmil nonmil nonmil nonmil nonmil nonmil P7 Transmission Fluid Temperature Sensor Out Of Self Test Range nonmil nonmil nonmil nonmil nonmil nonmil P7 Torque Converter Clutch Solenoid Circuit Performance nonmil nonmil nonmil nonmil nonmil nonmil P77F Unable To Fully Engage Neutral nonmil nonmil nonmil nonmil nonmil nonmil Page

29 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P780 Transmission Control Switch (O/D Cancel) Circuit Out Of Self Test Range nonmil nonmil OFF nonmil OFF OFF P78 Transmission Overtemperature Condition nonmil nonmil nonmil nonmil nonmil nonmil P9 Transmission Range Signal nonmil nonmil nonmil nonmil nonmil nonmil P9 Vehicle Speed Signal OFF OFF MIL OFF MIL OFF P9C Steering Wheel Angle Signal OFF OFF nonmil OFF OFF OFF P9E A/C Clutch Request Signal OFF OFF nonmil OFF nonmil OFF P067 Fuel Level Sensor "B" Circuit Low OFF OFF OFF OFF nonmil OFF P068 Fuel Level Sensor "B" Circuit High OFF OFF OFF OFF nonmil OFF P096 Post Catalyst Fuel Trim System Too Lean (Bank ) P097 Post Catalyst Fuel Trim System Too Rich (Bank ) P098 Post Catalyst Fuel Trim System Too Lean (Bank ) P099 Post Catalyst Fuel Trim System Too Rich (Bank ) P0 Throttle Actuator "A" Control Motor Circuit Range/Performance P07 Throttle Actuator "A" Control Module Processor P Throttle Actuator "A" Control System Stuck Open nonmil nonmil nonmil nonmil nonmil nonmil P Throttle Actuator "A" Control System Stuck Closed nonmil nonmil nonmil nonmil nonmil nonmil P9 Throttle Actuator "A" Control Throttle Body Range/Performance P Throttle/Pedal Position Sensor/Switch "D" Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P Throttle/Pedal Position Sensor/Switch "D" Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P7 Throttle/Pedal Position Sensor/Switch "E" Circuit Low nonmil nonmil nonmil nonmil nonmil nonmil P8 Throttle/Pedal Position Sensor/Switch "E" Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P5 Throttle/Pedal Position Sensor/Switch "A"/"B" Voltage Correlation P8 Throttle/Pedal Position Sensor/Switch "D"/"E" Voltage Correlation nonmil nonmil nonmil nonmil nonmil nonmil P95 Heated Exhaust Gas Oxygen Sensor Stuck P96 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) P97 O Sensor Signal Biased/Stuck Lean (Bank Sensor ) P98 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) P9A Bank AirFuel Ratio Imbalance P9B Bank AirFuel Ratio Imbalance Page 5

30 Code 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) P7 O Sensor Positive Current Control Circuit/Open (Bank Sensor ) P0 O Sensor Positive Current Control Circuit/Open (Bank Sensor ) P O Sensor Reference Voltage Circuit/Open (Bank Sensor ) P7 O Sensor Reference Voltage Circuit/Open (Bank Sensor ) P5 O Sensor Negative Current Control Circuit/Open (Bank Sensor ) P5 O Sensor Negative Current Control Circuit/Open (Bank Sensor ) P55 Ignition Switch Run/Start Position Circuit High nonmil nonmil nonmil nonmil nonmil nonmil P5B0 Fuel Level Sensor A Stuck nonmil nonmil nonmil nonmil nonmil nonmil P5B Fuel Level Sensor "B" Stuck OFF OFF OFF OFF nonmil OFF P60 ECM/PCM Engine Off Timer Performance P6 Fuel Pump B Control Circuit/Open P6F Engine Serial Number Not Programmed or Incompatible P665 Fuel Shutoff Valve "B" Control Circuit/Open nonmil nonmil nonmil nonmil nonmil nonmil P669 Actuator Supply Voltage "B" Circuit/Open P6B Fuel Shutoff Valve A Control Circuit Performance/Stuck Off nonmil nonmil nonmil nonmil nonmil nonmil P6B5 Fuel Shutoff Valve "B" Control Circuit Performance/Stuck Off P6EA Fuel Pump Control Module B P700 Transmission Friction Element "A" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P70 Transmission Friction Element "B" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P70 Transmission Friction Element "C" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P70 Transmission Friction Element "D" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P70 Transmission Friction Element "E" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P705 Transmission Friction Element "F" Apply Time Range/Performance nonmil nonmil nonmil nonmil nonmil nonmil P758 Torque Converter Clutch Pressure Control Solenoid Stuck On P760 Torque Converter Clutch Pressure Control Solenoid Intermittent U008 Lost Communication with Alternative Fuel Control Module U009 Loss of Communication on Fuel Pump Control Module A U0 Lost Communication With AntiLock Brake System (ABS) Control Module nonmil nonmil nonmil OFF nonmil OFF Page 6

31 Code U06 U00 U06C U0 U000 U05 U0 U0B U0 U0C Lost Communication With Steering Angle Sensor Module Lost Communication With Body Control Module Loss of Communication on Fuel Pump Control Module B Lost Communication With Steering Column Control Module Internal Control Module Software Incompatibility Invalid Data Received from AntiLock Brake System (ABS) Control Module Invalid Data Received from Body Control Module Lost Communication Between Fuel Pump Control Module A and Restraint Control Module Invalid Internal COntrol Module Monitoring Data Received from AntiLock Brake System (ABS) Control Module Lost Communication Between Fuel Pump Control Module B and Restraint Control Module 08 E50 08 E50 08 F50/ F F5/ F59 08 F650/ F Blue Bird Vision (Propane) N/A N/A nonmil N/A N/A N/A OFF OFF nonmil OFF nonmil OFF N/A N/A nonmil N/A nonmil N/A OFF OFF nonmil OFF nonmil OFF N/A N/A nonmil N/A nonmil N/A MIL MIL OFF OFF OFF OFF OFF OFF nonmil OFF OFF OFF MIL MIL OFF OFF OFF OFF N/A & OFF nonmil MIL Code not present DTC non MIL DTC MIL (two trips) NOTE: For any DTCs not specific to the ROUSH CleanTech fuel system, please reference the Ford PC/ED manual. EVAP System P0 EVAP System Leak Detected (small leak) Possible Causes Symptom Diagnostic Aid Action The Ford PCM has detected a leak in the Evaporative Emissions System (EVAP). Defective vapor management valve Damaged EVAP canister Leak in the EVAP system Defective fuel tank pressure transducer Check engine light. The fuel tank pressure transducer has been moved to a bracket near the EVAP canister. The system monitors the lines that go from the FRPCM bleed port to EVAP canister and purge valve. This system is used to depressurize the fuel rails after shutdown. The propane tank is sealed and is not part of this system. Test the EVAP system for leaks or damage. Page 7

32 P0 EVAP System Purge Control Valve "A" Circuit Possible Causes Symptom Diagnostic Aid Action This DTC sets when the signal moves outside the minimum or maximum limit for the commanded state. VPWR circuit open EVAPCP circuit open EVAPCP circuit short to ground EVAPCP circuit short to voltage Damaged EVAP purge valve Damaged PCM Check engine light. Purge control valve is located near the rear of the intake manifold. To verify normal function, monitor the EVMV PID or EVAPCP PID and the signal voltage (PCM control side). With the valve closed, the EVMV indicates 0 ma (0% duty cycle for EVAPCP) and voltage approximately equal to battery voltage. When the valve is commanded fully open, EVMV indicates,000 ma (00% duty cycle for EVAPCP) and a voltage drop of volts minimum is normal. Refer to the Ford PC/ED manual for P0 diagnostics. P06 EVAP System Vent Control Circuit Possible Causes Symptom Diagnostic Aid Action This DTC sets when the signal moves outside the minimum or maximum limit for the commanded state. VPWR circuit open KAPWR circuit open CANV circuit open CANV circuit short to ground CANV circuit short to voltage CANV circuit short to KAPWR Damaged EVAP canister vent valve Damaged PCM Check engine light. Vent control circuit is in the EVAP canister. To verify normal function, monitor the EVAP canister vent valve signal PID EVAPCV and the signal voltage (PCM control side). With the valve open, EVAPCV indicates 0% duty cycle and a voltage approximately equal to battery voltage. When the valve is commanded fully closed, EVAPCV indicates 00% duty cycle, and a minimum voltage drop of volts is normal. Refer to the Ford PC/ED manual for P06 diagnostics. Page 8

33 P05 EVAP System Pressure Sensor/Switch Range/Performance TROUBLESHOOTING Possible Causes Symptom Diagnostic Aid Action This DTC sets when a fuel tank pressure (FTP) sensor range (offset) concern is detected. The FTP sensor output is offset by greater than.7 inches of water or less than.7 inches of water. FTP circuit intermittent open FTP circuit intermittent short FTP sensor intermittent open FTP sensor intermittent short Contaminated FTP sensor Damaged FTP sensor Damaged PCM Check engine light. The FTP sensor is located on a bracket near the EVAP canister. With the FTP sensor at atmospheric pressure, the FTP PID normally indicates 0 inches of water. Remove the quick connect hose at the canister that goes to the FTP sensor, wait one minute to allow the pressure to equalize with the ambient air pressure before accessing the PID. Refer to ROUSH CleanTech wiring schematics. Page 9

34 P05 EVAP System Pressure Sensor/Switch Low Possible Causes Symptom Diagnostic Aid Action This DTC sets when the fuel tank pressure (FTP) sensor signal average drops below a minimum allowable calibrated parameter. Contamination internal to the FTP sensor connector FTP circuit open VREF circuit open FTP circuit short to ground FTP circuit short to SIGRTN Damaged FTP sensor Check engine light. The FTP sensor is located on a bracket near the EVAP canister. An FTP voltage PID reading less than 0. volt in ignition ON, engine OFF or ignition ON, engine running indicates a concern is present. Refer to ROUSH CleanTech wiring schematics. P05 EVAP System Pressure Sensor/Switch High Possible Causes Symptom Diagnostic Aid Action This DTC sets when the fuel tank pressure (FTP) sensor signal average jumps above a maximum allowable calibrated parameter. Contamination internal to the FTP sensor connector FTP circuit open VREF circuit open FTP circuit short to ground FTP circuit short to SIGRTN Damaged FTP sensor Check engine light. The FTP sensor is located on a bracket near the EVAP canister. An FTP voltage PID reading more than.85 volt in ignition ON, engine OFF or ignition ON, engine running indicates a concern is present. Refer to ROUSH CleanTech wiring schematics. P05 EVAP System Pressure Sensor/Switch Intermittent Possible Causes Symptom Diagnostic Aid Action This DTC sets when the fuel EVAP system pressure changes greater than inches of water in 0. seconds. Contamination internal to the FTP sensor connector FTP circuit open VREF circuit open FTP circuit short to ground FTP circuit short to SIGRTN Damaged FTP sensor Check engine light. The FTP sensor is located on a bracket near the EVAP canister. Monitor the FTP PID and note if it changes +/ 5 inches of water multiple times in minute. Refer to ROUSH CleanTech wiring schematics. Page 0

