DIAGNOSTIC MANUAL P-01B101-CA

Transcription

1 06-07 Ford E-Series and F-Series Products Liquid Propane Autogas Fuel System (th Generation) Includes: E-50 Custom Body F-59 F-50/550 F-650/750 Revision History -BA Initial Release 5/05 -CA Revisions /07 DIAGNOSTIC MANUAL P-0B0-CA

2 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 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 No Fill Slow Fill Over Fill Engine Does Not Crank Engine Cranks, No Start Engine Stumble, Stall, Rough Idle Excess Flow Valve Check Maximum Pressure Check Supply Solenoid Check Fuel System Fails to Bleed Fuel Pressure Drop Tank Solenoid Electrical Check Fuel Rail Pressure Control Module Electrical Check Injection Pressure Temperature Sensor Electrical Check Tank Pressure Temperature Sensor Electrical Check Fuel Pump Electrical Test Fuel Pump Control Module Electrical Continuity Test Smart Relay Module Electrical Test Fuel Level Sender Electrical Check Manual Solenoid Activation Procedure F-650/F-750 Dual Tank Transfer Pin Point Test (P5B DTC) E-50 GEN Wiring Harnesses and Connector Layout F-59 Wiring Harnesses and Connector Layout E-50 Roush Wiring Harnesses F-59 Roush Wiring Harnesses E-50 Electrical Schematic Underhood Harness Page i

3 TABLE OF CONTENTS E-50 Electrical Schematic CAN Bus Harness E-50 Electrical Schematic Rear Frame Harness E-50 Electrical Schematic Tank Harness F-59_F-50_F-550 Electrical Schematic Underhood Harness F-59_F-50_F-550 Electrical Schematic CAN Bus Harness F-59_F-50_F-550 Electrical Schematic Rear Frame Harness F-59_F-50_F-550 Electrical Schematic Tank Harness F-650_F-750 Electrical Schematic Underhood Harness F-650_F-750 Electrical Schematic CAN Bus Harness F-650_F-750 Electrical Schematic Left Tank Harness F-650_F-750 Electrical Schematic Right Tank Harness F-650_F-750 Electrical Schematic Transfer Overlay Harness Gen LPG F-650/F-750 Remote Start Installation Page ii

4 INTRODUCTION INTRODUCTION Page

5 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 (LP-Gas 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

6 INTRODUCTION Installation, Garaging and Training Chapter of NFPA 58 applies to engine fuel systems using LP-Gas 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 LP-Gas 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 LP-Gas engine fuel system shall be trained. Contact the Propane Education and Research Council to learn more about their CETP E-Learning computer-based training program: or Page

7 TROUBLESHOOTING Page

8 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 FLIM FLS FP FPCM FRP FRPCM FTS GRD HEGO IC IPTS KOEO KOER LPA MAF OEM OPD PCM PID PWR GND SIG RTN SRM SS TPTS TS VMV VPWR VREF WOT Description Bleed Solenoid Controller Area Network Diagnostic Trouble Code Electronic Fuel Pump Relay Electronic Returnless Fuel System Evaporative Flow Control Solenoid Fuel Level Interface Module 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 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

9 Diagnostic Trouble Code List Code Description 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 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 P6E Fuel Pressure Relief Valve Actuated P5 Fuel Tank Pressure Relief Valve Malfunction P95 Heated Exhaust Gas Oxygen Sensor Stuck P97 Heated Exhaust Gas Oxygen Sensor Stuck P5B0 Fuel Level Sensor A Stuck P5B Fuel Level Sensor B Stuck P6 Fuel Pump B Control Circuit/Open P665 Fuel Shutoff Valve B Control Circuit/Open P6B Fuel Shutoff Valve A Control Circuit Performance/Stuck Off Page 6

10 P6B5 P6EA U008 U009 U06C U0B U0C Code Description 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 Calibration Release OBD Summary Chart 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description c05d7 0 0 P0005 Fuel Shutoff Valve "A" Control Circuit/Open P000 HOS Heater Control Circuit (Bank Sensor ) P006 HOS Heater Control Circuit (Bank Sensor ) P000 Oxygen Sensor Signals Swapped Bank Sensor /Bank Sensor P0050 HOS Heater Control Circuit (Bank Sensor ) P0068 MAP/MAF - Throttle Position Correlation P0090 Fuel Pressure Regulator Control Circuit/Open P009B Fuel Pressure Relief Control Circuit/Open P009E Fuel Pressure Relief Control Performance/Stuck Off P000 Mass or Volume Air Flow Sensor "A" Circuit P00 Mass or Volume Air Flow Sensor "A" Circuit Low P00 Mass or Volume Air Flow Sensor "A" Circuit High P00 Mass or Volume Air Flow Sensor "A" Circuit Intermittent P0 Intake Air Temperature Sensor Circuit Range/Performance (Bank ) P0 Intake Air Temperature Sensor Circuit Low (Bank ) P0 Intake Air Temperature Sensor Circuit High (Bank ) P06 Engine Coolant Temperature Sensor Circuit Range/Performance P0 Throttle/Pedal Position Sensor "A" Circuit Low P0 Throttle/Pedal Position Sensor "A" Circuit High P05 Insufficient Coolant Temp For Closed Loop Fuel Control P0 O Sensor Circuit Low Voltage (Bank Sensor ) P0 O Sensor Circuit High Voltage (Bank Sensor ) P05 O Sensor Heater Circuit (Bank Sensor ) P07 O Sensor Circuit Low Voltage (Bank Sensor ) P08 O Sensor Circuit High Voltage (Bank Sensor ) P0 O Sensor Heater Circuit (Bank Sensor ) P08 Fuel Delivery Error P05 O Sensor Circuit Low Voltage (Bank Sensor ) Page 7

11 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P05 O Sensor Circuit High Voltage (Bank Sensor ) P055 O Sensor Heater Circuit (Bank Sensor ) 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 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 P08 Transmission Fluid Temperature Sensor "A" Over Temperature Condition P09 Engine Overspeed Condition 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 0 P097 Vehicle Overspeed Condition P098 Engine Oil Over Temperature Condition Page 8

12 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P0xx Misfire P09 Crankshaft Position Sensor "A" Circuit Intermittent P00 Camshaft Position Sensor "A" Circuit (Bank or single sensor) P05 Ignition Coil "A" Primary Control Circuit/Open P05 Ignition Coil "B" Primary Control Circuit/Open P05 Ignition Coil "C" Primary Control Circuit/Open P05 Ignition Coil "D" Primary Control Circuit/Open P055 Ignition Coil "E" Primary Control Circuit/Open P056 Ignition Coil "F" Primary Control Circuit/Open P057 Ignition Coil "G" Primary Control Circuit/Open P058 Ignition Coil "H" Primary Control Circuit/Open P059 Ignition Coil "I" Primary Control Circuit/Open P060 Ignition Coil "J" Primary Control Circuit/Open P0xx Misfire P0 EVAP System Purge Control Valve "A" Circuit P060 Fuel Level Sensor "A" Circuit 0 0 P06 Fuel Level Sensor A Circuit Range/Performance P06 Fuel Level Sensor A Circuit Low P06 Fuel Level Sensor A Circuit High P050 Brake Switch "A"/"B" Correlation P0505 Idle Control System P0506 Idle Control System - RPM Lower Than Expected P0507 Idle Control System - RPM Higher Than Expected P05 A/C Refrigerant Pressure Sensor "A" Circuit Low P05 A/C Refrigerant Pressure Sensor "A" Circuit High P056 System Voltage Low P056 System Voltage High P057 Brake Switch "A" Circuit Low P057 Brake Switch "A" Circuit High P0579 Cruise Control Multi-Function Input "A" Circuit Range/Performance 0 P058 Cruise Control Multi-Function Input "A" Circuit High 0 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 Internal Control Module Monitoring Processor Performance P060B Internal Control Module A/D Processing Performance P060C Internal Control Module Main Processor Performance Page 9

13 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P060D Internal Control Module Accelerator Pedal Position Performance P060 Control Module Vehicle Options Error P06A Internal Control Module Torque Performance P06B Internal Control Module Torque Calculation Performance P06C Internal Control Module Engine RPM Performance P06D Internal Control Module Engine Air Mass Performance P060 Generator Control Circuit P065 Generator Field/F Terminal Circuit Low P066 Generator Field/F Terminal Circuit High P067 Fuel Pump A" Control Circuit Open P06F Internal Control Module EEPROM Error 0 0 P060 VIN Not Programmed or Incompatible - ECM/PCM 0 0 P06 Sensor Reference Voltage "A" Circuit Low P06 Sensor Reference Voltage "A" Circuit High P065 A/C Clutch Relay Control Circuit P06A Fuel Pump Control Module A 0 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 Generator Control Circuit Range/Performance P06B8 Internal Control Module Non-Volatile Random Access Memory (NVRAM) Error P06E Control Module Wake-up Circuit Performance 0 0 P06E9 Engine Starter Performance P070 Transmission Control System Range/Performance P070 Transmission Control System Electrical P0706 Transmission Range Sensor "A" Circuit Range/Performance P0707 Transmission Range Sensor "A" Circuit Low P0708 Transmission Range Sensor "A" Circuit High P070 Transmission Fluid Temperature Sensor "A" Circuit P07 Transmission Fluid Temperature Sensor "A" Circuit Range/ Performance P07 Transmission Fluid Temperature Sensor "A" Circuit Low P07 Transmission Fluid Temperature Sensor "A" Circuit High P075 Input/Turbine Shaft Speed Sensor "A" Circuit P077 Input/Turbine Shaft Speed Sensor "A" Circuit No Signal P078 Input/Turbine Shaft Speed Sensor "A" Circuit Intermittent P070 Output Shaft Speed Sensor Circuit P07 Output Shaft Speed Sensor Circuit No Signal P079 Gear 6 Incorrect Ratio Page 0

14 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P07 Gear Incorrect Ratio P07 Gear Incorrect Ratio P07 Gear Incorrect Ratio P07 Gear Incorrect Ratio P075 Gear 5 Incorrect Ratio 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 P07 Torque Converter Clutch Solenoid Circuit Intermittent P078 Pressure Control Solenoid "A" Electrical P0750 Shift Solenoid "A" P075 Shift Solenoid "A" Performance/Stuck Off P075 Shift Solenoid "A" Stuck On P075 Shift Solenoid "A" Electrical 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 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 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 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 P077 Shift Solenoid "E" Intermittent P088 TCM Power Input Signal Low P088 TCM Power Input Signal High P0885 TCM Power Relay Control Circuit /Open Page