35 P055 EVAP System Leak Detected (large leak) Possible Causes Symptom Diagnostic Aid Action The PCM monitors the complete evaporative emission (EVAP) control system for no purge flow, the presence of a large fuel vapor leak, or multiple small fuel vapor leaks. This DTC sets when no purge flow, which is attributed to fuel vapor blockages or restrictions, a large fuel vapor leak, or multiple fuel vapor leaks are detected by the EVAP running loss monitor test with the engine running, but not at idle. Disconnected or cracked fuel EVAP canister tube, EVAP canister purge outlet tube, or EVAP return tube EVAP purge valve stuck closed Slow responding EVAP purge valve Blockages or restrictions in the fuel vapor hoses or tubes Loose fuel vapor hose or tube connections to the EVAP system components EVAP canister vent valve stuck open Damaged fuel tank pressure (FTP) sensor Damaged EVAP canister Check engine light. The fuel tank pressure transducer has been moved to a bracket near the EVAP canister. The system monitors the lines that go from the FRPCM bleed port to EVAP canister and purge valve. This system is used to depressurize the fuel rails after shutdown. The propane tank is sealed and is not part of this system. Check for audible vacuum noise in the engine compartment or near the EVAP canister with engine running. P056 EVAP System Leak Detected (very small leak) Possible Causes Symptom Diagnostic Aid Action The Ford PCM has detected a leak in the Evaporative Emissions System (EVAP). Very small holes or breaks in the fuel vapor hoses or tubes Loose fuel vapor hose or tube connections to the EVAP system components EVAP system component seals leaking Damaged wiring to the EVAP purge control valve Check engine light. The fuel tank pressure transducer has been moved to a bracket near the EVAP canister. The system monitors the lines that go from the FRPCM bleed port to EVAP canister and purge valve. This system is used to depressurize the fuel rails after shutdown. The propane tank is sealed and is not part of this system. Check for loose or damaged vapor hoses. Visually inspect the EVAP canister inlet port, EVAP canister vent valve filter, and EVAP canister vent hose assembly for contamination or debris. Page

36 Flow Control Solenoid P0090 Fuel Pressure Regulator Circuit Open Possible Causes Symptom Diagnostic Aid Action FCS circuit fault. SRM monitors FCS circuit for open and short circuit faults. Short to voltage Water in the harness connector Open power circuit GND circuit Low battery voltage Corrosion Incorrect connections Damaged FCS coil Blown fuse Fuel pressure in the rail does not change when commanded. Extended fuel rail flush time. Check the FRPCM and SRM electrical connector for damage, corrosion and water intrusion. Refer to the Flow Control Solenoid procedure in Tank Solenoid Electrical Check. Bleed Solenoid P009E/P6B Fuel Pressure Relief Control Performance Stuck Off/Fuel Shutoff Valve A Control Circuit Performance Stuck Off Possible Causes Symptom Diagnostic Aid Action Fuel rail failed to bleed. The PCM measures fuel rail pressure on keyup to determine if fuel rail has been properly bled. BS did not open FRPCM check valve leaked (P6B) FRPCM supply solenoid leaked (P6B) Bleed port (bleed rate restrictor in outlet to VMV) clogged EVAP line kinked Blown fuse Fuel pressure present in the fuel rail after bleed event should have occurred; this may result in hard starts. Check that FRPCM bleeds fuel from rail. Leaks to FRPCM can also trigger a fault. Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures. Page

37 P009B Fuel Pressure Relief Control Circuit Open Possible Causes Symptom Diagnostic Aid Action Bleed solenoid circuit fault. The SRM monitors bleed solenoid circuit for open and short circuit faults. Short to voltage Water in the harness connector Open power circuit Open GND circuit Low battery voltage Corrosion Incorrect connections Damaged BS coil Fuel rail bleed system does not operate correctly. There is a potential for fuel odor or hard start. Check the FRPCM and SRM electrical for damage, corrosion and water intrusion. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Tank Solenoid P0005 Fuel Shutoff Valve A Control Circuit Open Possible Causes Symptom Diagnostic Aid Action TS circuit fault. The SRM monitors tank solenoid circuit for open and short circuit faults. Short to voltage Water in the harness connector Open power circuit Open GND circuit Low battery voltage Corrosion Incorrect connections Damaged TS coil Blown fuse Vehicle does not start. The pumps run but no pressure builds in the fuel rail. Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Refer to the Tank Solenoid Electrical Check procedure in Diagnostic Tests and Procedures. Page

38 Fuel Rail Pressure Control Module Supply Solenoid and Wiring P6B5 Fuel Shutoff Valve B Control Circuit Performance/Stuck Off Possible Causes Symptom Diagnostic Aid Action The SRM monitors fuel rail pressure before and after the start sequence is initiated. If the fuel rail pressure rise is below a threshold, the fault is set. Excess flow valve activated Fuel pumps weak or inoperable Manual shutoff valve not fully open Tank supply solenoid not opening FRPCM supply solenoid not opening Restricted supply line filter Kinked or restricted fuel lines IPTS or TPTS signal inaccurate Blown fuse The vehicle will crank no start or start and run poorly. Start sequence will be extended and fuel pumps and supply solenoids will be commanded on and off multiple times, attempting to build rail pressure. Check Measuring Fuel Rail and Fuel Tank Pressure procedure. Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures. P665 Fuel Shutoff Valve B Control Circuit/Open Possible Causes Symptom Diagnostic Aid Action FRPCM supply solenoid circuit fault. SRM monitors supply solenoid circuit for open and short circuit faults. Short to voltage Water in the harness connector Open power circuit Open GND circuit Low battery voltage Corrosion Incorrect connections Damaged SS coil Blown fuse Vehicle does not start. The pumps run but no pressure builds in the fuel rail. Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Page

39 SRM, CAN Bus Circuit Wiring U008 Lost Communication with Alternative Fuel Control Module Possible Causes Symptom Diagnostic Aid Action Lost communication with SRM. The PCM monitors CAN bus communication for missing messages from the SRM. If the messages are continuously missing, a fault is set. Wiring between the SRM and PCM SRM lacks power Blown fuse SRM loses power or ground Rough idle. Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Check for power at the SRM. Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures. Fuel System P08 Fuel Delivery Error Possible Causes Symptom Diagnostic Aid Action To maintain target fuel rail pressure increase, the fuel pump voltage has been increased to a maximum adaptive limit and the fuel trims have gone lean. Severely restricted fuel filter Severely restricted fuel supply line Damaged or worn fuel pump Fuel pump wiring or fuse faults Excess flow valve tripped Tank supply solenoid or FRPCM supply solenoid closed Tank manual shutoff valve not completely open Vehicle hesitation or stall condition. This is a nonmil setting DTC to aid the technician in diagnosing a possible fuel system fault. Do not diagnose if no symptoms or other fault codes are present. If other fault codes are present, diagnose those first. If symptoms are present, refer to diagnostic flow chart for that vehicle symptom. P6E Fuel Pressure Relief Valve Actuated Possible Causes Symptom Diagnostic Aid Action Maximum injection pressure reached. The PCM monitors fuel rail pressure and battery voltage. Based on these measurements, the PCM adjusts fuel pump speed to stay below the maximum operating pressure of the injectors. Operating the vehicle in high ambient conditions Vehicle operated in a low voltage condition Vehicle hesitation, stall, rough idle, misfire or no start. The P6E code is meant as an indication that the fuel system was operated at the limits of the system. The customer may have experienced drive issues although the system is performing as expected. Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures. Page 5

40 P07, P07 System Too Lean (Bank and Bank respectively) TROUBLESHOOTING Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes The LPA system was operated in the vapor region Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. P07, P075 System Too Rich (Bank and Bank respectively) Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes The LPA system was operated in the vapor region Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. P5 Fuel Tank Pressure Relief Valve Malfunction Possible Causes Symptom Diagnostic Aid Action The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. If the pressure value of the propane fuel tank approaches the Pressure Relief Valve popoff pressure, a fault is set. High ambient temperature operation Propane tank fill is contaminated with nitrogen or other constituents Vehicle is parked over heat source Tank Pressure Temperature Sensor shorted or reading higher than expected values Overfill prevention device allowed tank to overfill The driver is alerted with a coolant gauge High setting until the fault condition clears. Use mechanical pressure gauge to check tank pressure and an inferred temp gun to check tank temperature. Check for other diagnostic fault codes such as Tank Pressure or Temperature P0A or P0AD and correct them first. Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures. P0xx Misfire Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes The LPA system was operated in the vapor region Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Page 6

41 Heated Exhaust Gas Oxygen Sensor P95, P97 Heated Exhaust Gas Oxygen Sensor Stuck Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes The LPA system was operated in the vapor region Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Electronic Fuel Pump Relay (A/B) U009, U06C Lost Communication with Fuel Pump Control Module A/B The SRM repeats the signal from the second EFPR to the PCM over the CAN bus. The PCM monitors this communication. If there is a lack of communication for a long enough period of time, a fault is set. Possible Causes Wire fault between the EFPR and SRM Wire fault between SRM and PCM No power to the EFPR SRM fault CAN bus fault Faulty EFPR Blown fuse Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Crank, no start, rough idle or lack of power. Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure and also the Smart Relay Module Electrical Test procedure in Diagnostic Tests and Procedures. P05A Fuel Pump Module A Control Circuit/Open The Fuel Pump Control Module (FPCM) A receives control commands from the PCM on a Fuel Pump Command (FPC) pin. The FPCM A passes diagnostic information on the CAN bus to the PCM. If the FPCM A does not receive a control command from the PCM on the FPC, it sends a corresponding signal to the PCM on the CAN bus and the fault is set. Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Poor starts, rough idle, hesitation/surge. Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Page 7

42 P05B Fuel Pump Module A Control Circuit Range/Performance TROUBLESHOOTING The Fuel Pump Control Module (FPCM) A receives control commands from the PCM on a Fuel Pump Command (FPC) pin. The FPCM A passes diagnostic information on the CAN bus to the PCM. If the FPCM A receives an invalid control command from the PCM on the FPC, it sends a corresponding signal to the PCM on the CAN bus and the fault is set. Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. P07B Fuel Pump Module B Control Circuit Range/Performance The SRM receives the output of the second fuel pump monitor line and repeats the output over the CAN bus to the PCM. The PCM monitors the commanded output versus the monitor s feedback. If the monitor is outofrange, a fault is set. Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. U0B Lost Communication Between Fuel Pump Control Module A and Restraint Control Module Possible Causes Symptom The FPCM A constantly receives either an OK signal or a disable signal from the RCM on a dedicated disable wire. The FPCM A passes diagnostic information on the CAN bus to the PCM. If the FPCM A fails to receive a signal from the RCM, the FPCM A passes a signal, indicating it lost communication with the RCM, to the PCM and the fault is set. Wire fault between EFPR A and RCM Wire fault between SRM and PCM No power to the EFPR A SRM fault CAN fault Blown fuse RCM failure EFPR A failure Diagnostic Aid Action Page 8

43 U0C Lost Communication Between Fuel Pump Control Module B and Restraint Control Module Possible Causes Symptom The FPCM B constantly receives either an OK signal or a disable signal from the RCM on a dedicated disable wire. The FPCM B passes diagnostic information on the CAN bus to the SRM. The SRM passes that diagnostic information on the CAN bus to the PCM. If the FPCM B fails to receive a signal from the RCM, the FPCM B passes a signal, indicating it lost communication with the RCM, to the SRM. The SRM passes that signal on the CAN bus to the PCM and the fault is set. Wire fault between EFPR B and RCM Wire fault between SRM and PCM No power to the EFPR B SRM fault CAN fault Blown fuse RCM failure EFPR B failure Diagnostic Aid Action P067 Fuel Pump A Control Circuit Open P06A Fuel Pump Control Module A The Fuel Pump Control Module (FPCM) A diagnoses faults of fuel pump A. The FPCM A passes diagnostic information on the CAN bus to the PCM. If the PCM receives a FPCM A signal indicating a fuel pump problem, the fault is set. Possible Causes Wiring fault between FPCM A and fuel pump A Open circuit FPCM A fault CAN fault Faulty fuel pump Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. The Fuel Pump Control Module (FPCM) A has its own internal diagnostics. The FPCM A passes diagnostic information on the CAN bus to the PCM. If the PCM receives a FPCM A signal indicating an internal problem, the fault is set. Possible Causes FPCM A fault CAN fault Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Page 9

44 P6 Fuel Pump B Control Circuit/Open P6EA Fuel Pump Control Module B The Fuel Pump Control Module (FPCM) B diagnoses faults of fuel pump B. The FPCM passes the information to the SRM on a dedicated circuit. The SRM then sends the diagnostic information to the PCM over the CAN network. Possible Causes Wiring fault between FPCM A and fuel pump A Open circuit FPCM A fault CAN fault Faulty fuel pump Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. The Fuel Pump Control Module (FPCM) B diagnoses faults of fuel pump B. The FPCM passes the information to the SRM on a dedicated circuit. The SRM then sends the diagnostic information to the PCM over the CAN network. Possible Causes FPCM B fault CAN fault Open fuel pump monitor circuit (FPM) Symptom Diagnostic Aid Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Integrated Pressure Temperature Sensor P08 Fuel Temperature Sensor A Circuit Range/Performance The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM Short in harness Short in harness Open circuit Open or short to voltage in harness Incorrect harness connection Damaged IPTS IPTS failure SRM failure Symptom Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 0

45 P08 Fuel Temperature Sensor A Circuit Low The SRM reads the IPTS and passes the voltage reading over the CAN to the PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM Short in harness VREF open or short Low ambient temperature operation Incorrect harness connection Damaged IPTS (or FTS) IPTS failure SRM failure Symptom Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P08 Fuel Temperature Sensor A Circuit High The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM Open circuit Open or short to voltage in harness Incorrect harness connection Damaged IPTS (FTS) IPTS failure SRM failure Symptom Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page

46 P090 Fuel Rail Pressure Sensor Circuit The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM VREF open in harness VREF open in sensor Vacuum leaks IPTS failure SRM failure Symptom Diagnostic Aid VREF should be between.55.5 volts. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P09 Fuel Rail Pressure Sensor Circuit Low The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM IPTS FRP signal short to SIG RTN or PWR GND Damaged IPTS (or FRP) IPTS failure SRM failure Symptom Diagnostic Aid A FRP PID value during ignition ON, engine OFF, or ignition ON, engine running is less than 0. volt. This indicates a concern is present. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P09 Fuel Rail Pressure Sensor Circuit High The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between IPTS and SRM IPTS FRP signal short to VREF or VPWR IPTS (or FRP) open signal Damaged IPTS (or FRP) IPTS failure SRM failure Symptom Diagnostic Aid Verify the FRP PID value to determine open or short. Action Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page

47 P0A0 Alternate Fuel Tank A Pressure Sensor Circuit Low TROUBLESHOOTING The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between TPTS and SRM VREF open in harness VREF open in sensor Vacuum leaks TPTS failure SRM failure Symptom Diagnostic Aid VREF should be between.55.5 volts. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. P0A Alternate Fuel Tank "A" Pressure Sensor Circuit High The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between TPTS and SRM TPTS Fuel Pressure signal short to SIG RTN or PWR GND TPTS (or Fuel Pressure) open signal Damaged TPTS TPTS failure SRM failure Symptom Diagnostic Aid Verify the Propane Tank Fuel Pressure PID value to determine open or short. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page

48 P0A Alternative Fuel Tank A Pressure Sensor Circuit Intermittent/Erratic The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Intermittent wiring fault between TPTS and SRM TPTS Fuel Pressure intermittent signal short to SIG RTN or PWR GND TPTS (or Fuel Pressure) intermittent open signal VREF intermittent open in harness VREF intermittent open in sensor Vacuum leaks Damaged TPTS TPTS failure SRM failure Symptom Diagnostic Aid Verify the Propane Tank Fuel Pressure PID value to determine open or short. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. P0AC Alternate Fuel Tank Temperature Sensor Circuit Low The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between TPTS and SRM Short in harness VREF open or short Low ambient temperature operation Incorrect harness connection Damaged TPTS TPTS failure SRM failure Symptom Diagnostic Aid Verify the Propane Tank Fuel Pressure PID value to determine open or short. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page

49 P0AD Alternate Fuel Tank Temperature Sensor Circuit High TROUBLESHOOTING The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Wiring fault between TPTS and SRM Open circuit Open or short to voltage in harness Incorrect harness connection Damaged TPTS TPTS failure SRM failure Symptom Diagnostic Aid Verify the Fuel Temperature PID value to determine open or short. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. P0AE Alternative Fuel Tank Temperature Sensor Circuit Intermittent/Erratic The SRM reads the TPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes CAN bus fault between the SRM and PCM Intermittent wiring fault between TPTS and SRM TPTS Fuel Pressure intermittent signal short to SIG RTN or PWR GND TPTS (or Fuel Pressure) intermittent open signal VREF intermittent open in harness VREF intermittent open in sensor Vacuum leaks Damaged TPTS TPTS failure SRM failure Symptom Diagnostic Aid Verify the Propane Tank Fuel Pressure PID value to determine open or short. Action Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page 5

50 Fuel Level Sender P06 Fuel Level Sender A Circuit Range/Performance Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the sender and the SRM and not the IPC. Symptom Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IPC and PCM. Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures. P06 Fuel Level Sender A Circuit Low Possible Causes Symptom Diagnostic Aid Action This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value. Fuel level sender wiring shorted to ground Damaged Fuel Level Sender Smart Relay Module P06 Fuel gauge may read empty all the time P067 Fuel gauge will only show primary tank Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster. Refer to the following tests located later in this manual. SRM Electrical Test Fuel Level Sender Test P06 Fuel Level Sender A Circuit High Possible Causes Symptom Diagnostic Aid Action This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value. Fuel level sender wiring is disconnected or shorted to above 5 volts Damaged Fuel Level Sender Smart Relay Module P06 Fuel gauge may read full all the time P068 Fuel gauge will only show primary tank Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster. Refer to the following tests located later in this manual. SRM Electrical Test Fuel Level Sender Test Page 6

51 P5B0 Fuel Level Sensor A Stuck Possible Causes Symptom Diagnostic Aid Action The SRM reads Fuel Level Sender (FLS) input and broadcasts it to the IPC and PCM. If the vehicle is driven a considerable distance and the FLS value doesn't change, the fault is set. Wire fault between FLS and SRM Defective fuel level sender or sender twin site SRM fault The driver is unaware of a low fuel condition. Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures. P5B Fuel Level Sensor B Stuck Possible Causes Symptom Diagnostic Aid Action The SRM monitors the fuel level position on the driver and passenger side fuel tanks while commanding a fuel transfer to occur. If the SRM sees that the fuel level in the driver side tank is not increasing while the passenger side tank fuel level is decreasing, it will stop the transfer, set a P5B code and try again. After three failed attempts, the fuel level on the cluster will decrease to its usable amount (driver's side tank only) to notify the driver there is an issue with the transfer system. Defective fuel level sender or sender twin site Transfer OPD stuck closed Passenger tank supply valve fault Weak or defective fuel pump SRM fault Wiring concern The driver will notice the fuel gauge on the dash drop to approximately half of its previous amount or the fuel gauge in the IPC only goes to half after the vehicle is filled. Smart Relay Module (SRM) reads both fuel level signals and determines when to set the fault based on changes in fuel level. Refer to the F650/F750 Dual Tank Transfer Pin Point Test procedure. Secondary Tank Fuel Will Not Transfer F650 vehicles can be equipped with a unique ROUSH CleanTech liquid propane autogas storage system which includes two fuel tanks. The system operates as if it were just one large tank. A few key points about the system: The engine is always running from the driver's side tank. All fuel to the engine, and the excess fuel returning to the tank, is only connected to this tank. The passenger's side tank is used to store extra fuel only. When the driver's side tank fuel level drops, the system will activate fuel pumps in passenger's side tank to transfer fuel automatically. Both tanks are filled at the same time from the single fuel filler located on the driver's side. There is a ball valve on the fill line for the righthand tank, which is used for periodic inspections only. It should always be open during normal operation in order to use the full system capacity. The ROUSH CleanTech control system reads the usable fuel level in each tank and adds them together to provide a single reading for the instrument cluster. However, if the system detects a failure in the fuel transfer system which may interfere with the ability to transfer fuel, it will provide a reading based on the driver's side tank only. This ensures that the driver is warned before the vehicle runs out of fuel. If this occurs, the vehicle is fully usable, but should be serviced in order to restore full function and use of the full system fuel capacity. Page 7