15 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description 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 P00 KOER Not Able to Complete, KOER Aborted 0 P0 Mass Air Flow Sensor Out Of Self Test Range P Throttle Position Sensor "A" Out Of Self Test Range P7 Exhaust Temperature Out of Range, O Sensor Tests Not Completed P5E Throttle Actuator Control Throttle Body Air Flow Trim at Max Limit P6E Fuel Pressure Relief Valve Actuated P60 Theft Detected, Vehicle Immobilized 0 0 P85 Cylinder Head Over Temperature Condition P88 Cylinder Head Temperature Sensor Out Of Self Test Range P89 Cylinder Head Temperature Sensor Circuit High P90 Cylinder Head Temperature Sensor Circuit Low P6 Crankshaft/Camshaft Sensor Range/Performance P97 System Voltage Out Of Self Test Range P5 Fuel Tank Pressure Relief Valve Malfunction P6 A/C Demand Out Of Self Test Range P50 Vehicle Speed Sensor Out Of Self Test Range P56 Brake Line Pressure Sensor Circuit 0 P575 Pedal Position Out Of Self Test Range P59 P595 Forced Engine Shutdown - Remote Start System Fault, No Unattended Vehicle Timeout Forced Engine Shutdown - Remote Start System Fault, Transmission Range Not In Park Position 0 0 P60 Immobilizer/ECM Communication Error 0 0 P60A Control Module Vehicle Options Reconfiguration Error 0 0 Page

16 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P6A Incorrect Response from Immobilizer Control Module 0 0 P6 Immobilizer ID Does Not Match 0 0 P6E Internal Control Module PTO Control Performance P6F Starter Motor Disabled - Engine Crank Time Too Long P6 Keep Alive Power Voltage Too Low 0 P65 Tire/Axle Out of Acceptable Range 0 P66 Inductive Signature Chip Communication Error P69 Vehicle ID Block Corrupted, Not Programmed 0 0 P66 Linear O Sensor Control Chip (Bank ) P67 Linear O Sensor Control Chip (Bank ) P67 Control Module Software Corrupted P70 Transmission Range Sensor Circuit Intermittent P70 Brake Switch Out Of Self Test Range P705 Transmission Range Circuit Not Indicating Park/Neutral During Self Test P7 Transmission Fluid Temperature Sensor Out Of Self Test Range P7 Torque Converter Clutch Solenoid Circuit Performance P77F Unable To Fully Engage Neutral P780 Transmission Control Switch (O/D Cancel) Circuit Out Of Self Test Range 0 P78 Transmission Overtemperature Condition P9 Transmission Range Signal P9 Vehicle Speed Signal 0 0 P9E A/C Clutch Request Signal 0 0 P067 Fuel Level Sensor "B" Circuit Low 0 0 P068 Fuel Level Sensor "B" Circuit High 0 0 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 P Throttle Actuator "A" Control System - Stuck Closed P Throttle/Pedal Position Sensor/Switch "D" Circuit Low P Throttle/Pedal Position Sensor/Switch "D" Circuit High P7 Throttle/Pedal Position Sensor/Switch "E" Circuit Low P8 Throttle/Pedal Position Sensor/Switch "E" Circuit High P5 Throttle/Pedal Position Sensor/Switch "A"/"B" Voltage Correlation P8 Throttle/Pedal Position Sensor/Switch "D"/"E" Voltage Correlation Page

17 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description P95 Heated Exhaust Gas Oxygen Sensor Stuck P96 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) P97 Heated Exhaust Gas Oxygen Sensor Stuck P98 O Sensor Signal Biased/Stuck Rich (Bank Sensor ) P9A Bank Air-Fuel Ratio Imbalance 0 P9B Bank Air-Fuel Ratio Imbalance 0 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 P5B0 Fuel Level Sensor A Stuck P5B Fuel Level Sensor "B" Stuck 0 0 P60 ECM/PCM Engine Off Timer Performance P6 Fuel Pump B Control Circuit/Open 0 P6F Engine Serial Number Not Programmed or Incompatible P665 Fuel Shutoff Valve "B" Control Circuit/Open P669 Actuator Supply Voltage "B" Circuit/Open P6B Fuel Shutoff Valve A Control Circuit Performance/Stuck Off P6B5 Fuel Shutoff Valve "B" Control Circuit Performance/Stuck Off P6EA Fuel Pump Control Module B 0 P700 Transmission Friction Element "A" Apply Time Range/Performance P70 Transmission Friction Element "B" Apply Time Range/Performance P70 Transmission Friction Element "C" Apply Time Range/Performance P70 Transmission Friction Element "D" Apply Time Range/Performance P70 Transmission Friction Element "E" Apply Time Range/Performance P705 Transmission Friction Element "F" Apply Time Range/Performance 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 Anti-Lock Brake System (ABS) Control Module U00 Lost Communication With Body Control Module 0 0 U06C Loss of Communication on Fuel Pump Control Module B 0 U0 Lost Communication With Steering Column Control Module 0 0 U000 Internal Control Module Software Incompatibility Page

18 6.8L V LPG E-50 Custom Body 6.8L V LPG F-650 (dual tank) 6.8L V LPG F-5 (Motorhome) F-59 (Step Van) Code Description U05 Invalid Data Received from Anti-Lock Brake System (ABS) Control 0 0 Module U0 Invalid Data Received from Body Control Module 0 0 U0B Lost Communication Between Fuel Pump Control Module A and 0 0 Restraint Control Module U0C Lost Communication Between Fuel Pump Control Module B and Restraint Control Module 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. Page 5

19 Flow Control Solenoid P0090 Fuel Pressure Regulator Circuit Open Description 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 Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Bleed Solenoid P009E/P6B Fuel Pressure Relief Control Performance Stuck Off/Fuel Shutoff Valve A Control Circuit Performance Stuck Off Description Possible Causes Symptom Diagnostic Aid Action Fuel rail failed to bleed. The PCM measures fuel rail pressure on key-up 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 6

20 P009B Fuel Pressure Relief Control Circuit Open Description 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 Description 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 7

21 Fuel Rail Pressure Control Module Supply Solenoid and Wiring P6B5 Fuel Shutoff Valve B Control Circuit Performance/Stuck Off Description Possible Causes Symptom Diagnostic Aid Action Fuel supply solenoid stuck. The SRM monitors fuel rail pressure before and after the solenoid was commanded open. If the pressure rise is below a threshold, the fault is set. Electrical fault Damaged SS coil Damaged SS armature Excess flow valve tripped Tank solenoid stuck closed Tank manual valve closed Fuel pumps not powering on Blown fuse Vehicle does not start. The pumps run (or may not) but no pressure builds in the fuel rail. Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures. P665 Fuel Shutoff Valve B Control Circuit/Open Description 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 8

22 SRM, CAN Bus Circuit Wiring U008 Lost Communication with Alternative Fuel Control Module Description 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 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 Description LPA system is operating in vapor space. At least one bank is lean at WOT. Possible Causes Severely restricted fuel filter Severely restricted fuel supply line Damaged or worn fuel pump Damaged or contaminated MAF sensor Excess flow valve tripped TS or SS closed Tank manual shutoff valve not completely open Symptom Vehicle hesitation or stall condition. Diagnostic Aid Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures. P6E Fuel Pressure Relief Valve Actuated Description 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 9

23 P07, P07 System Too Lean (Bank and Bank respectively) Description Possible Causes Symptom Diagnostic Aid Action TROUBLESHOOTING Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. 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. Verify that no LPA system faults are present and then follow the Ford service manual procedure. Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. P07, P075 System Too Rich (Bank and Bank respectively) Description Possible Causes Symptom Diagnostic Aid Action Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. 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. Verify that no LPA system faults are present and then follow the Ford service manual procedure. Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Page 0

24 P5 Fuel Tank Pressure Relief Valve Malfunction Description Possible Causes Symptom Diagnostic Aid Action The SRM reads the FPTS 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 pop-off 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 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 Description Possible Causes Symptom Diagnostic Aid Action Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. 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. Verify that no LPA system faults are present and then follow the Ford service manual procedure. Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Heated Exhaust Gas Oxygen Sensor P95, P97 Heated Exhaust Gas Oxygen Sensor Stuck Description Possible Causes Symptom Diagnostic Aid Action Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. 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. Verify that no LPA system faults are present and then follow the Ford service manual procedure. Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Page

25 Electronic Fuel Pump Relay (A/B) U009, U06C Lost Communication with Fuel Pump Control Module A/B Description Possible Causes Symptom Diagnostic Aid Action 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. Wire fault between the EFPR and SRM Wire fault between SRM and PCM No power to the EFPR SRM fault CAN bus fault Blown fuse Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. 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 Description Possible Causes Symptom Diagnostic Aid Action 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 out-of-range, a fault is set. Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Poor starts, rough idle, hesitation/surge. Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. P05B Fuel Pump Module A Control Circuit Range/Performance Description Possible Causes Symptom Diagnostic Aid Action 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. Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Page

26 P07B Fuel Pump Module B Control Circuit Range/Performance Description Possible Causes Symptom Diagnostic Aid Action TROUBLESHOOTING The Fuel Pump Control Module (FPCM) B receives control commands from the PCM on a Fuel Pump Command (FPC) pin. The FPCM B passes diagnostic information on the CAN bus to the PCM. If the FPCM B 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. Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. 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 Description 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

27 U0C Lost Communication Between Fuel Pump Control Module B and Restraint Control Module Description 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 Description Possible Causes Symptom Diagnostic Aid Action P06A Fuel Pump Control Module A Description Possible Causes Symptom Diagnostic Aid Action 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. Wiring fault between FPCM A and fuel pump A Open circuit FPCM A fault CAN fault 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. FPCM A fault CAN fault Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Page

28 P6 Fuel Pump B Control Circuit/Open Description Possible Causes Symptom Diagnostic Aid Action P6EA Fuel Pump Control Module B Description Possible Causes Symptom Diagnostic Aid Action The Fuel Pump Control Module (FPCM) B diagnoses faults of fuel pump B. The FPCM B passes diagnostic information on the CAN bus to the PCM. If the PCM receives a FPCM B signal indicating a fuel pump problem, the fault is set. Wiring fault between FPCM A and fuel pump A Open circuit FPCM A fault CAN fault Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. The Fuel Pump Control Module (FPCM) B has its own internal diagnostics. The FPCM B passes diagnostic information on the CAN bus to the PCM. If the PCM receives a FPCM B signal indicating an internal problem, the fault is set. FPCM B fault CAN fault 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 Description Possible Causes Symptom Diagnostic Aid Action 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. 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 Verify the fuel rail temperature PID value to determine open or short. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 5

29 P08 Fuel Temperature Sensor A Circuit Low Description Possible Causes Symptom Diagnostic Aid Action 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. 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 Verify the fuel rail temperature PID value to determine open or short. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P08 Fuel Temperature Sensor A Circuit High Description Possible Causes Symptom Diagnostic Aid Action 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. 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 Verify the fuel rail temperature PID value to determine open or short. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 6

30 P090 Fuel Rail Pressure Sensor Circuit Description Possible Causes Symptom Diagnostic Aid Action 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. 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 P09 Fuel Rail Pressure Sensor Circuit Low Description Possible Causes Symptom VREF should be between 6 volts. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. 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. 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 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 Description Possible Causes Symptom Diagnostic Aid Action 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. 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 Verify the FRP PID value to determine open or short. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 7