52 The fuel transfer line from the passenger's side tank is connected to a dedicated overfill prevention device (OPD) on the driver's side tank. This is a safety device which ensures that even if there is a fault in the control system, it is not possible for the driver's side tank to overfill during transfers. Fuel Tank Maximum Pressure Reached While the propane system is under normal operation, the tank pressure and temperature are monitored by the smart relay module (SRM). The SRM is used to ensure that the fuel system provides the proper pressure to the fuel rails based on the pressure and temperature of the tank. If the fuel tank pressure is close to the maximum pressure allowed where the pressure relief valve could vent to atmosphere for eight seconds, the SRM will send a level signal to the Ford PCM to trigger the OEM "Failsafe Cooling" feature. This means that the coolant gauge on the cluster will move into the red zone and turn on a coolant temp light as an indication that the driver should discontinue use of the vehicle. A P5 diagnostic trouble code will also be stored in the PCM when this condition is activated. Please see the Ford PCED manual for further information in regards to the "Failsafe Cooling" feature for your specific application. If this feature is activated on your vehicle, discontinue use of the vehicle and allow the fuel system to cool until the coolant gauge on the cluster returns to a normal operation. Page 8

53 Fuel Level Indication Check The ROUSH CleanTech fuel level indication system differs from the gasoline system as the fuel level sender is not wired directly to the instrument cluster. Instead, the fuel level sender is wired to the SRM, which reads the fuel level and transmits the signal to the PCM via the CAN bus, which in turn simulates the resistance the instrument cluster expects to see for a given fuel level. The gauge on the sending unit must not be used for any diagnostics. The gauge is not accurate. Only voltage outputs should be used for diagnostic purposes. Symptom Fuel gauge does not move on a partial fill Malfunction Indicator Lamp (MIL) Gauge points below E Doesn t read full after a fill a. Tank should be filled on a level surface both fronttoback and sidetoside (a level needs to be placed on the vehicle to verify this). b. Tank pressure and sending unit voltage should be recorded prior to the fill and when the fuel station shuts off along with number of gallons filled. c. Differential and bypass pressure settings need to be confirmed on the fuel station and verified by fueling provider (station output pressure must be at least 5 psi greater than the vehicle tank pressure at time of filling. Recommended differential pressure settings are greater than 5 psi). d. HP rating of the pump on the station needs to be verified. (5 hp pump recommended.) Note: Fueling provider can fill unit on level ground with a bobtail to eliminate any issues that may be present with the fueling station. e. Fuel level electrical checks and SRM checks can be performed per the diagnostic manual. Cause/Action to be taken This behavior is not uncommon. The fuel level sender may not move far enough to trigger movement on the gauge if only a small amount of fuel is added to the tank. Once driven, the gauge may move to reflect the fill. There is a circuit fault that has been identified by the PCM. If customer fills vehicle with key ON this could cause the gauge not to move. Customer should drive vehicle for some time to allow gauge to move and fill with key OFF in the future. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is called for, refer to the Fuel Level Sender Electrical Check procedure. This is an indication of an error state. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is recommended, refer to the Fuel Level Sender Electrical Check procedure. This could be the result of either a fuel level sender fault or an OPD valve triggering prematurely. Refer to fill issues and the Fuel Level Sender Electrical Check procedure for more information. Page 9

54 DIAGNOSTIC TESTS AND PROCEDURES General Information Measuring Fuel Rail and Fuel Tank Pressure Measuring Fuel Tank Pressure Fuel tank pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 0 Ford E50/50/50/50 or 0 F50/50 Liquid Propane Autogas Fuel System Service Manual Supplement for more information regarding the tools required. Method Install a psi (0 7 kpa) fuel pressure gauge on the bleeder valve at the tank, or to the remote bleeder valve location. Open the valve to monitor the fuel tank pressure. Record the value. Method If a psi (0 7 kpa) fuel pressure gauge is not available, fuel rail pressure can be used to infer fuel tank pressure. Refer to Method of Measuring Fuel Rail Pressure. Monitor fuel rail pressure with the engine running. Turn the engine off and continue to monitor fuel rail pressure. When the pressure has stabilized, record the value as fuel tank pressure. Measuring Fuel Rail Pressure Fuel rail pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 0 Ford E50/50/50/50 or 0 F50/50 Liquid Propane Autogas Fuel System Service Manual for more information regarding the tools required. Method Using an OBDII scan tool, read the fuel rail pressure PID. If using the Ford IDS tool, select the toolbox tab > select Powertrain > OBD Test Modes > Mode Powertrain Data. Then select FRP (pressure) from PID selection table. Alternately you can select manual vehicle entry and enter PCM part number PBBBAA. This will ID the vehicle as a Vision bus, and offer addtional PIDs in datalogger. Method Empty the fuel rails and fuel lines. Refer to the Fuel Line Purging Procedure in the 0 Ford E50/50/50/50 or 0 F50/50 Liquid Propane Autogas Fuel System Service Manual Supplement for more information. Disconnect the fuel supply line at the rear of the RH fuel rail. Install the ROUSH service port adapter between the fuel line and the fuel rail. Attach psi (0 7 kpa) fuel pressure gauge to the service port on the adapter. Record the value. Expected Fuel Tank Pressure On a tank at ambient temperature conditions, the following pressures can be expected: Pressure (psi) Temperature ( F) Min. Nominal Max On vehicles that have been operated for extended periods of time, the tank (fuel) can be much warmer and so higher pressures are to be expected. Expected Fuel Rail Pressure Under normal operating conditions, the fuel pump will operate at variable speeds. The fuel pump duty cycle will vary to maintain liquid in the fuel rails under different temperatures and operating conditions. Page 50

55 The fuel pressure controls are designed to keep the rails at a certain pressure over tank pressure, therefore, it is important to measure tank pressure prior to collecting fuel rail pressure data. For example, if the fuel tank is at 50 psi (0 kpa) and pressure in the rail is measured at 00 psi (79 kpa), the rail is running at 50 psi (5 kpa) over tank. Fuel rail pressure should maintain a minimum of 0 psi over tank under normal operating conditions, and will increase based on fuel system demand. Pinpoint Test A: No Fill Step Procedure Action Inspect vehicle to check for kinked fill lines. Are fill lines kinked? Determine the location of the overflow protection device (OPD). Is the OPD located in the end cap of the fuel tank? Check the fuel gauge in the instrument cluster. Is the gauge indicating less than / full? Check to see if the OPD is being activated. Yes Replaced kinked fill lines. No Go to Step. Yes Go to Step. No Go to Step 6. Yes Go to Step. No Go to Step 6. Yes Go to Step 5. No Go to Step 6. Fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line. a. Loosen the fuel fill line at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line and release the OPD valve. Retighten the fill line. b. Install a fuel fill pressure tester on the fill valve and close the ball valve. c. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 0 gal (8 L) of fuel. d. Did the tank fill? 5 Remove the fuel fill pressure tester and attempt to fill the vehicle fuel tank to full 80% capacity. Does the vehicle fuel tank fill to capacity? 6 Check the fuel gauge in the instrument cluster. Is the gauge indicating more than / full? 7 Reverse direction of vehicle at the pump and try to fill the vehicle. Does the vehicle fuel tank fill? 8 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? 9 Open bleeder valve. Does liquid fuel vent? 0 Check fuel gauge. Does fuel gauge read full? Yes Diagnostic is complete. No Go to Step 6. Yes Go to Step 7. No Go to Step. Yes Vehicle not on level ground. Diagnostic is complete. No Drive vehicle until fuel gauge indicates less than / full and go to Step 8. Yes Go to Step 9. No Go to Step. Yes Go to Step 0. No Go to Step. Yes Diagnostic complete. No Refer to Fuel Level Indication Check. Page 5

56 Step Procedure Action Check for sufficient fill station pressure. a. Connect pressure gauge service tool to the fuel tank bleeder valve and record pressure. b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle. c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure. d. Is fill station pump pressure at least 0 psi (8 kpa) greater than tank pressure? Check body side fuel fill valve; it may be stuck closed. a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line. b. Attempt to push open the piston in the fill valve to determine if it is stuck closed. c. Is the fill valve piston stuck closed? Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Replace the filter in the fuel fill line and then attempt to fill the vehicle fuel tank. Does the vehicle fuel tank fill? 5 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? 6 Replace the OPD valve in the vehicle fuel tank. Is the OPD valve located in the end cap of the fuel tank? 7 Attempt to fill the vehicle fuel tank as follows: When filling a new tank that has the OPD valve mounted in the end cap of the fuel tank, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line. Yes Go to Step. No Fill station may not be providing enough pressure to fill. Go to Step 9. Yes Replace bodyside fill valve and go to Step. No Replace filter in the fuel fill line and go to Step 5. Yes Diagnostic is complete. No Go to Step. Yes Diagnostic is complete. No Go to Step 6. Yes Diagnostic is complete. No Go to Step 6. Yes Go to Step 7. No Go to Step 8. Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at a. Install a fuel fill pressure tester on the fill valve and close the ball valve. b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 0 gal (8 L) of fuel. c. Remove the fuel fill pressure tester. d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle. e. Did the tank fill? 8 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? 9 Fill station is not providing enough pressure to fill. a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature. b. Is the vehicle fuel tank pressure greater than 0 psi (8 kpa) over the nominal expected pressure? Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at Yes Go to Step 0. No Locate a dispensing facility with pump output capacity in excess of 00 psi (689 kpa) (preferably an Auto Gastype facility). Then, go to Step. Page 5