31 P0A0 Alternate Fuel Tank A Pressure Sensor Circuit Low Description Possible Causes Symptom Diagnostic Aid Action 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. 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 VREF should be between -6 volts. 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 Description Possible Causes Symptom Diagnostic Aid Action 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. 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 Verify the Propane Tank Fuel Pressure PID value to determine open or short. Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page 8

32 P0A Alternative Fuel Tank A Pressure Sensor Circuit Intermittent/Erratic Description Possible Causes Symptom Diagnostic Aid Action 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. 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 FPTS FPTS failure SRM failure Verify the Propane Tank Fuel Pressure PID value to determine open or short. Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. P0AC Alternate Fuel Tank Temperature Sensor Circuit Low Description Possible Causes Symptom Diagnostic Aid Action 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. 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 FPTS FPTS failure SRM failure Verify the Propane Tank Fuel Pressure PID value to determine open or short. Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page 9

33 P0AD Alternate Fuel Tank Temperature Sensor Circuit High Description Possible Causes Symptom Diagnostic Aid Action 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. 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 FPTS FPTS failure SRM failure Verify the Fuel Temperature PID value to determine open or short. 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 Description Possible Causes Symptom Diagnostic Aid Action 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. 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 FPTS TPTS failure SRM failure Verify the Propane Tank Fuel Pressure PID value to determine open or short. Refer to the Tank Pressure Temperature Sensor Electrical Check procedure in the Diagnostic Tests and Procedures. Page 0

34 Fuel Level Sender P06 Fuel Level Sender A Circuit Range/Performance Description Possible Causes Symptom Diagnostic Aid Action Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Refer to the Ford service manual. Causes are the same except that communication is between the sender and the SRM and not the IC. The SRM reads fuel level sender input and broadcasts it to the IC and PCM. Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures. P06 Fuel Level Sender A Circuit Low Description 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 Fuel Level Interface Module P06 Fuel Level Sender A Circuit High Description 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 Fuel Level Interface Module Page

35 P5B0 Fuel Level Sensor A Stuck Description Possible Causes Symptom Diagnostic Aid Action The SRM reads Fuel Level Sender (FLS) input and broadcasts it to the IC and PCM. If the vehicle is driven a considerable distance and the FLS value doesn't change, the fault is set. Fuel Level Sender fault Wire fault between FLS and SRM 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 Description 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 drop to half of its usable amount to notify the driver there is an issue with the transfer system. Defective fuel level sender(s) 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. 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 F-650/F-750 Dual Tank Transfer Pin Point Test procedure. Secondary Tank Fuel Will Not Transfer F-650 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 right-hand 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

36 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

37 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 front-to-back and side-to-side (a level needs to be placed on the vehicle to verify this). b. Tank pressure and sending unit resistance 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 Interface Module Electrical Test 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

38 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 E-50/50/50/50 or 0 F-50/50 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 E-50/50/50/50 or 0 F-50/50 Liquid Propane Autogas Fuel System Service Manual for more information regarding the tools required. Method Using the OBD-II scan tool, read the fuel rail pressure PID. If using the Ford IDS tool, it will be necessary to select the tool box tab, then select Powertrain near bottom of selection, OBD Test Modes, Mode Powertrain Data. Then locate and select FRP (pressure) from PID selection table. Method Empty the fuel rails and fuel lines. Refer to the Fuel Line Purging Procedure in the 0 Ford E-50/50/50/50 or 0 F-50/50 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: Temperature ( F) Pressure (psi) 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 has variable operating speeds. The pump operates in a lower speed mode at idle and during moderate fuel flow/part throttle driving. Once a fuel demand threshold is met, the pump is ramped to a higher speed. The pump is also operated at high speed during the pre-start flush sequence. Page 5

39 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. Condition Pump Speed Engine Off Off <0 Idle Low >0 Part Throttle Low <5 Part Throttle High >5 WOT High >5 Pressure Over Tank Under extreme operating conditions, there is a third pump mode. In the event that the fuel system has degraded and the sensor detects vapor, or if the fuel rail pressure is approaching the limit of the fuel system, the pump runs in a variable speed mode, controlling to a target pressure. In this mode there is no predicted rise over tank pressure. The fuel pump will adjust the pressure to maintain a required operating pressure. This condition will likely result in a P6E or P08 code. 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? 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. Page 6

40 Step Procedure Action 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? 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 9. No Go to Step. Yes Go to Step 0. No Go to Step. Yes Diagnostic complete. No Refer to Fuel Level Indication Check. Yes Go to Step. No Fill station may not be providing enough pressure to fill. Go to Step 9. Yes Replace body-side 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? Yes Diagnostic is complete. No Call ROUSH CleanTech Customer Service at Page 7

41 Step Procedure Action 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? 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? Yes Go to Step 0. No Locate a dispensing facility with pump output capacity in excess of 00 psi (689 kpa) (preferably an Auto Gas-type 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 Gas-type facility). Yes Diagnostic is complete. No Go to Step. 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? 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. Page 8

42 Step Procedure Action 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? 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 Diagnostic is complete. No Go to Step 7. Yes Diagnostic is complete. No Go to Step 8. 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 Gas-type 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 Gas-type facility). Yes Diagnostic is complete. No Go to Step. Page 9

43 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 0

44 Step Procedure Action 8 Refuel the vehicle as follows: Yes Record the volume of fuel dispensed and then go to Step 9. No Go to Step 7. If the key is ON during refueling, it will take the fuel level gauge in the instrument cluster longer to register full. 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. 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

45 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: a. Is there fuel in the tank of at least /8 tank or more? (add fuel if necessary). b. Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 0 volts? Check for diagnostic trouble codes (DTC). Are any codes present? Yes Go to Step. No Correct fault and retry. Yes Go to Step. No Go to Step. Is the DTC identified on the ROUSH LPA DTC list? Yes Refer to Diagnostic Trouble Code List. No Refer to Ford service manual DTC chart. Check fuel pressure. a. Measure and record fuel rail and fuel tank pressure, Key ON Engine OFF (KOEO). b. While monitoring fuel pressure, attempt to start engine. c. Record the highest pressure observed. d. Does fuel pressure rise 5 psi (7 kpa) before engine crank? 5 Check fuel pump operation. a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank 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? 6 Check excess flow valve (XFV). a. Turn ignition key to the OFF position. b. Close the manual shutoff valve on tank. c. Wait minute and then slowly open manual shutoff valve. d. Measure and record fuel pressure, using a scan tool, at injection pressure temperature sensor (IPTS). e. Is problem resolved? 7 Check ROUSH fuel pump (FP) fuse. Is fuse intact and OK? 8 Check the tank solenoid (TS) and supply solenoid (SS) fuses. a. Locate the TS fuse (E-E) and check its condition. b. Locate the SS fuse (F-F) and check its condition. c. Are the fuses blown? Yes Go to Step. No Go to Step 5. Yes Go to Step 6. 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 0. Yes Go to Step. No Go to Step 7. Yes Go to Step 8. No Determine the cause of the short and repair; replace the fuse. Diagnostic is complete. Yes Determine the cause of the short and repair; replace the fuse. No Go to Step 9. Page

46 Step Procedure Action 9 Verify that there is power and proper grounding at the tank solenoid (TS) and supply solenoid (SS) wiring circuits. a. Check for + volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure. b. Is + volts present at the TS connector? c. Is + volts present at the SS connector? 0 Verify that there is power and proper grounding in the wiring circuit to the tank. a. Check for + volts at the fuel pump (FP) and fuel pump (FP) connectors. Refer to the Fuel Pump Electrical Check procedure. b. Is + volts present at the FP connector? c. Is + volts present at the FP connector? Injection Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification procedure? Check wiring. a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information. b. Remove tank service cover. c. Check for open or short circuits on tank pass-through harness. d. Is a wiring problem present? Check fuel hoses and quick-connect fittings. Are in-tank fuel hoses and quick-connect fittings connected and in good condition? Yes Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly. No Check for an open(s) in the wiring circuits and repair. Diagnostic is complete. Yes Go to Step. No Check for an open(s) in the wiring circuits and repair. Yes Refer to the Injection Pressure Temperature Sensor Electrical Check. No Verify that wiring in circuit is OK. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor. Yes Replace harness. No Go to Step. Yes Replace fuel pump assembly. No Replace hose assemblies as needed. Page

47 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 fuel in the tank of at least /8 tank or more? (Add fuel if necessary.) b. Is the tank supply manual shutoff valve fully open? c. Is battery voltage above volts with engine running? Check for diagnostic trouble codes (DTCs). Are any codes present? Identify the DTC. a. Is the DTC covered in the ROUSH CleanTech DTC listing for LPA-fueled vehicles? b. Correct all DTCs before continuing. Yes Go to Step. No Correct the fault and retry. Yes Go to Step. No Go to Step. Yes Refer to ROUSH CleanTech Diagnostic Trouble Code List. No Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at Does the problem occur only after cold start? Yes Go to Step 6. No Go to Step 5. 5 Determine fuel pressure. a. Measure tank pressure with Key ON Engine OFF (KOEO). b. Measure fuel rail pressure with Key ON Engine Running (KOER). c. Subtract the KOEO pressure from the KOER pressure to obtain the difference. Compare to the chart in Expected Fuel Rail Pressure. d. Is the resulting fuel pressure reading within the expected range? 6 Determine if the excess flow valve (XFV) is tripped. a. Turn OFF the engine. b. Wait one minute and then restart the engine. c. Is the fault condition resolved? 7 Check fuel pump operation. a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank 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? 8 Verify that there is power and proper grounding in the wiring circuit to the tank. a. Check for + volts at the fuel pump (FP) and fuel pump (FP) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. b. Is + volts present at the FP connector? c. Is + volts present at the FP connector? Yes Go to Step 7. No Go to Step 6. Yes Refer to the Excess Flow Valve Check procedure. No Go to Step 7. Yes Go to Step. 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 8. Yes Go to Step 9. No Check for an open/short in the wiring circuit and repair. Page

48 Step Procedure Action 9 Check wiring. a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information. b. Remove tank service cover. c. Check for open or short circuits on tank pass-through harness. d. Is a wiring problem present? 0 Check fuel hoses and quick-connect fittings. Are in-tank fuel hoses and quick-connect fittings connected and in good condition? Injection Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? Refer to the Injection Pressure Temperature Sensor Electrical Check procedure. Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at Yes Replace harness. No Go to Step 0. Yes Replace fuel pump assembly. No Replace hose assemblies as needed. Yes Go to Step. No Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor. Excess Flow Valve Check The excess flow valve (XFV) 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 XFV should not trip. The XFV will reset itself after the fuel pumps have been off for about one minute. 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. It is common to trip the XFV after the fuel lines have been serviced and contain no pressure. If the XFV trips, turn the vehicle off, wait one minute, and restart. This may take more than one attempt. Step Procedure Action Verify fuel supply line pressure prior to cranking engine. a. Read fuel rail pressure and tank pressure. b. Energize bleed solenoid until rail pressure is at least 50 psi (5 kpa) below tank pressure. If rail is bled, skip to Step D. c. Let pressure stabilize for minute. d. Open the supply solenoid. e. Read fuel rail pressure and tank pressure. f. Does fuel rail pressure jump to tank pressure? Yes Check is OK. No Repair the leak in the fuel supply line. Page 5