57 Step Procedure Action 0 Vehicle fuel tank is at a higher pressure. a. Higher pressure is likely caused by heavy vehicle usage heating the fuel. b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank. Measure and compare vehicle fuel tank and fill station pressures. a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle. c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure. d. Is fill station pump pressure at least 0 psi (8 kpa) greater than fuel tank pressure? Attempt to fill the vehicle fuel tank. Does the fuel tank fill? When tank pressure is within 0 psi (69 kpa) of expected tank pressure, go to Step. Yes Go to Step. No Fill station is not providing enough pressure to fill vehicle tank. Go to Step. Locate a dispensing facility with pump output capacity in excess of 00 psi (689 kpa) (preferably an Auto Gastype facility). Yes Diagnostic is complete. No Go to Step. Pinpoint Test B: Slow Fill Step Procedure Action Inspect vehicle to check for kinked fill lines. Are fill lines kinked? Determine flow rate at which the vehicle fuel system fills. a. Time the fill station pump for 0 seconds and record the number of gallons dispensed. b. Multiply the gallons dispensed by six to determine the flow rate in gallons per minute. c. Is the fill station pump flow rate at least 6 gal ( L) per minute? Measure and compare vehicle fuel tank and fill station pressures. a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle. c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure. d. Is fill station pump pressure at least 50 psi (5 kpa) greater than fuel tank pressure? Check fuel fill valve; it may not be opening completely. a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line. b. Attempt to push open the piston in the fill valve to determine if it is opening completely. Piston should travel / inch. c. Is the fill valve piston opening completely? 5 Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal ( L) per minute? 6 Replace the filter in the fuel fill line. Does the vehicle fuel tank fill at greater than six gal ( L) per minute? 7 Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal ( L) per minute? Yes Replaced kinked fill lines. No Go to Step. Yes System fill rate is OK; diagnostic is complete. No Fill station is not providing enough pressure to fill vehicle tank. Go to Step. Yes Go to Step. No Fill station is not providing enough pressure to fill vehicle tank. Go to Step. Yes Replace the filter in the fuel fill line and then go to Step 7. No Replace the fuel fill valve and then go to Step 5. Yes Diagnostic is complete. No Go to Step 6. Yes Diagnostic is complete. No Go to Step 7. Yes Diagnostic is complete. No Go to Step 8. Page 5

58 Step Procedure Action 8 Replace the overfill protection device (OPD) valve in the vehicle fuel tank. Is the OPD valve located in the end cap of the fuel tank? 9 Attempt to fill the vehicle fuel tank as follows: When filling a new tank that has the OPD valve mounted in the end cap, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line. Yes Go to Step 9. No Go to Step 0. Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at a. Install a fuel fill pressure tester on the fill valve and close the ball valve. b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 0 gal (8 L) of fuel. c. Remove the fuel fill pressure tester. d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle. a. Did the tank fill? 0 Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal ( L) per minute? Fill station is not providing enough pressure to fill. a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature. b. Is the vehicle fuel tank pressure greater than 0 psi (8 kpa) over the nominal expected pressure? Vehicle fuel tank is at a higher pressure. a. Higher pressure is likely caused by heavy vehicle usage heating the fuel. b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank. Measure and compare vehicle fuel tank and fill station pressures. a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. b. Using a fuel fill pressure tester installed on the fuel fill valve, attempt to fill the vehicle. c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure. d. Is fill station pump pressure at least 50 psi (5 kpa) greater than fuel tank pressure? Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal ( L) per minute? Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at Yes Go to Step. No Locate a dispensing facility with pump output capacity in excess of 00 psi (689 kpa) (preferably an Auto Gastype facility). Then, go to Step. When tank pressure is within 0 psi (69 kpa) of expected tank pressure, go to Step. Yes Go to Step. No Fill station is not providing enough pressure to fill vehicle tank. Go to Step. Locate a dispensing facility with pump output capacity in excess of 00 psi (689 kpa) (preferably an Auto Gastype facility). Yes Diagnostic is complete. No Go to Step. Page 5

59 Pinpoint Test C: Over Fill Step Procedure Action Suspect overfill because fuel fill volumes achieved during refueling exceed the rated fuel capacity or excessive vehicle range between refueling. a. Check the fuel gauge. b. Is the gauge reading below / tank? Open bleeder valve located on the tank or remotely mounted on the vehicle. a. Listen at valve to verify propane vapor is venting. b. Is propane vapor venting? Park the vehicle at the refueling station. a. Check to determine if the vehicle is level using the vehicle frame as reference. b. Does the vehicle sit level? Locate the American Society of Mechanical Engineers (ASME) inspection plate on the fuel tank. a. Note the tank water capacity listed on the plate. b. Multiply the listed capacity by 0.05 (5%) and record the value. 5 Refuel the vehicle as follows: If the key is on during refueling, it will take the fuel level gauge in the instrument cluster longer to register full. Yes Go to Step. No Drive vehicle until gauge reads below / tank. Yes Go to Step. No Bleeder valve is not functioning properly. Replace the valve. Yes Go to Step. No Using a jack, raise the vehicle to obtain a level condition. Then, go to Step. With the value recorded, go to Step 5. Yes Record the volume of fuel dispensed and then go to Step 6. No Go to Step 7. a. Verify that the ignition is in the OFF position. b. Install the fuel fill pressure tester on the fill valve and close the ball valve. c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is open. d. With the bleeder valve open, turn on the pump. Open the ball valve slightly to very slowly refuel the vehicle. e. While refueling, observe the bleeder valve for fuel discharge. f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically. g. Did a solid stream of liquid flow from the bleeder valve? 6 Resume filling until the dispensing pump stops automatically. a. Record the total volume of fuel dispensed and subtract the amount from the volume recorded in Step 5. b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step? 7 The dispensing pump stopped automatically and a liquid fuel stream was not observed flowing from bleeder valve. Yes Tank does not overfill. Diagnostic is complete. No Tank is overfilling. Replace the OPD fill valve in the fuel tank; then, go to Step 8. Tank does not overfill. Diagnostic is complete. Page 55

60 Step Procedure Action 8 Refuel the vehicle as follows: If the key is ON during refueling, it will take the fuel level gauge in the instrument cluster longer to register full. Yes Record the volume of fuel dispensed and then go to Step 9. No Go to Step 7. a. Verify that the ignition is in the OFF position. b. Install the fuel fill pressure tester on the fill valve and close the ball valve. c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is OPEN. d. With the bleeder valve open, turn ON the pump. Open the ball valve slightly to very slowly to refuel the vehicle. e. While refueling, observe the bleeder valve for fuel discharge. f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically. g. Did a solid stream of liquid flow from the bleeder valve? 9 Resume filling until the dispensing pump stops automatically. a. Record the volume of fuel dispensed and subtract the amount from the volume recorded in Step 8. b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step? Yes Tank does not overfill. Diagnostic is complete. No Tank is overfilling. Replace the fuel tank assembly. Pinpoint Test D: Engine Does Not Crank Step Procedure Action Is battery voltage above 0 volts? Yes Go to Step. No Determine cause of low battery voltage. Verify that the smart relay module (SRM) has communication. Yes Go to Step. Can fuel rail pressure and temperature be read with a scan tool? No Go to the Smart Relay Module Electrical Test procedure. Refer to the Ford Powertrain Control/Emission Diagnosis Service Manual. Is the problem corrected? Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at Page 56

61 Pinpoint Test E: Engine Cranks, No Start For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step Procedure Action Verify the following: Yes Go to Step. a. Is there is at least /8 tank of fuel or more? (add fuel if necessary). No Correct fault and retest. b. Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 0 volts? d. Are fuel lines free of kinks or damage? e. Inspect all fuses in both the Ford and ROUSH fuse boxes. Record any Diagnostic Trouble Codes (DTCs). Are any codes present? Measure and record fuel tank and fuel rail pressure at during start sequence. Yes If circuit faults or nonfuel system related faults are set, correct condition and retest. If symptom continues go to step. No Go to Step. Yes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual. No Go to step. If the key is ON during refueling, it will take the fuel level gauge in the instrument cluster longer to register full. Is fuel rail pressure 55 psi or greater over tank? During start sequence, test voltage across terminal A and B (harness side) of each fuel pump connector located at the fuel pump access plate. Do both connectors have at least 6 volts? Yes Go to Step. No Perform Fuel Pump Electrical Test and repair wiring concern. For warranty submission record amp draw of each fuel pump (if possible), and resistance across pin A and B of the fuel pump connectors, tank side. 5 Is fuel rail pressure greater than 5 psi over tank during start sequence? 6 Disconnect Tank Supply Solenoid electrical connector, and perform circuit load test, using a test light during a start sequence. Repeat with fuel rail pressure control module supply solenoid. Do both circuits light a test light? Yes Go to Step 6. No Replace fuel pump assembly. Yes Go to Step 7. No Perform Tank Solenoid Electrical Test or Fuel Rail Pressure Control Module Electrical Test. Page 57

62 Step Procedure Action 7 With ignition off, activate the tank supply solenoid and the fuel rail pressure control module (FRPCM) supply solenoid by unplugging the connector and supplying v power and ground to the solenoid coil terminals. Yes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual. No Replace defective solenoid coil. If symptom continues call 80059ROUSH. If you have access for Ford IDS this can be done through manual solenoid activation. Actuate shutoff valve A (tank supply solenoid) and shutoff valve B (FRPCM supply solenoid). Is there an audible click when the solenoid is activated? Pinpoint Test F: Engine Stumble, Stall, Rough Idle For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step Procedure Action Verify the following: a. Is there is at least /8 tank of fuel or more? (add fuel if necessary). b. Is the tank supply manual shutoff valve fully open? c. Is battery voltage above.5 volts with engine running? d. Are fuel lines free of kinks or damage? Record any Diagnostic Trouble Codes (DTCs). Are any codes present? Measure and record fuel tank and fuel rail pressure at idle. Refer to Measuring Fuel Tank and Fuel Rail Pressure to read these values. Yes Go to Step. No Correct the fault and retry. Yes If ROUSH circuit faults are present, refer to the DTC Chart. If nonfuel system related circuit faults are set, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual. Correct condition and retest. If symptom continues, go to step. No Go to Step. Yes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual. No Go to Step. Is fuel rail pressure 55 psi or greater over tank? Disconnect Tank Supply Solenoid electrical connector, and perform circuit load test, using a test light during a start sequence. Repeat with fuel rail pressure control module supply solenoid. Do both circuits light a test light? Yes Go to Step 5. No Perform Tank Solenoid Electrical Test or Fuel Rail Pressure Control Module Electrical Test. Page 58

63 Step Procedure Action 5 With engine running, test voltage across terminal A and B (harness side) of each fuel pump connector located at the fuel pump access plate. Do both connectors have at least 6 volts? Yes Go to Step 6. No Perform Fuel Pump Electrical Test and repair wiring concern. For warranty submission record amp draw of each fuel pump (if possible), and resistance across pin A and B of the fuel pump connectors, tank side. 6 Is fuel rail pressure greater than 5 psi over tank at idle? Yes Go to step 7. No Replace fuel pump assembly. 7 Using a scan tool, measure fuel pump duty cycle. Is fuel pump duty cycle greater than 0.9 at idle? 8 Drive the vehicle with an assistant. Monitor fuel rail pressure and fuel pump duty cycle. During a hard acceleration, does the fuel rail pressure drop more than 0 psi while fuel pump duty cycle is at.0? Yes Replace fuel pump assembly. No Go to Step 8. Yes Replace fuel pump assembly. No Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual. Pinpoint Test G: Excess Flow Valve Check The excess flow valve (EFV) is designed to restrict fuel exiting the tank if the pump is energized while the fuel lines are not connected to the fuel tank. Under normal circumstances, the EFV should not trip. The EFV will reset itself after the fuel pumps have been off for about one minute. It is common to trip the EFV after the fuel lines have been serviced and contain no pressure. If the EFV trips, turn the vehicle off, wait one minute, and restart. This may take more than one attempt. If the fuel lines have not been serviced recently and the problem persists, there may be a leak in the supply side fuel line. If the problem is only present after the vehicle has been sitting for a length of time, but not present during a short soak, or there is a propane odor when the vehicle is running, refer to the Fuel Line Leak Detection procedure. To manually reset the EFV, with the vehicle off, close the manual shutoff valve and wait one minute. Then key the vehicle to start and slowly open the manual shutoff valve. Page 59

64 Pinpoint Test H: Maximum Pressure Check The LPA system operates over a wide range of pressures depending on ambient temperature, driving mode, etc. When the vehicle is subjected to a severe drive cycle in high ambient temperatures, the fuel rail pressure can rise to the limit of the injectors capabilities. This limit is a function of injector voltage and fuel rail pressure. The PCM protects for this condition by reducing the fuel pump speed when the condition is sensed, however, there still may be drive concerns. When the PCM starts controlling the fuel pump a P6E code is set. While this condition can occur in a normally functioning TROUBLESHOOTING vehicle, it can also be exacerbated by several factors. If the fuel tank was not properly bled during the first fill, trapped air in the vapor space can increase tank pressure. In this condition there is often only a faint smell of propane when the bleeder valve is opened. The tank should be vented until there is a strong propane odor coming from the bleeder valve. The tank pressure should be confirmed against the expected pressure. Allow the fuel tank to cool to ambient temperature before performing the following procedure. Step Procedure Action Measure tank pressure and tank surface temperature. Is tank pressure more than 5 psi (0 kpa) over expected tank pressure? Yes Vent the tank until pressure is within the expected range. No Vehicle is working properly; inform and explain operating characteristics to customer. Page 60

65 Pinpoint Test I: Fuel System Fails to Bleed Step Procedure Action Check for diagnostic trouble codes (DTC). Yes Go to Step 8. a. Are both DTC 6B and P009E present? No Go to Step. Check for oil contamination at vapor port/evap line. Yes Replace vapor port and perform Step. a. Disconnect EVAP line from vapor port. No Go to Step. b. Is oil present in EVAP line or vapor port? Determine if fault condition repeats. Yes Potential intermittent fault. Return a. START the engine and allow it to run for a few minutes. vehicle to customer and see if problem persists. b. Turn OFF the engine and wait one minute. No Go to Step. c. Measure and record the fuel rail pressure, fuel rail temperature and fuel tank pressure with the Key ON Engine OFF (KOEO). d. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid. e. With the engine OFF, monitor fuel rail pressure for 5 minutes. f. Does fuel rail pressure drop more than 0 psi (8 kpa)? Verify vapor port function. a. Disconnect the EVAP line from the FRPCM port. b. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid. c. Is there propane flowing from the port? 5 Verify bleed solenoid function. a. Remove the vapor port. b. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid. c. Is there propane flowing from the port? 6 Verify that wiring is in good condition and functioning. a. Perform wiring checks of the FRPCM harness. b. Is the wiring OK? 7 Check for a kinked EVAP line. a. Inspect the EVAP line between the FRPCM and EVAP canister. b. Are there kinks in the line? 8 Check for leaks to the FRPCM. a. START the engine and allow it to run for a few minutes. b. Turn OFF the engine. c. Measure and record fuel rail pressure. d. Activate bleed solenoid to bleed pressure from fuel rail until fuel pressure drops more than 50 psi (5 kpa). Refer to the Manual Solenoid Activation Procedure. e. Deenergize bleed solenoid. f. Disconnect the FRPCM and wait 0 minutes. g. Measure fuel rail pressure and fuel tank pressure. h. Does fuel rail pressure rise more than 0 psi (69 kpa)? Yes Go to Step 7. No Go to Step 5. Yes Replace vapor port and repeat Step. No Go to Step 6. Yes Bleed solenoid stuck closed. Replace the FRPCM. No Repair wiring and repeat Step. Yes Replace the kinked EVAP line and then repeat Step. No Go to Step 8. Yes FRPCM leaks at either supply solenoid or return check valve. Replace FRPCM. No Potential intermittent fault. Return vehicle to customer and see if problem persists. Page 6

66 Pinpoint Test J: Fuel Pressure Drop For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step Procedure Action Verify the following: a. Is there fuel in the tank of at least /8 tank? b. Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 0 volts? Determine fuel pressure. a. Measure and record fuel tank pressure. b. Measure and record fuel rail pressure with Key ON Engine Running (KOER). c. Subtract the tank measurement from the KOER measurement. d. Is the resulting fuel pressure in the expected range? Determine if the excess flow valve is tripped. a. Turn OFF the engine. b. Wait one minute and then restart the engine. c. Is the problem resolved? Check fuel pump operation. a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to InTank Harness for correct circuits. b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of amps should be recorded on both fuel pump circuits. c. Do fuel pumps draw current? 5 Check tank solenoid (TS) and supply solenoid (SS) fuses. a. Locate the TS (EE) and SS (FF) fuses. b. Are the fuses blown? 6 Verify that there is power and ground in the wiring circuit to the tank. a. Check for >5 volts at the fuel pump (FP) and fuel pump (FP) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. b. Is >5 volts present at the FP connector? c. Is >5 volts present at the FP connector? 7 Injection Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? See the Injection Pressure Temperature Sensor Electrical Check procedure. 8 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at Yes Go to Step. No Correct the fault condition and retry. Yes Go to Step. No Go to Step. Yes Refer to the Excess Flow Valve Check procedure. No Go to Step. Yes Go to Step 5. No If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.) If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 6. Yes Find and repair the short; replace the fuse. No Go to Step 8. Yes Refer to Engine Stumble, Stall, Rough Idle Step 9. No Check for an open/short in the wiring circuit and repair. Yes Go to Step 8. No Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor. Page 6

67 Pinpoint Test K: Tank Solenoid Electrical Check TROUBLESHOOTING For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS RELAY D FUSE FUSE FUSE FUSE FUSE 6 HARNESS FUSE BOX D D D5 D D F F F E E E A B A A5 A B B5 B A B F F5 E E5 C C C5 C F6 E6 C FUSE 5 RELAY A RELAY B RELAY C C C PBT/ASAGF0 9 A a Figure Underhood Harness Connectors C6 C a Figure Rear Frame Harness Connectors 7 8 FLOW CONTROL SOLENOID (GRAY) SUPPLY SOLENOID (BLACK) C C C7 0060a Figure Tank Harness Connectors Page 6

68 PROCEDURE Step Procedure Action Unplug the solenoid harness connector C7 from the tank solenoid. Go to Step. Using a multimeter, measure resistance of the solenoid. Is the measured resistance within 6 ohms? Using a multimeter, measure voltage at the tank solenoid as follows: a. With the ignition key ON, check for voltage present at pin, connector C7 (tank harness). Use the body as the reference ground. b. Is battery (B+) voltage present? Check fuse (EE, 0A) in auxiliary fuse box. Is fuse blown? 5 Check relay. Is relay functioning properly? 6 Check supply circuit continuity from solenoid harness to fuse box. a. Check continuity between: Pin, connector C7 and pin0, connector C (tank harness) Pin, connector C6 and pin0, connector C (rear frame harness) Pin, connector C and cavity A5, fuse box (underhood harness) b. Is there good continuity in the circuit? 7 Check ground circuit continuity from tank harness to smart relay module (SRM) connector. a. Check continuity between: Pin, connector C7 and pin7, connector C (tank harness) Pin7, connector C6 and pin7, connector C (rear frame harness) Pin7, connector C and pin, connector C (underhood harness) b. Is there good continuity in the circuit? Yes Go to Step. No Replace the tank solenoid. Yes Supply circuit OK. No Go to Step. Yes Replace fuse and locate the short. No Fuse OK; go to Step 5. Yes Go to Step 6. No Replace relay. Yes Go to Step 7. No Repair supply circuit wiring. Yes Refer to the Smart Relay Module Electrical Test procedure. No Repair ground circuit wiring. Page 6

69 Pinpoint Test L: Return Valve Procedure For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. PROCEDURE Step Procedure Action Unplug the solenoid harness connector C from the tank solenoid. Go to Step. Using a multimeter, measure the resistance of the solenoid. Is the measured resistance within 65 ohms? Using a multimeter, measure the voltage at the tank solenoid as follows: a. With the ignition key ON, check for voltage present at pin, connector C (tank harness). Use the body as the reference ground. b. Is battery (B+) voltage present? Check fuse (FF, 0A) in auxiliary fuse box. Is fuse blown? 5 Check relay. Is relay functioning properly? 6 Check supply circuit continuity from the solenoid harness to the fuse box. a. Check continuity between: Pin, connector C and Pin, connector C (tank harness). Pin, connector C6 and Pin, connector C (rear frame harness). Pin, connector C and Cavity F, fuse box (underhood harness). b. Is there good continuity in the circuit? 7 Check ground circuit continuity from the tank harness to the Smart Relay Module (SRM) connector. a. Check continuity between: Pin, connector C and Pin, connector C (tank harness). Pin, connector C6 and Pin, connector C (rear frame harness). Pin, connector C and Pin 0, connector C (underhood harness). b. Is there good continuity in the circuit? Yes Go to Step. No Replace the tank solenoid. Yes Supply circuit OK. No Go to step. Yes Replace the fuse. No Fuse OK. Go to Step 5. Yes Go to Step 6. No Replace the relay. Yes Go to Step 7. No Repair supply circuit wiring. Yes Refer to the Smart Relay Module Electrical Test procedure. No Repair ground circuit wiring. Page 65