49 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 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. Supply Solenoid Check 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 or more? (Add fuel if necessary.) b. Is the tank supply manual shutoff valve fully OPEN? c. Is battery voltage above 0 volts? Check for diagnostic trouble codes (DTC). Are any codes present? Is the DTC identified on the ROUSH liquid propane autogas DTC list? Check fuel pressure. a. Measure and record fuel rail pressure and fuel tank pressure at Key ON Engine OFF (KOEO). b. While monitoring fuel pressure, attempt to start engine. c. Record the highest pressure observed. d. Does fuel pressure rise 0 psi (8 kpa) before engine crank? Yes Go to Step. No Correct fault and retry. Yes Go to Step. No Go to Step. Yes Refer to Diagnostic Trouble Code List. No Refer to the Ford service manual DTC chart. Yes Go to Step. No Go to Step 5. Page 6

50 Step Procedure Action 5 Check fuel pump operation. a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank 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. a. Do fuel pumps draw current? 6 Check XFV. a. Turn OFF engine. b. Wait minute and then restart engine. c. Measure and record fuel rail pressure and fuel tank pressure. d. Is problem resolved? 7 Check ROUSH FP fuse. Is fuse intact and OK? 8 Check the TS and SS fuses. a. Locate the TS fuse (E-E) and check its condition. b. Locate the SS fuse (F-F) and check its condition. c. Are the fuses blown? 9 Verify that there is power and grounding in the TS and SS wiring circuits. a. Check for + volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure. b. Is + volts present at the TS connector? c. Is + volts present at the SS connector? 0 Verify that there is power and grounding in the wiring circuit to the tank. a. Check for + volts at the fuel pump (FP) and fuel pump (FP) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. b. Is + volts present at the FP connector? c. Is + volts present at the FP connector? Injection Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at Yes Go to Step 6. 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 0. Yes Go to Step. No Go to Step 7. Yes Go to Step 8. No Determine the cause of the short and repair; replace the fuse. Yes Determine the cause of the short and repair; replace the fuse. No Go to Step 9. Yes Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly. No Check for an open/short in the wiring circuit and repair. Yes Refer to Engine Stumble, Stall, Rough Idle Step. No Check for an open/short in the wiring circuit and repair. Yes Go to Step. No Verify that wiring in circuit is OK. Refer to the Injection Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor. Page 7

51 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 vehicle to customer and see if problem persists. No Go to Step. a. START the engine and allow it to run for a few minutes. b. Turn OFF the engine and wait one minute. 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. Disconnect the EVAP line from the FRPCM port. b. Remove the vapor port. c. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid. d. 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. De-energize 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 8

52 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 In-Tank 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 (E-E) and SS (F-F) fuses. b. Are the fuses blown? 6 Verify that there is power and ground in the wiring circuit to the tank. a. Check for + volts at the fuel pump (FP) and fuel pump (FP) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. b. Is + volts present at the FP connector? c. Is + 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 9

53 Tank Solenoid Electrical Check 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 FUSE BOX HARNESS D F F F D D5 D D E E E A A A5 A B B B5 B A B F E C C C F5 E5 C5 F6 E6 C FUSE 5 RELAY A RELAY B RELAY C C C PBT/ASA-GF0 8 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 50

54 PROCEDURE Step Procedure Action Unplug the solenoid harness connector C7 from the tank solenoid. Using a multimeter, measure resistance of the solenoid. Is the measured resistance within 6 5 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 (E-E, 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 pin-0, connector C0 (tank harness) Pin-, connector C6 and pin-0, 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 pin-7, connector C0 (tank harness) Pin-7, connector C6 and pin-7, connector C (rear frame harness) Pin-7, connector C and pin-, connector C (underhood harness) b. Is there good continuity in the circuit? Go to Step. Yes Go to Step. No Replace the tank solenoid. Yes Supply circuit OK. No Go to Step. Yes Replace fuse. 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 5

55 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 F-F FUSE BOX 5 5 E F A B 0060a C 6 C5 SUPPLY SOLENOID (BLACK) C6 BLEED SOLENOID (GRAY) PBT/ASA-GF0 5 6 A a Figure Underhood Harness Connectors PROCEDURE Step Procedure Action Unplug the fuel rail pressure control module (FRPCM) connector 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. Is resistance value the same? Check supply voltage to FRPCM solenoids. Using a multimeter, measure voltage between the terminal for each solenoid at the harness side connectors and ground as follows: Go to Step. Yes Go to Step. No Replace the FRPCM if resistance for any one of the solenoids is not within the specified range. Go to Steps 6. Supply Solenoid Pin- and body ground B+ Voltage Go to Step 5. No Voltage Go to Step 5. Page 5

56 5 Bleed Solenoid Pin- and body ground B+ Voltage Continue with Step 8. No Voltage Go to Step 7 if Step has voltage; if Step has no voltage, go to Step 6. 6 Check fuses (F-F, 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. 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 5

57 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/ASA-GF0 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 8 (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 pin-0, connector C Pin-, connector C and pin-0, connector C Pin-, connector C and pin-8, connector C Pin-, connector C and pin-5, 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 5

58 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/ASA-GF0 8 9 A a 0060a Figure 6 Underhood Harness Connectors 5 C6 C a Figure 7 Rear Frame Harness Connectors Page 55

59 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 8 (underhood 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 pin-0, connector C Pin-6, connector C and pin-, connector C Pin-5, connector C and pin-9, connector C Pin-, connector C and pin-5, 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. Fuel Pump Electrical Test 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 In-Tank Harness Connectors Page 56

60 PROCEDURE Step Procedure Action Check fuel pump circuit continuity. a. Unplug the EFPR connector C for fuel pump. Check fuel pump circuit continuity. b. Using a multimeter, measure resistance between pin-5 and pin-8. c. Is resistance between 0..0 ohm? Check continuity for each fuel pump. a. Unplug connectors and of in-tank harness. b. Check continuity across connector pins A and B. Is the resistance between Ohms? c. Check continuity across connector pins A and B. Is the resistance between Ohms? Check harness circuit continuity from fuel pumps to FPCM. a. Check continuity for pump, wire FPPWR, V+ across: Pin-A, connector C5 (tank harness) to pin-8, C (tank harness) Pin-8, connector C (rear frame harness) and pin-5, connector C9 (rear frame harness) b. Check continuity for pump, wire FPRTN, V across: Pin-B, connector C5 (tank harness) to pin-6, C (tank harness) Pin-6, connector C (rear frame harness) and pin-8, connector C9 (rear frame harness) c. Check continuity for pump, wire FPPWR, V+ across: Pin-A, connector C6 (tank harness) to pin-, C (tank harness) Pin-, connector C (rear harness) and pin-5, connector C (rear harness) d. Check continuity for pump, wire FPRTN, V across: Pin-B, connector C6 (tank harness) to pin-9, C (tank harness) Pin-9, connector C (rear frame harness) and pin-8, connector C (rear frame harness) e. Is there good continuity in all circuits? Yes Go to Step. No Go to Step. Yes Go to Step. No Replace fuel pump assembly. Yes Refer to the Fuel Pump Control Module Electrical Continuity Test procedure. No Repair circuit wiring. Page 57

61 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 58

62 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. a. Disconnect rear frame harness connectors C0 and C. 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 Pin-5, connector C0 and pin-5, connector C Pin-6, connector C0 and pin-6, connector C Pin-7, connector C0 and pin-7, 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 cavity-a5, fuse box (underhood harness) Cavity-A, fuse box (underhood harness) and cavity-e, fuse box (underhood harness) c. Is there good continuity in each circuit? Check fuse condition (E-E). 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 pin-5, connector C9 Pin-6, connector C0 and pin-6, connector C9 Pin-9, connector C and pin-8, connector C9 Pin-5, connector C6 and pin-7, connector C9 b. Is there good continuity in each circuit? Yes Go to Step. No Repair circuit wiring. Yes Go to Step. No Repair circuit wiring. Yes Replace the 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 59

63 Smart Relay Module Electrical Test For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS FUSE BOX E-E 5 5 E F C PBT/ASA-GF 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 (E-E, 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 60

64 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 CAN-H(+) continuity across: Pin-8, SRM connector C (underhood harness) and pin-, connector (underhood harness) Pin-, connector C (CAN harness) and pin-6, connector C (CAN harness) b. Is there good continuity in the circuits? 7 Check CAN and underhood harness continuity. a. Check CAN-H( ) 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 6

65 Fuel Level Sender Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS C C PBT/ASA-GF0 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 6

66 C 008a C 0079a Figure 8 Tank Harness Connectors PROCEDURE Step Procedure Action Note: When performing the following continuity test make sure to verify off-set of DVOM being used. When you touch the leads together a value will be present this could be 0. or greater. Remember to deduct this value from reading for actual resistance value. 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. Check for 5v vref present at pin-a harness side of FLS connector and Pin C. Check for continuity of harness for 5v vref circuit and ground circuit of Fuel Level Sender. a. Check for continuity from FLS pin-a frame side harness to pin- of SRM connector: Continuity present - Yes, go to Step b. b. Check for continuity from FLS pin-c frame harness at FLS and pin-0 of SRM connector. c. Is there good continuity in each circuit? a. Check for continuity from SRM connector C, pin- to connector C, pin-0 (under-hood harness). Continuity present - Yes, go to Step b. b. Check for continuity from connector C6, pin-0 to connector C8, pin- (rear frame harness). 5 Perform output voltage check using a universal probe on Pin B at FLS connector. a. With harness fully connected place the universal probe into pin-b of sending unit connector and monitor for voltage b. Is voltage present? 6 Perform sending unit range voltage test. a. Remove the electronic portion of the sender by removing the phillips screws securing it. Use a non-magnetized piece of ferrous metal (such as a screwdriver bit) to move the sight-glass needle through it's range. Voltage should range from 0.v at empty to.7v at full. b. Was the voltage range output test within specifications? Example DVOM off-set value is 0. ohms, When a circuit reading is taken and the value is 0.6 ohms you would subtract the 0. from 0.6 for an actual value of 0. ohms. 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 in-tank sending unit replacement procedure to replace the in-tank sending unit. Page 6

67 Manual Solenoid Activation Procedure 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/ASA-GF0 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 Disconnect the smart relay module (SRM) wire harness connector at the SRM. Energize the individual solenoids on the FRPCM by providing a ground to the following pins in the SRM connector: Pin Bleed Solenoid Pin Supply Solenoid Page 6

68 F-650/F-750 Dual Tank Transfer Pin Point Test (P5B DTC) TROUBLESHOOTING 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 in-board 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? Sender voltages and corresponding fuel levels: Master: [V] [%] Slave: [V] [%] 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? NOTE: To test the transfer function, ensure the driver's side fuel tank level is under 5% and the passenger side tank is above approximately 5% fuel level. 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 of the SRM connector measured to chassis ground, the passenger side tank is pin 5 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 ROUSH (Opt ). 7 Is voltage present to the tank supply solenoid while a transfer is being 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. 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 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. Yes Repair complete. No Contact ROUSH (Opt ) for assistance. Page 65