70 Pinpoint Test M: Fuel Rail Pressure Control Module Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS FF FUSE BOX 5 5 E F A B 0060a C 6 C5 SUPPLY SOLENOID (BLACK) C6 BLEED SOLENOID (GRAY) PBT/ASAGF0 5 6 A a Figure Underhood Harness Connectors PROCEDURE Step Procedure Action Unplug the fuel rail pressure control module (FRPCM) connector Go to Step. from connector of underhood harness. Using a multimeter, check the resistance of each solenoid. a. Check resistance across the terminals of the FRPCM solenoid in sequence as follows: Supply Solenoid Pin and pin Bleed Solenoid Pin and pin b. Are both solenoids between 6 ohms? Yes Go to Step. No Replace the FRPCM if resistance for any one of the solenoids is not within the specified range. Check supply voltage to FRPCM solenoids. Go to Steps 6. Using a multimeter, measure voltage between the terminal for each solenoid at the harness side connectors and ground as follows: Supply Solenoid Pin and body ground B+ Voltage Go to Step 5. No Voltage Go to Step 5. Page 66

71 Step Procedure Action 5 Bleed Solenoid Pin and body ground B+ Voltage Continue with Step 8. No Voltage If Step has voltage, go to Step 7. If Step has no voltage, go to Step 6. 6 Check fuses (FF, 0A) in auxiliary fuse box. Is a fuse blown? 7 Check solenoid supply circuit continuity. a. Check continuity between: Supply Solenoid Pin, connector C5 (underhood harness) and cavity F (auxiliary fuse box) Bleed Solenoid Pin, connector C6 (underhood harness) and cavity F (auxiliary fuse box) b. Is there good continuity in all three circuits? 8 Check solenoid ground circuit continuity. a. Check continuity in the underhood harness between: Supply Solenoid Pin, connector C5 and pin, connector C at SRM Bleed Solenoid Pin, connector C6 and pin, connector C at SRM b. Is there good continuity in all three circuits? Yes Replace fuse and locate the short. No Go to Step 7. Yes Go to Step 8. No Repair wiring circuit. Yes Refer to the Smart Relay Module Electrical Test procedure. No Repair wiring circuit. Page 67

72 Pinpoint Test N: Injection Pressure Temperature Sensor Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS C 0 C PBT/ASAGF0 5 6 A a IPTS CONNECTOR INSERTION VIEW 009a C IPTS CONNECTOR FACEVIEW 000a POWER TERMINAL (VOLTAGE IN) TEMPERATURE OUTPUT TERMINAL (VOLTAGE OUT) C IPTS SENSOR PINOUT PRESSURE OUTPUT TERMINAL (VOLTAGE OUT) GROUND TERMINAL (GROUND) 00a Figure 5 Underhood Harness Connectors PROCEDURE Step Procedure Action Unplug the connector C (underhood harness) to the IPTS. Go to Step. Check resistance of the injection pressure temperature sensor (IPTS). a. With vehicle at ambient room temperature (0 0 C, F) and using a multimeter, measure resistance across the IPTS terminals (between pin and pin). b. Is the resistance value between 8K K ohms? Check circuit continuity between the IPTS and the smart relay module (SRM). a. Using a multimeter, check continuity in the underhood harness between: Pin, connector C and pin0, connector C Pin, connector C and pin0, connector C Pin, connector C and pin8, connector C Pin, connector C and pin5, connector C b. Is there good continuity in the circuits? Yes Go to Step. No Replace the IPTS. Yes Refer to the Smart Relay Module Electrical Test procedure. No Repair circuit wiring. Page 68

73 Pinpoint Test O: Tank Pressure Temperature Sensor Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS C 0 C PBT/ASAGF0 8 9 A a 0060a Figure 6 Underhood Harness Connectors 5 C6 C a Figure 7 Rear Frame Harness Connectors Page 69

74 6 C TPTS CONNECTOR FACEVIEW POWER TERMINAL (VOLTAGE IN) TEMPERATURE OUTPUT TERMINAL (VOLTAGE OUT) TPTS SENSOR PINOUT PRESSURE OUTPUT TERMINAL (VOLTAGE OUT) GROUND TERMINAL (GROUND) 0080a C a Figure 8 Fuel Tank Connectors PROCEDURE Step Procedure Action Unplug the connector C (fuel tank harness) to the TPTS. Go to Step. Check resistance of the fuel pressure temperature sensor (TPTS). a. With vehicle at ambient room temperature (0 0 C, F) and using a multimeter, measure resistance across the FPTS terminals (between pin and pin). b. Is the resistance value between 8K K ohms? Check circuit continuity between the TPTS and the smart relay module (SRM). a. Using a multimeter, check continuity in the underhood harness between: Pin, connector C and pin0, connector C Pin6, connector C and pin, connector C Pin5, connector C and pin9, connector C Pin, connector C and pin5, connector C b. Is there good continuity in the circuits? Yes Go to Step. No Replace the TPTS. Yes Refer to the Smart Relay Module Electrical Test procedure. No Repair circuit wiring. Page 70

75 Pinpoint Test P: Fuel Pump Function/Electrical Test Procedure For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 7 8 C9 C C 8 7 A B A B A B a Figure 9 Rear Frame Harness Connectors 0060a 00076a Figure 0 InTank Harness Connectors PROCEDURE Step Procedure Action With vehicle at idle (during start procedure if it will not start) read fuel rail and fuel tank pressure at the same time using a scan tool or manual pressure gauge. Is rail pressure greater than 5psi over tank pressure? Yes Go to Step. No Go to Step. Using the ROUSH Diagnostic Tool. Page 7

76 Pinpoint Test Q: Fuel Pump Control Module Electrical Continuity Test For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 9 FUSE BOX E A D 5 5 B E F 5 5 C 5 6 C A5 A 005a Figure Underhood Harness Connectors 0 C0 C9 C 5 8 C Figure Rear Frame Harness Connectors 0078a Page 7

77 PROCEDURE Step Procedure Action For fuel pump control module (FPCM) functional testing and diagnostic trouble codes, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at Check Ford FPCM circuit continuity to Ford harness. Yes Go to Step. a. Disconnect rear frame harness connectors C0 and C. No Repair circuit wiring. b. Check for continuity in the rear frame harness across: Pin, connector C0 and pin, connector C Pin, connector C0 and pin, connector C Pin, connector C0 and pin, connector C Pin5, connector C0 and pin5, connector C Pin6, connector C0 and pin6, connector C Pin7, connector C0 and pin7, connector C c. Is there good continuity in each circuit? Check FPCM circuit continuity to Ford harness. a. Disconnect rear frame harness connector C9. b. Check wire VPWR (V+) for continuity across: Pin, connector C9 (rear frame harness) and pin, connector C6 (rear frame harness) Pin, connector C (underhood harness) and cavitya5, fuse box (underhood harness) CavityA, fuse box (underhood harness) and cavitye, fuse box (underhood harness) c. Is there good continuity in each circuit? Check fuse condition (EE). Is the fuse blown? Check ROUSH CleanTech FPCM circuit continuity to Ford harness. a. Check for continuity in the rear frame harness across: Pin, connector C6 and pin, connector C9 Pin, connector C0 and pin, connector C9 Pin, connector C and pin5, connector C9 Pin6, connector C0 and pin6, connector C9 Pin9, connector C and pin8, connector C9 Pin5, connector C6 and pin7, connector C9 b. Is there good continuity in each circuit? Yes Go to Step. No Repair circuit wiring. Yes Inspect for shorted wire and replace fuse. No Go to Step. Yes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the FPCM. No Repair circuit wiring. Page 7

78 Pinpoint Test R: Smart Relay Module Electrical Test TROUBLESHOOTING For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS FUSE BOX EE 5 5 E F C PBT/ASAGF A 6 7 A B 00079a Figure Underhood Harness Connectors C 6 9 C 8 005a Figure CAN Harness Connectors PROCEDURE Step Procedure Action Disconnect the smart relay module (SRM) connector C (underhood harness). Check for battery voltage (B+) to the SRM. a. Using a multimeter, check for B+ voltage at pin, connector C. Use a body ground for reference. b. Is there voltage (B+)? Check for battery voltage (B+) to the SRM. a. Check circuit continuity between pin, connector C and cavity E, auxiliary fuse box. b. Is there good continuity in the circuit? Check for battery voltage (B+) to the SRM. a. Check condition of SRM power fuse (EE, 5A) in the auxiliary fuse box. b. Is fuse blown? Go to Step. Yes Go to Step 5. No Go to Step. Yes Go to Step. No Repair circuit wiring. Yes Replace fuse. No Go to Step 5. Page 7

79 Step Procedure Action 5 Check the SRM ground circuit for continuity. a. Using a multimeter, check ground at pin, connector C (underhood harness). Use a body ground for reference. b. Is there good continuity? 6 Check CAN and underhood harness continuity. a. Check CANH(+) continuity across: Pin8, SRM connector C (underhood harness) and pin, connector (underhood harness) Pin, connector C (CAN harness) and pin6, connector C (CAN harness) b. Is there good continuity in the circuits? 7 Check CAN and underhood harness continuity. a. Check CANH( ) continuity across: Pin, SRM connector C (underhood harness) and pin, connector (underhood harness) Pin, connector C (CAN harness) and pin, connector C (CAN harness) b. Is there good continuity in the circuits? Yes Go to Step 6. No Repair circuit wiring. Yes Go to Step 7. No Repair circuit wiring. Yes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the CAN bus. No Repair circuit wiring. Page 75

80 Pinpoint Test S: Fuel Level Sender Electrical Check TROUBLESHOOTING For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS C C PBT/ASAGF0 8 9 A a 00605a C6 Figure 5 Underhood Harness Connectors C a 5 Figure 6 Rear Frame Harness Connectors C8 Figure 7 Rear Frame Harness Connector 0057a Page 76