69 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS Page 66

70 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 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 IN-TANK HARNESS UNDERHOOD HARNESS BCUTS BLUNT CUTS FOR CRANK WARNING, FUEL COOLER, AC REQ, AND A/C CLUTCH C SRM, 6-PIN C UNDERHOOD / TANK INLINE, 6-PIN 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, 6-PIN C CAN / UNDERHOOD INLINE, -PIN C OBD INLINE TO FORD HARNESS, 6-PIN G PASS-THRU GROMMET REAR FRAME HARNESS C REAR FRAME / TANK HARNESS INLINE, 6-PIN C FORD FTPT HARNESS INLINE, -PIN C FORD FTPT SENSOR, -PIN C6 REAR FRAME / UNDERHOOD INLINE, 6-PIN C9 RCT EFPR, 8-PIN C0 FORD FPCM HARNESS INLINE, 8-PIN C FORD EFPR, 8-PIN C8 FORD FUEL TANK HARNESS INLINE, -PIN T FRAME GROUND, RING TERMINAL TANK HARNESS C TANK / REAR FRAME HARNESS INLINE, 6-PIN C FUEL LEVEL SENDER, -PIN C IPTS #, -PIN C FLOW CONTROL SOLENOID (GRAY), -PIN C5 TANK / IN-TANK FP # INLINE, -PIN C6 TANK / IN-TANK FP # INLINE, -PIN C7 SUPPLY SOLENOID (BLACK), -PIN IN-TANK HARNESS C FUEL PUMP # INLINE, -PIN C FUEL PUMP # INLINE, -PIN 7 TANK PASS-THRU GROMMET Page 67

71 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59 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 IN-TANK HARNESS UNDERHOOD HARNESS C SRM, 6-PIN C UNDERHOOD / REAR FRAME INLINE CONNECTOR, 6-PIN 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, 6-PIN C CAN / UNDERHOOD INLINE, -PIN C CAN / MORGAN INLINE CONNECTOR, -PIN (UPS ONLY) C OBD INLINE CONNECTOR TO FORD HARNESS, 6-PIN D DIODE (UPS ONLY) G GROMMET S SPLICE TO MORGAN OLSON IP HARNESS (UPS ONLY) REAR FRAME HARNESS C REAR FRAME / TANK INLINE, 6-PIN C FTPT FORD HARNESS INLINE, -PIN C FTPT SENSOR, -PIN C6 REAR FRAME / UNDERHOOD INLINE, 6-PIN C9 RCT EFPR, 8-PIN C0 FORD FPCM INLINE, 8-PIN C FORD EFPR, 8-PIN C8 FORD FUEL TANK HARNESS INLINE, -PIN T FRAME GROUND (FP SHIELD), RING TERMINAL TANK SOLENOID HARNESS C TANK / REAR FRAME INLINE, 6-PIN 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 IN-TANK HARNESS C FUEL PUMP # INLINE CONNECTOR C FUEL PUMP # INLINE CONNECTOR 7 GROMMET Page 68

72 A B C WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 Roush Wiring Harnesses T - GND C-0-8 BLEED SOLENOID (GRAY) C6 DT06-S-CE0 SUPPLY SOLENOID (BLACK) C5 DT06-S-CE05 CL IPTS C T - BATT PWR C-0-8 UNDERHOOD HARNESS P6JC-8A00-A ACCESSORY BLUNT CUTS FUSE BOX 059 D D D5 D A A A5 A D A F F F E E E B B B5 B B F F5 F6 E E5 E6 C C C C C5 FTPT SENSOR C 5996 T - FRAME GND 0507 REAR FRAME HARNESS P6JC-8C00-A FORD FPCM HARNESS INLINE (NO KEYWAY) C0 P6JC-8C05-AA FORD FTPT HARNESS INLINE C 568 FORD FUEL TANK ASSY INLINE C8 500 DT06-S-CE0 C UNDERHOOD/ CAN INLINE (GRAY) T - CASE GND 987 REAR FRAME/ UNDERHOOD INLINE C REAR FRAME/ TANK INLINE C C UNDERHOOD/ REAR FRAME INLINE 60- C SRM CAN/OBD FORD HARNESS INLINE C C FORD EFPR C9 RCT EFPR FUEL LEVEL SENDER C 09 IPTS # C CAN HARNESS P6JC-8B00-A TANK HARNESS P6JC-8K77-A TANK/IN-TANK INLINE # C6 007 CAN/UNDERHOOD INLINE C DT0-P-CE0 GRAY SUPPLY SOLENOID (BLACK) C7 DT06-S-CE05 TANK/REAR FRAME INLINE C C OBD FLANGE MOUNT BLACK 0097 C5 TANK/IN-TANK INLINE # DT06-S-CE0 C FLOW CONTROL SOLENOID (GRAY) 0059a Page 69

73 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59 Roush Wiring Harnesses UNDERHOOD HARNESS P6MB-8A00-A BLEED SOLENOID (GRAY) C6 DT06-S-CE0 SUPPLY SOLENOID (BLACK) C5 DT06-S-CE05 FTPT SENSOR C 5996 REAR FRAME HARNESS P6MB-8C00-A FORD EFPR C RCT EFPR C T - GND C-0-8 IPTS C UH/CAN INLINE C DT06-S UH/REAR FRAME INLINE C REAR FRAME/ UNDERHOOD INLINE C FORD HARNESS FPCM INLINE C C-0-8 T - BATT PWR ACCESSORY BLUNT CUTS T - CASE GND 987 SRM C 60- FTPT FORD HARNESS INLINE C T - FRAME GND A B A A5 A B B5 B C C5 C C A B C D D D5 D E E E E E5 E6 D F F F F F5 F6 059 FUSE BOX OBD FORD HARNESS INLINE C C REAR FRAME/TANK INLINE FUEL LEVEL SENDER C 09 A B C 500 C8 FORD HARNESS FUEL TANK INLINE FCS SOLENOID (GRAY) C DT06-S-CE0 CAN/UNDERHOOD INLINE C DT0-P-C05 CAN HARNESS P6MB-8B00-A TANK/REAR FRAME INLINE C TANK HARNESS P6MB-8K77-A IPTS # C C OBD FLANGE MOUNT BLACK GRAY C5 C6 FUEL PUMP FUEL PUMP INLINE # INLINE # DT06-S-CE05 C7 SUPPLY SOLENOID (BLACK) 006a Page 70

74 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 Electrical Schematic Underhood Harness PWR W B FUSIBLE LINK A B SP SP5 PWR W A T - BATT PWR NOT USED NOT USED C5 SP6 VPWR RO GND VPWR RI PWR W 6 PWR W SRM PWR PWR W SOL PWR PWR W C C C B5 RELAY_C B B B A5 A A A FUSE 5A A B E E FUSE 0A A B F F FUSE 0A A B E E FUSE 0A A B F F FUSE_5_0A A B E5 E6 FUSE_6_5A A B F5 F6 RELAY_B NOT USED SPARE PRI FUEL TANK RELAY A F6 F5 F F F F D D5 D D E E E E E5 E6 D C C C5 C C A B A A5 A B B5 B A B SRM UH/REAR FRAME INLINE T - CASE GND SUPPLY SOLENOID SRM PWR FUEL LEVEL OUTPUT FUEL LEVEL SENDER # FUEL LEVEL SENDER # AC REQUEST UPS STARTER ENABLE SPARE SPARE NOT POP NOT POP SPARE SPARE SLAVE TANK PRESSURE SPARE5 SPARE6 SLAVE TANK SOLENOID IPTS# TEMP IPTS# TEMP IPTS# PRES IPTS# PRES LOW COOLANT (BLUEBIRD) CAN, J99 + CAN, J V SENSOR PWR SRM WAKE AC REQUEST FORD CAN+ FORD CAN- CRUISE CTRL ON/OFF (BB) FLOW CTRL SOLENOID SRM GROUND SUPPLY SOLENOID BLEED SOLENOID CRANK WARNING LED FUEL COOLER A/C CLUTCH ENGINE RUN SPARE7 SPARE8 SENSOR RETURN BLUEBIRD CRUISE RES/ACCEL BLUEBIRD CRUISE SET/DECEL EFPR FPM SPARE9 SLAVE TANK FP RELAY SUPPLY SOL SRM PWR FUEL LEVEL FL SND NOT USED AC REQ NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED IPTS TEMP IPTS TEMP IPTS PRES IPTS PRES NOT USED NOT USED NOT USED SNS PWR NOT USED NOT USED TW NOT USED FCS GND CRANK WARNING FUEL COOLER A/C CLUTCH NOT USED NOT USED NOT USED SNS GND NOT USED NOT USED FPM NOT USED NOT USED SNS PWR SP7 SP SNS GND SUPPLY SOL PWR SUPPLY SOL C5 BLEED SOLENOID BLEED SOL PWR BLEED SOL SUPPLY SOLENOID IPTS SENSOR IPTS TEMP TEMP OUT IPTS PRES PRESSURE OUPUT IPTS PWR PWR IP GND GND SP8 C FCS C6 CRANK WARNING FUEL COOLER AC REQ A/C CLUTCH VPWR RO VPWR RI IPTS GND IPTS PWR IPTS TEMP IPTS PRES SUPPLY SOL FUEL LEVEL FCS FCS PWR FL GND FL SND FPM CAN-H (+) CAN-H (-) UH/CAN INLINE TW C C BLUNT BLUNT BLUNT BLUNT BLUNT CUT WIRES GND C A/C CLUTCH IPTS PWR GND GND GND SP GND T - GND 0067a Page 7

75 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 Electrical Schematic CAN Bus Harness OBD FLANGE MOUNT OBD FORD HARNESS INLINE OBD OBD OBD OBD 5 OBD 7 OBD 9 CAN-H (+) A SP5 CAN-H (+) B CAN-H (-) A CAN-H (-) B TW TW SP6 TW TW C TW C CAN/UH INLINE DELPHI GROMMET TW CAN-H (+) CAN-H (-) C 0068a Page 7

76 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 Electrical Schematic Rear Frame Harness C 8 PLUG PLUG PLUG J VPWR VT-GN J FPC_ Y-OR J FORD GND BK J ENS Y-VT J FPM BN-W PLUG PLUG PLUG 5 8 Roush EFPR C Ford FPCM Harness Inline (no keyway) VPWR NOT_USED_ FUEL PUMP COMM. GND ENS FUEL PUMP RETURN FUEL PUMP PWR FUEL PUMP MONITOR VT-GN VPWR P PLUG Y-OR FPC_ BK FORD GND Y-VT ENS_ GY A FPRTN RD A FPPWR BN-WH FPM B C9 VPWR RI A BK-RD VPWR FPC_ FORD GND ENS_ FPM_ VT-GN PLUG Y-OR BK Y-VT PLUG BN-W PLUG C Ford EFPR FPM_ ENS_ FORD GND FPC VPWR A FPRTN BU A FPPWR YE-GY SH BN-W PLUG Y-VT BK Y-OR VT-GN TW C FUEL PUMP MONITOR NOT_USED_ ENS GND FUEL PUMP COMM. VPWR FUEL PUMP RETURN FUEL PUMP PWR Rear Frame / Ford FTPT Inline VT-GN BK-RD GN-BU BN GY OG VT YE BK RD GN-BU YE-VT BN-WH C6 VPWR RO A VPWR RI A IPTS GND B IPTS PWR B IPTS TEMP B IPTS PRES B SUPPLY SOL B FUEL LEVEL B FCS B FCS PWR B FL GND B FL SND B FPM B VPWR P SUPPLY SOL PWR B S0 DRAIN GND DRAIN SH BARE BK BARE SH FTP SIG RTN FTP_REF VT-GN YE-VT BN-BU C TW A FPPWR RD A FPRTN GY SHIELD GND B BK S9 A FPPWR YE-GY A FPRTN BU TW IPTS GND B GN-BU IPTS PWR B BN IPTS TEMP B GY IPTS PRES B OG SUPPLY SOL B VT SUPPLY SOL PWR B VT-GN FCS B BK FCS PWR B RD FL GND B GN-BU FL SND B YE-VT Rear Frame / Tank Inline C T - Frame GND GND BK Ford Fuel Tank Assy Inline PLUG FUEL LEVEL B YE PLUG PLUG C8 FTPT Sensor FTP SIG RTN FTP_REF VT-GN YE-VT BN-BU Default Connector Symbol C 00606a Page 7

77 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-50 Electrical Schematic Tank Harness SUPPLY VALVE IPTS # C7 SUPPLY SOL PWR A SUPPLY SOL A IPTS GND A IPTS PRES OUT A IPTS TEMP OUT A SNSR PWR C FUEL LEVEL SENDER FLOW CONTROL VALVE C FCS PWR A FCS A S SNSR PWR FL SND A FL GND A C A B C A B METRI-PACK 50 SERIES SEALED FEMALE C TANK/IN-TANK INLINE TANK/REAR FRAME INLINE TW FPPWR A FPRTN A SHIELD GND A FPPWR A FPRTN A TW IPTS GND A IPTS PWR A IPTS TEMP OUT A IPTS PRES OUT A SUPPLY SOL A SUPPLY SOL PWR A FCS A FCS PWR A FL GND A FL SND A SH S SH DRAIN DRAIN SH SH FPPWR A FPRTN A SH TW C6 A B FPPWR A FPRTN A GRAY SH TW TANK/IN-TANK INLINE C5 A B BLACK C 0070a Page 7

78 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59_F-50_F-550 Electrical Schematic Underhood Harness PWR W B A RD SP FUSIBLE LINK B SP5 PWR W A RD T - BATT PWR NOT USED NOT USED C5 SP6 PWR W B VPWR RO GND VPWR RI PWR W 6 PWR W SRM PWR PWR W SOL PWR PWR W PWR W 6 VTGN BLK BK-RD RD RED BN RD PK RD RD C C C B5 RELAY_C B B B A5 A A A FUSE 5A A B E E FUSE 0A A B F F FUSE 0A A B E E FUSE 0A A B F F FUSE_5_0A A B E5 E6 FUSE_6_5A A B F5 F6 RELAY_B NOT USED SPARE PRI FUEL TANK RELAY A F6 F5 F F F F D D5 D E E E E E5 E6 D D C C C5 C C A B A A5 A B B5 B A B SRM UH / Rear Frame Inline T - Case Gnd GND BK SUPPLY SOLENOID SRM PWR FUEL LEVEL OUTPUT FUEL LEVEL SENDER # FUEL LEVEL SENDER # AC REQUEST UPS STARTER ENABLE SPARE SPARE NOT POP NOT POP SPARE SPARE SLAVE TANK PRES SPARE5 SPARE6 SLAVE TANK SOLENOID IPTS# TEMP IPTS# TEMP IPTS# PRES IPTS# PRES LOW COOLANT (BLUEBIRD) CAN, J99 + CAN, J V SENSOR PWR SRM WAKE AC REQUEST FORD CAN+ FORD CAN- CRUISE CTRL ON/OFF (BB) FLOW CTRL SOLENOID SRM GROUND SUPPLY SOLENOID BLEED SOLENOID CRANK WARNING LED FUEL COOLER A/C CLUTCH ENGINE RUN SPARE7 SPARE8 SENSOR RETURN BLUEBIRD CRUISE RES/ACCEL BLUEBIRD CRUISE SET/DECEL EFPR FPM SPARE9 SLAVE TANK FP RELAY C VT SUPPLY SOL BN SRM PWR VPWR RO VTGN YE FUEL LEVEL Plug 9 YE-VT FL SND VPWR RI BK-RD NOT USED Plug 8 GY-BK AC REQ Plug 6 GN-VT STARTER ENABLE IPTS GND GN-BU NOT USED Supply Solenoid IPTS PWR BN NOT USED IPTS TEMP GY 5 NOT USED SUPPLY SOL PWR PNK IPTS PRES OG 6 NOT USED SUPPLY SOL GN SUPPLY SOL VT 7 NOT USED FUEL LEVEL YE 0 C5 NOT USED FCS BU NOT USED SP SOL PWR PK Bleed Solenoid FCS PWR PNK NOT USED FL GND GN-BU NOT USED BLEED SOL PWR PNK FL SND YE-VT NOT USED BLEED SOL GY FPM BN-WH 5 GRY IPTS TEMP GY IPTS TEMP C6 C ORG IPTS PRES PNK FCS PWR OG IPTS PRES NOT USED NOT USED NOT USED BRN SNS PWR UH / CAN Inline NOT USED NOT USED TW TW WH-BU CAN-H (+) CAN-H (+) WH-BU WH CAN-H (-) CAN-H (-) WH NOT USED STARTER ENABLE GN-VT BU FCS BK GND GN SUPPLY SOL C GY BLEED SOL OG CRANK WARNING CRANK WARNING OG Blunt YE FUEL COOLER FUEL COOLER YE Blunt GY A/C CLUTCH IPTS SENSOR AC REQ GY-BK Blunt NOT USED A/C CLUTCH GY Blunt NOT USED IPTS TEMP GRY TEMP OUT NOT USED IPTS PRES ORG PRESSURE OUPUT SP7 GN-BU SNS GND SNS PWR BRN IPTS PWR BN PWR NOT USED SNS GND GN-BU IP GND GN-BU GND NOT USED SP8 BN-WH FPM C NOT USED FCS NOT USED GN-BU FL GND GN-BU BN IPTS GND IPTS PWR GND GND GND BLK BK BK SP GND BLUNT CUT WIRES BK T - GND 00589a Page 75

79 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59_F-50_F-550 Electrical Schematic CAN Bus Harness OBD Flange Mount CAN-M ONLY APPLICABLE FOR F50/550 OBD Ford Harness Inline C WHBU WH CAN-H (+) A CAN-H (-) A GY CAN-M(+) GY CAN-M(-) GY OBD GY OBD GY OBD 5 GY OBD 9 SP5 SP6 TW CAN-H (+) B CAN-H (-) B WHBU WH C CAN-H (+) CAN-H (-) CAN / UH Inline DELPHI GROMMET WH-BU WH CAN-H (+) CAN-H (-) TW C 00590a Page 76

80 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59_F-50_F-550 Electrical Schematic Rear Frame Harness Roush EFPR VT-GN VPWR P PLUG Y-OR FPC_ BK FORD GND Y-VT ENS_ GY A FPRTN RD A FPPWR BN-WH FPM B C9 VPWR RI A BK-RD S5 S S S VPWR FPC_ FORD GND ENS_ FPM_ VT-GN PLUG Y-OR BK Y-VT PLUG BN-W PLUG C Ford FPCM Inline Ford EFPR SH TW FPM_ ENS_ FORD GND FPC VPWR A FPRTN A FPPWR BN-W PLUG Y-VT BK Y-OR VT-GN BU YE-GY C Rear Frame / UH Inline VT-GN PLUG BK-RD PLUG PLUG GN-BU BN GY OG VT YE BK RD GN-BU YE-VT BN-WH C6 VPWR RO A VPWR RI A IPTS GND B IPTS PWR B IPTS TEMP B IPTS PRES B SUPPLY SOL B FUEL LEVEL B FCS B FCS PWR B FL GND B FL SND B FPM B VPWR P VT-GN VT-GN SUPPLY SOL PWR B FTP SIG RTN FTP_REF VT-GN YE-VT BN-BU SH DRAIN BARE TW A FPPWR A FPRTN GND BK SHIELD GND B A FPPWR A FPRTN DRAIN BARE TW SH IPTS GND B IPTS PWR B IPTS TEMP B IPTS PRES B SUPPLY SOL B SUPPLY SOL PWR B FCS B FCS PWR B FL GND B FL SND B C Rear Frame / Ford FP Harness Inline RD GY BK YE-GY BU GN-BU BN GY OG VT BK RD GN-BU YE-VT PLUG C Rear Frame / Tank Inline T - Frame Gnd GND BK Ford Fuel Tank Assy Inline FUEL LEVEL B PLUG YE PLUG PLUG C8 FTPT Sensor FTP SIG RTN FTP_REF VT-GN YE-VT BN-BU C 0059a Page 77

81 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-59_F-50_F-550 Electrical Schematic Tank Harness WIRE TABLE Index Wire Color Spec. CSA MAT From Connector Cavity To Connector Cavity Multicore DRAIN DRAIN FPPWR A FPRTN A 5 FPPWR A 6 FPRTN A 7 FCS A 8 FCS PWR A 9 FL GND A 0 FL SND A IPTS GND A IPTS PRES OUT A IPTS PWR A IPTS TEMP OUT A 5 SHIELD GND A 6 SNSR PWR 7 SNSR PWR 8 SUPPLY SOL A 9 SUPPLY SOL PWR A BARE BARE YE-GY BU RD GY BK RD BL/OG YE/WH GN/BU OG BR GY BK BN BN BK RD GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL S S Tank / In-Tank Inline (black) Tank / In-Tank Inline (black) Tank / Underhood Inline Tank / In-Tank Inline (gray) FLOW CONTROL VALVE FLOW CONTROL VALVE Tank / Underhood Inline Tank / Underhood Inline IPTS # IPTS # S IPTS # Tank / Underhood Inline S S SUPPLY VALVE SUPPLY VALVE - - C5 C5 C C6 C C C C C C - C C - - C7 C7 - - A B B Tank / Underhood Inline Tank / Underhood Inline Tank / In-Tank Inline (gray) Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline FUEL LEVEL SENDER FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline S IPTS # FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline - - C C C6 C C C C C C C C C - C C C C A 9 C B A 7 0 SH SH TW TW TW TW TWISTED PAIR Index Multicore Name Contents Type TW TW TW TW FPPWR A FPRTN A FPPWR A FPRTN A Twisted Twisted Twisted Twisted SHIELD TABLE Index Shield Name Contents SH SH SH SH DRAIN TW DRAIN TW SUPPLY VALVE IPTS # C7 RD BK SUPPLY SOL PWR A SUPPLY SOL A IPTS GND A IPTS PRES OUT A IPTS TEMP OUT A SNSR PWR GN/BU OG GY BN C FUEL LEVEL SENDER FLOW CONTROL VALVE C RD BK FCS PWR A FCS A SUPPLY SOL A SUPPLY SOL PWR A SNSR PWR FL SND A FL GND A Tank / In-Tank Inline (gray) BN YE/WH BL/OG C A B C A METRI-PACK 50 SERIES SEALED FEMALE B C Tank / Underhood Inline SH TW DRAIN RD FPPWR A 9 GY FPRTN A BK SHIELD GND A 8 YE-GY FPPWR A 6 BU FPRTN A TW DRAIN GN/BU IPTS GND A SH BR IPTS PWR A 5 GY 6 OG IPTS PRES OUT A 7 BK SUPPLY SOL A 0 RD SUPPLY SOL PWR A BK FCS A RD FCS PWR A BL/OG FL GND A YE/WH FL SND A 5 SH BARE BARE SH FPPWR A FPRTN A RD GY SH TW C6 A B FPPWR A FPRTN A GRAY Tank / In-Tank Inline (black) SH TW YE-GY A BU B C5 BLACK C 0059a Page 78