81 C 008a C 0079a Figure 8 Tank Harness Connectors PROCEDURE Step Procedure Action Note: The fuel level indication system is calibrated to the voltage output from the fuel level sender. The needle position on the sending unit twin sight is a raw reading of the sender arm position and is not an accurate representation of the fuel level in the tank. The fuel level gauge on the cluster should display the correct fuel level. All continuity (OHMS) readings should be less than 0.5 OHMS If any SRM or TPTS DTC's present go to Pin Point test and resolve those faults prior to diagnosing the Fuel Level Sender fault. Turn key to on position. Check for 5volt reference present across pina and pinc harness side of the FLS connector. Is 5v power present? Check for continuity of harness for 5v vref circuit and ground circuit of Fuel Level Sender. a. Check for continuity from FLS pina frame side harness to pin of SRM connector: Continuity present Yes, go to Step b. b. Check for continuity from FLS pinc frame harness at FLS and pin0 of SRM connector. c. Is there good continuity in each circuit? a. Check for continuity from SRM connector C, pin to connector C, pin0 (underhood harness). Continuity present Yes, go to Step b. b. Check for continuity from connector C6, pin0 to connector C8, pin (rear frame harness). 5 Perform output voltage check using a universal probe on Pin B and Pin C at FLS connector. a. With harness fully connected, place the universal probes into pinb and pinc of sending unit connector and monitor for voltage. b. Is voltage present? 6 Perform sending unit range voltage test. a. With your probe still on pinb and pinc, remove the sending unit electronic portion from the sender body by removing the phillips screws securing it. Leave the wire harness connected. Using a nonmagnetic socket or other steel/iron object, move sender from full to empty. Make sure the voltage smoothly changes between 0. volts min. to.98 volts max. b. Was there any concern with voltage range output test? Yes Go to SRM or TPTS PPT. No Go to Step. Yes Go to Step 5. No Go to Step. Yes Go to Step. No Locate and repair open circuit or replace harness. Yes Go to Step 5. No Repair circuit issues or replace harness. Yes Go to Step 6. No Replace electronic portion of sending unit. Yes Replace electronic portion of sending unit clear faults and test. No Refer to the tank draining and intank sending unit replacement procedure to replace the intank sending unit. Page 77

82 Pinpoint Test T: Manual Solenoid Activation Procedure TROUBLESHOOTING For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTOR 7 8 C 6 BLEED SOLENOID SUPPLY SOLENOID PBT/ASAGF0 8 9 A a Figure 9 Connector End View BLEED/ VAPOR PORT RETURN PORT SUPPLY PORT 0058a Figure 0 FRPCM Solenoid Locations PROCEDURE Step Procedure Action Turn ignition to off. Disconnect the smart relay module (SRM) wire harness connector. Energize the individual solenoids by providing a ground to the following pins in the SRM connector: Note: Use caution not to damage SRM connector terminals. Always connect lead to the connector then to ground. Pin Bleed Solenoid Pin Supply Solenoid Pin 0 Flow Control Solenoid Note: The tank supply solenoid cannot be actuated from the SRM. v power and ground must be applied to the solenoid connector. Page 78

83 Pinpoint Test U: F650/F750 Dual Tank Transfer Pinpoint Test (P5B DTC) Step Procedure Action Determine if any other DTCs that could contribute to a failure to transfer are stored in the PCM (fuel pump faults, slave tank solenoid fault, fuel level sending unit faults). Perform visual inspection of the fuel transfer line which connects the passenger side tank supply valve to the transfer OPD located inboard of the driver's side fuel tank assembly to ensure there are no restrictions or damage to the transfer line assembly. Are any restrictions present? The OPD should have a notch or the word TOP stamped into the part on the face of the brass on the OPD and this should be oriented at the o clock position. Is the transfer OPD located inboard on the driver's side fuel tank assembly oriented properly? Perform the sending unit voltage range test on both sending unit dials to ensure they are properly functioning before continuing the pin point test. Are the fuel level senders reading properly? Remove the sending unit twinsite by removing the small phillips head screws. Leave wire harness connected. Read voltage between pins B and C of the sending unit twinsite connector. Sender voltages and corresponding fuel levels: Master: [V] [%] Slave: [V] [%] Attempt a fuel transfer by ensuring the driver's side fuel tank level is under 0% and the passenger side tank is above 5% fuel level. Start the vehicle and listen for the transfer to attempt to occur. After the vehicle has started, the system should command the passenger side tank supply solenoid open and fuel pumps to run after approximately 60 seconds of run time. Did the unit attempt to command the transfer? Determine fuel level in each tank by viewing the parameters in the ROUSH Diagnostic Tool (driver side MUX_FUELLVL_ACTV_SIDE, passenger side MUX_FUELLVL_PSSV_SIDE) or performing the voltage test. DO NOT use the needle on the sending units as reference. 6 Using the wiring diagrams from the diagnostic manual, ensure the sending unit voltages are present at pins of the SRM connector. The driver side tank sender output is pin 0 of the SRM connector measured to chassis ground, the passenger side tank is pin 0 of the SRM connector measured to chassis ground. Ensure these voltages are the same as listed in step. If still no resolution, contact tech support at 80059ROUSH (Opt ). 7 Is volts present at the passenger side tank supply solenoid when the transfer is commanded? 8 Is voltage present to the fuel pumps while the transfer is being commanded? NOTE: The fuel pump should have resistance through each motor of less than.0 ohm and should draw a minimum of amps when running. If pumps are out of spec, replace fuel pump assembly and retest. Tank supply solenoid should have resistance value of 6 ohms. If out of spec, replace tank supply solenoid and retest. Yes Resolve DTCs and retest. No Continue to Step. Yes Repair/replace transfer line and retest. No Continue to step. Yes Continue to step. No See OPD installation instructions from the service manual to determine if OPD can be reused or replaced. Yes If yes: Continue to step 5. No If No: Replace fuel gauge and retest. Yes Continue to step 7. No Continue to step 6. Yes Continue to step 8. No Repair circuit wiring. Yes Continue to step 9. No Repair circuit wiring. Page 79

84 Step Procedure Action 9 Depressurize the transfer line and drivers side fuel tank using the depressurization procedures in the service manual. Replace the OPD and retest the transfer operation. Does vehicle transfer successfully? NOTE: Once tank is refilled after repair, it will be necessary to purge the tank of air using the fuel tank purging procedure located within the service manual. The fuel levels will need to be set back to the values listed in step 5 above. Yes Repair complete. No Contact 80058ROUSH (Opt ) for assistance. Page 80

85 WIRING DIAGRAMS AND SCHEMATICS WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS Page 8

86 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E50 GEN Wiring Harnesses and Connector Layout T + BATTERY T C C5 C6 C C FB C C C6 C C9 C C0 T C C8 C C C7 C C5 C6 C C 7 T C C G C BCUTS C 007a UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS TANK HARNESS INTANK HARNESS UNDERHOOD HARNESS BCUTS BLUNT CUTS FOR CRANK WARNING, FUEL COOLER, AC REQ, AND A/C CLUTCH C SRM, 6PIN C UNDERHOOD / TANK INLINE, 6PIN C IPTS, PIN C5 SUPPLY SOLENOID, PIN C6 BLEED SOLENOID, PIN C UNDERHOOD / CAN HARNESS INLINE, PIN FB FUSE BOX T BATTERY PWR, RING TERMINAL T BATTERY GROUND, RING TERMINAL T SRM CASE GROUND, RING TERMINAL CAN HARNESS C OBD FLANGE MOUNT, 6PIN C CAN / UNDERHOOD INLINE, PIN C OBD INLINE TO FORD HARNESS, 6PIN G PASSTHRU GROMMET REAR FRAME HARNESS C REAR FRAME / TANK HARNESS INLINE, 6PIN C FORD FTPT HARNESS INLINE, PIN C FORD FTPT SENSOR, PIN C6 REAR FRAME / UNDERHOOD INLINE, 6PIN C9 RCT EFPR, 8PIN C0 FORD FPCM HARNESS INLINE, 8PIN C FORD EFPR, 8PIN C8 FORD FUEL TANK HARNESS INLINE, PIN T FRAME GROUND, RING TERMINAL TANK HARNESS C TANK / REAR FRAME HARNESS INLINE, 6PIN C FUEL LEVEL SENDER, PIN C IPTS #, PIN C FLOW CONTROL SOLENOID (GRAY), PIN C5 TANK / INTANK FP # INLINE, PIN C6 TANK / INTANK FP # INLINE, PIN C7 SUPPLY SOLENOID (BLACK), PIN INTANK HARNESS C FUEL PUMP # INLINE, PIN C FUEL PUMP # INLINE, PIN 7 TANK PASSTHRU GROMMET Page 8

87 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F59 Wiring Harnesses and Connector Layout BATTERY + T T T C9 C C0 C8 C P D B C T C FB BC C5 C6 S D C C C G C C C C6 C C C C5 C5 C C C7 C a UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS TANK SOLENOID HARNESS INTANK HARNESS UNDERHOOD HARNESS C SRM, 6PIN C UNDERHOOD / REAR FRAME INLINE CONNECTOR, 6PIN C IPTS, PIN C5 SUPPLY SOLENOID, PIN C6 BLEED SOLENOID, PIN C UNDERHOOD / CAN INLINE CONNECTOR, PIN FB AUX FUSE BOX T BATT POWER, RING TERMINAL T BATT GROUND, RING TERMINAL T SRM CASE GROUND, RING TERMINAL BC BLUNT CUTS FOR CK WRNG, FU CLR, A/C CL, A/C CL, AC REQ, AC REQ CAN HARNESS C OBD FLANGE MOUNT, 6PIN C CAN / UNDERHOOD INLINE, PIN C CAN / MORGAN INLINE CONNECTOR, PIN (UPS ONLY) C OBD INLINE CONNECTOR TO FORD HARNESS, 6PIN D DIODE (UPS ONLY) G GROMMET S SPLICE TO MORGAN OLSON IP HARNESS (UPS ONLY) REAR FRAME HARNESS C REAR FRAME / TANK INLINE, 6PIN C FTPT FORD HARNESS INLINE, PIN C FTPT SENSOR, PIN C6 REAR FRAME / UNDERHOOD INLINE, 6PIN C9 RCT EFPR, 8PIN C0 FORD FPCM INLINE, 8PIN C FORD EFPR, 8PIN C8 FORD FUEL TANK HARNESS INLINE, PIN T FRAME GROUND (FP SHIELD), RING TERMINAL TANK SOLENOID HARNESS C TANK / REAR FRAME INLINE, 6PIN C FUEL LEVEL SENDER, PIN C IPTS #, PIN C FLOW CONTROL SOLENOID VALVE, PIN C5 TANK / FUEL PUMP # INLINE, PIN (BLK) C6 TANK / FUEL PUMP # INLINE, PIN (GRAY) C7 SUPPLY SOLENOID VALVE, PIN INTANK HARNESS C FUEL PUMP # INLINE CONNECTOR C FUEL PUMP # INLINE CONNECTOR 7 GROMMET Page 8

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