82 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650_F-750 Electrical Schematic Underhood Harness PWR W_B FL A B RD SP5 SP6 A PUMP PWR_B PK SP FL B SP RD PWR W_A PK PUMP PWR_A T - BATT PWR T - BATT PWR SEC TANK PUMP SEC TANK PUMP ROUSH EFPR ROUSH EFPR VPWR RD RH VPWR RH VPWR RD VPWR RH VPWR RD C5 NOT_USED_ PLUG SP0 PLUG NOT_USED_ PUMP AC BK C FUEL PUMP COMM. YE RH FPC RH FPC YE FUEL PUMP COMM. SP5 PUMP R PK C GND BK RH GND RH GND BK GND C PUMP PWR PK ENS PLUG 6 SP 6 PLUG ENS 8 8 B5 RELAY C FUEL PUMP RETURN BU RH RTN RH RTN GY FUEL PUMP RETURN RH VPWR RD 5 5 SP6 B FUEL PUMP PWR YE RH DRIVE RH DRIVE VT FUEL PUMP PWR PUMP AC BK FUEL PUMP MONITOR PLUG 7 7 PLUG FUEL PUMP MONITOR PUMP R PK B PUMP PWR PK B A5 C9 C0 VPWR RO VT-GN GND BK A VPWR RI BU-RD A PWR W 6 RD A FUSE 5A A B PWR W RD E SRM PWR E RD FUSE 0A A B F SP PWR W RD SOL PWR F PK Underhood / Ford FP Harness Inline # FUSE 0A A B PWR W RD E E VT-GN FTP PWR W 6 RD YE-VT SIG RTN FUSE 0A SP A B BN FTP RTN PUMP PWR PK F PUMP PWR 6 PK F C6 SP7 FUSE_5_0A A B PUMP PWR 5 PK E5 PUMP PWR PK E6 FUSE_6_5A RH PUMP ACTIVE A B SP GN-VT LH SUP SOL PWR F5 F6 RH FPC RH GND PWR W_B VPWR RO RH PUMP ACTIVE RELAY B NOT USED PRI FUEL TANK RELAY A F6 F5 F F F F D D5 D E E E E E5 E6 D D C C C5 C C A B A A5 A B B5 B A B Ford FTPT Sensor VT-GN YE-VT BN C FTP SIG RTN FTP RTN ROUSH EFPR VPWR VT-GN VPWR P NOT_USED_ PLUG FUEL PUMP COMM. YE-OR FPC GND BK GND 5 ENS 6 YE-VT ENS FUEL PUMP RETURN 8 GY LH FPRTN 5 FUEL PUMP PWR RD LH FPPWR FUEL PUMP MONITOR 7 BN-WH FPM RH SUP SOL PWR GND VPWR RI FUSE_BOX Ford FPCM Harness Inline SP8 VPWR VT-GN PLUG SP FPC YE-OR FORD GND BK SP 6 ENS YE-VT 5 PLUG 7 FPM BN-WH 8 PLUG C C8 RT - SRM CASE GND GND BK SUPPLY SOLENOID SRM PWR FUEL LEVEL OUTPUT FUEL LEVEL SENDER # FUEL LEVEL SENDER # AC REQUEST UPS STARTER ENABLE SPARE SPARE NOT POP NOT POP SPARE SPARE SLAVE TANK PRES SPARE5 SPARE6 SLAVE TANK SOLENOID IPTS TEMP FPTS TEMP IPTS PRES FPTS PRES LOW COOLANT (BLUEBIRD) CAN, J99 + CAN, J V SENSOR PWR SRM WAKE AC REQUEST FORD CAN+ FORD CAN- CRUISE CTRL ON/OFF (BB) FLOW CTRL SOLENOID SRM GROUND SUPPLY SOLENOID BLEED SOLENOID CRANK WARNING LED FUEL COOLER A/C CLUTCH ENGINE RUN SPARE7 SPARE8 SENSOR RETURN BLUEBIRD CRUISE RES/ACCEL BLUEBIRD CRUISE SET/DECEL FPM SPARE9 SLAVE TANK FP RELAY Blunt GY-BK AC REQ Blunt GY A/C CLUTCH Blunt YE FUEL COOLER Blunt OG CRANK WARNING Blunt 5 BLU AC Req Blunt 6 BRN A/C Clutch SRM VT LH SUPPLY SOL RD SRM PWR YE FUEL LEVEL YE-VT LH FL SND 5 VT-YE RH FL SND 6 GY-BK AC REQ GN FPTS PRES BU RH SUPPLY SOL 8 GY IPTS TEMP 9 GY FPTS TEMP 0 OG IPTS PRES BN FPTS PRES 5 OG SNS PWR 6 7 BLU AC Req 8 WH-BL CAN-H (+) WH CAN-H (-) 9 0 BU FCS BK GND GN SUPPLY SOL GY BLEED SOL OG CRANK WARNING 5 YE FUEL COOLER 6 GY A/C CLUTCH 7 BRN A/C Clutch 9 0 GN-BU SNS GND BN-WH FPM YE RH FPC 6 BU RH PUMP ACTIVE C TANK SNS PWR SNS PWR OG SNS GND PLUG FUEL LEVEL YE PLUG PLUG C7 SUPPLY SOL PWR SUPPLY SOL SP BLEED SOL PWR BLEED SOL FCS PWR BK RH GND VT RH DRIVE GY RH RTN BU RH RTN YE RH DRIVE Underhood / Ford FP Harness Inline # Supply Solenoid PK GN C Bleed Solenoid PK GY C UH / CAN Inline CAN-H (+) WH-BL CAN-H (-) WH CF IPTS Sensor IPTS TEMP GY TEMP OUT IPTS PRES OG PRESSURE OUPUT SP0 IPTS PWR OG PWR GN-BU IPTS GND GN-BU GND SP C5 GN-BU TANK SNS GND SP8 TANK SNS PWR OG SP5 GND 5 GND GND TANK SNS GND BK BK BK BK RH GND BK SP7 BK BK GND GND FORD EFPR FPM BN-WH 7 FUEL PUMP MONITOR PLUG NOT_USED_ ENS YE-VT 6 ENS FORD GND BK GND FPC YE-OR FUEL PUMP COMM. VPWR VT-GN VPWR LH FPRTN BU 8 FUEL PUMP RETURN LH FPPWR YE-GY 5 FUEL PUMP PWR C GND BK Underhood / Tank (LH) Inline SHIELD GND C BK LH FPPWR RD LH FPRTN GY 9 DRAIN SHIELD GND B BK SP6 LH FPPWR YE-GY 8 LH FPRTN BU 6 DRAIN FPTS GND GN-BU SNSR PWR OG FPTS TEMP GY 5 FPTS PRES BN 6 LH SUPPLY SOL VT 7 LH SUP SOL PWR GN-VT 0 FCS BU PK FCS PWR LH FL GND GN-BU LH FL SND YE-VT PLUG 5 C9F Underhood / Tank (RH) Inline SHIELD GND C BK RH DRIVE VT RH RTN GY 9 DRAIN SHIELD GND D BK SP RH RTN BU 8 RH DRIVE YE 6 DRAIN FPTS GND GN-BU FPTS PWR OG PLUG 5 FPTS PRES GN 6 RH SUPPLY SOL BU 7 RH SUP SOL PWR G-VT 0 PLUG PLUG RH FL GND GN-BU RH FL SND VT-YE PLUG 5 C0F GND T - BATT GND 00595a Page 79

83 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650_F-750 Electrical Schematic CAN Bus Harness OBD Flange Mount OBD Ford Harness Inline TW CAN-H (+) A CAN-H (-) A TW C WH-BU WH TW OBD 7 GY OBD GY OBD GY OBD GY OBD 5 GY OBD 9 SP GY SP TW TW WH-BU CAN-H (+) B WH CAN-H (-) B TW TW C CAN / UH Inline G GROMMET 5096 DELPHI TW CAN-H (+) WH-BU CAN-H (-) WH CM 00596a Page 80

84 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650_F-750 Electrical Schematic Left Tank Harness WIRE TABLE Index Wire Color Spec. CSA MAT From Connector Cavity To Connector Cavity Multicore DRAIN DRAIN FPPWR A FPRTN A 5 FPPWR A 6 FPRTN A 7 FCS A 8 FCS PWR A 9 FL GND A 0 FL SND A FPTS GND A FPTS PRES A FPTS TEMP A SHIELD GND A 5 SNSR PWR 6 SNSR PWR 7 SNSR PWR A 8 SUP SOL PWR A 9 SUPPLY SOL A BARE BARE YE-GY BU RD GY BK RD BU-OG YE/WH GN-BU OG GY BK BN BN BR RD BK BSTW BSTW GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL SP SP Tank / In-Tank Inline (black) Tank / In-Tank Inline (black) Tank / Underhood Inline Tank / In-Tank Inline (gray) Flow Control Solenoid Flow Control Solenoid Tank / Underhood Inline Tank / Underhood Inline FPTS # FPTS # FPTS # Tank / Underhood Inline SP SP SP Supply Solenoid Supply Solenoid - - C5A C5A C9M C6A C C C9M C9M C C C C9M C C - - A B B Tank / Underhood Inline Tank / Underhood Inline Tank / In-Tank Inline (gray) Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline FUEL LEVEL SENDER FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline SP FPTS # FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline - - C9M C9M C6A C9M C9M C9M C C C9M C9M C9M - C C C9M C9M C9M A 9 C B A 0 7 SH SH TW TW TW TW TWISTED PAIR Index Multicore Name Contents Type TW TW TW TW FPPWR A FPRTN A FPPWR A FPRTN A Twisted Twisted Twisted Twisted SHIELD TABLE Index Shield Name Contents SH SH SH SH DRAIN TW DRAIN TW Supply Solenoid FPTS # C RD BK SUP SOL PWR A SUPPLY SOL A FPTS GND A FPTS PRES A FPTS TEMP A SNSR PWR GN-BU OG GY BN C FUEL LEVEL SENDER Flow Control Solenoid C RD BK FCS PWR A FCS A Tank / Underhood Inline BARE DRAIN TW RD FPPWR A 9 GY FPRTN A SP BK SHIELD GND A BARE DRAIN 8 YE-GY FPPWR A 6 BU FPRTN A TW SH GN-BU FPTS GND A BR SNSR PWR A 5 GY FPTS TEMP A 6 OG FPTS PRES A 7 BK SUPPLY SOL A 0 RD SUP SOL PWR A BK FCS A RD FCS PWR A BU-OG FL GND A YE/WH FL SND A 5 SH SP SH TW FPPWR A FPRTN A Tank / In-Tank Inline (gray) RD A GY B C6A SH SNSR PWR FL SND A FL GND A BN YE/WH BU-OG C A B C Tank / In-Tank Inline (black) TW FPPWR A YE-GY A FPRTN A BU B C5A A METRI-PACK 50 SERIES SEALED FEMALE B C C9M 00597a Page 8

85 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650_F-750 Electrical Schematic Right Tank Harness WIRE TABLE Index Wire Color Spec. CSA MAT From Connector Cavity To Connector Cavity Multicore DRAIN. DRAIN. FPPWR A FPRTN A 5 FPPWR A 6 FPRTN A 7 FL GND A 8 FL SND A 9 FPTS GND A 0 FPTS PRES A SHIELD GND SNSR PWR SNSR PWR SNSR PWR A 5 SUP SOL PWR A 6 SUPPLY SOL A BARE YE-GY BU RD GY BU-OG YE/WH GN-BU OG BK BN BN BR RD BK BSTW GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL SP SP Tank / In-Tank Inline (black) Tank / In-Tank Inline (black) Tank / Underhood Inline Tank / In-Tank Inline (gray) Tank / Underhood Inline Tank / Underhood Inline FPTS # FPTS # SP SP SP SP Supply Solenoid Supply Solenoid - - C5A C5A C9M C6A C9M C9M C C C C - - A B B Tank / Underhood Inline Tank / Underhood Inline Tank / In-Tank Inline (gray) Tank / Underhood Inline FUEL LEVEL SENDER FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline FPTS # FUEL LEVEL SENDER Tank / Underhood Inline Tank / Underhood Inline Tank / Underhood Inline - - C9M C9M C6A C9M C C C9M C9M C9M C C C9M C9M C9M A 9 C B 6 A 0 7 SH SH TW TW TW TW TWISTED PAIR Index Multicore Name Contents Type TW TW TW TW FPPWR A FPRTN A FPPWR A FPRTN A Twisted Twisted Twisted Twisted SHIELD TABLE Index Shield Name Contents SH SH SH SH DRAIN. TW DRAIN. TW Supply Solenoid FPTS # C RD BK SUP SOL PWR A SUPPLY SOL A FPTS GND A FPTS PRES A SNSR PWR GN-BU OG BN C FUEL LEVEL SENDER SP SNSR PWR FL SND A FL GND A BN YE/WH BU-OG A B C A B C C METRI-PACK 50 SERIES SEALED FEMALE Tank / Underhood Inline Tank / In-Tank Inline (gray) RD FPPWR A GY FPRTN A BK SHIELD GND YE-GY FPPWR A BU FPRTN A GN-BU FPTS GND A BR SNSR PWR A OG BK RD FPTS PRES A SUPPLY SOL A SUP SOL PWR A BU-OG FL GND A YE/WH FL SND A SP DRAIN. DRAIN. FPPWR A FPRTN A RD GY A B C6A FPPWR A FPRTN A Tank / In-Tank Inline (black) YE-GY BU C5A A B C9M 00599a Page 8

86 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650_F-750 Electrical Schematic Transfer Overlay Harness SRM SUPPLY SOLENOID SRM PWR FUEL LEVEL OUTPUT FUEL LEVEL SENDER # FUEL LEVEL SENDER # AC REQUEST UPS STARTER ENABLE SPARE SPARE NOT POP NOT POP SPARE SPARE SLAVE TANK PRES SPARE5 SPARE6 SLAVE TANK SOLENOID IPTS TEMP FPTS TEMP IPTS PRES FPTS PRES LOW COOLANT (BLUEBIRD) CAN, J99 + CAN, J V SENSOR PWR SRM WAKE AC REQUEST FORD CAN+ FORD CAN- CRUISE CTRL ON/OFF (BB) FLOW CTRL SOLENOID SRM GROUND SUPPLY SOLENOID BLEED SOLENOID CRANK WARNING LED FUEL COOLER A/C CLUTCH ENGINE RUN SPARE7 SPARE8 SENSOR RETURN BLUEBIRD CRUISE RES/ACCEL BLUEBIRD CRUISE SET/DECEL FPM SPARE9 SLAVE TANK FP RELAY C EFPR_A VPWR GND FUEL PUMP COMM. NOT_USED_ PLUG FUEL PUMP PWR ENS PLUG 6 FUEL PUMP MONITOR PLUG 7 FUEL PUMP RETURN A PWR PWR. SP WH PWR. BK GND. B GND GND. WH PUMP-POS BKPUMP-NEG SG BK WH P FPC DRAIN GND-DRAIN FPC S SP VPWR FUEL PUMP COMM. PLUG NOT_USED_ FUEL PUMP PWR PLUG ENS PLUG FUEL PUMP MONITOR FUEL PUMP RETURN P P P WH DRAIN A B PWR PWR. FPC GND GND. P SG78 GND. BK PWR. WH WH PUMP-POS BK PUMP-NEG EFPR_B GND PUMP INLINE (GRAY) P PUMP INLINE (BLACK) 00598a Page 8

87 GEN LPG F-650/F-750 REMOTE START INSTALLATION Revision History -CA Initial Release 0/0/06 -CB Page 8 & 5 changes 05//06 P6FB-0F00-CB

88 Overview ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 Wire splice procedure Application GEN LPG F-650 Preparation Interior panel removal Installation Antenna mounting Wire installation and signal taps Hood safety switch mounting Underhood warning label Programming Module Settings Configure Bank Option 7 for key-in sense Test RMST operation Installation Continued Mounting module securing harness Troubleshooting P6FB-0F00-CB

89 Wire Splice Procedure A ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 PROCEDURE A: Follow this procedure when a wire can be spliced without cutting a signal wire in half. Strip approx. two inches of insulation from the wire to be installed. Strip approx. one inch of insulation from vehicle wire. On the vehicle wire to be spliced into, evenly separate the strands to place the new wire between the parted strands. Insert the new wire between the parted strands. Wrap the new wire around one side of the split strands, then wrap it around the other side. Solder the connection. Source: Proper Wire Splicing Techniques, GENERAL PROCEDURES, Ford 0 P6FB-0F00-CB

90 ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 Wire Splice Procedure A (continued) Wrap the connection with electrical tape so the tape covers the wires approximately two inches on both sides of the connection. Tape the wires as shown in the illustration. Electrical Tape P6FB-0F00-CB

91 Wire Splice Procedure B ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 PROCEDURE B: Follow this procedure when both ends of wire can be cut. To make end to end connections strip one inch of insulation from each wire and part them into equal strands. Twist the wires as illustrated Solder the wires then lay the strands on each side of the union. Wrap the connection with electrical tape to cover approx. two inches on each side of the connection. Electrical Tape P6FB-0F00-CB 5

92 Application ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 The intended use of these instructions is to install a Remote Start Module System (RMST) on a Ford F-650/750 equipped with a ROUSH CleanTech GEN LPG fuel system. The F-650 vehicle wiring is subject to change. All efforts are made to ensure that the information contained here is accurate as of the revision date. P6FB-0F00-CB 6

93 Preparation ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 Confirm the vehicle operates normally and all active codes have been properly repaired before continuing. Confirm the horn, brakelights, and headlights are operational.. Plug the wiring from the RMST kit into the RMST module. A - Harness: -way. B - Harness: 0-way.. Place the RMST and harness on vehicles floor.. Remove lower steering column cover.. Remove LH A-Pilar 5. Remove LH and RH kick panel. P6FB-0F00-CB 7

94 Installation ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ The RMST antenna has an adhesive lined face for mounting onto the windshield. Mount the antenna to the windshield above the rear view mirror mount. Clean the windshield surface with alcohol base solution. Position the wire pointing up to route in the headliner. 7. Route antenna cable along the headliner and down LH A-pillar towards the floor P6FB-0F00-CB 8

95 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ In the LH kick panel connect the RMST BLACK ground wire near existing chassis ground point. Remove the finish from the vehicle surface for an electrical contact. Use a self taping screw from RMST kit to secure the ground eyelet to the vehicle as marked below. Apply rustproofing compound PM-A or equivalent. P6FB-0F00-CB 9

96 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ The RMST harness connects inline with the OEM harness at the ignition switch. Unplug the ignition switch connector, C50, then mate RMST harness to this connector and ignition switch. C50 P6FB-0F00-CB 0

97 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Route and splice RMST BROWN/BLACK wire to the horn circuit at Steering Column Control Module (SCCM) connector, CA, terminal 8 (VIOLET/GRAY). Use wire splice procedure A outlined earlier in this manual. Position the splice two inches or more away from the back of the connector. CA P6FB-0F00-CB

98 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750. From the interrupt relay assembly in the RMST kit, remove the red wire from the relay connector.. Connect the BLUE and BLACK wire from relay connector to ground in LH kick panel using eyelet and screw from kit.. Connect the WHITE wire from relay connector to RMST harness WHITE wire (light output).. Route and splice the YELLOW wire from relay connector to SCCM connector, CA, terminal (YELLOW-ORANGE). Connector CA is the connector outlined on the previous page. Use wire splice procedure A outlined earlier in this manual. SCCM Position the splice two inches or more away from the back of the connector. 5. Plug the interrupt relay into the relay connector. OEM LIGHT WIRING YELLOW-ORANGE YELLOW COLOR FUNCTION A WHITE Light Output WHITE BLACK CA BLUE GROUND P6FB-0F00-CB

99 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Route RMST BROWN wire to the RH kick panel Body Control Module (BCM) Route along OEM harness in the instrument panel. BCM P6FB-0F00-CB

100 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Splice RMST BROWN wire to 5-way connector, C80B, terminal 8 (VIOLET-WHITE). Use wire splice procedure A outlined earlier in this manual. Position the splice two inches or more away from the back of the connector. BCM Brake Pedal Input (Violet-White) BCM C80B Terminal 8 C80B P6FB-0F00-CB

101 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Install the Hood Open Safety Switch to the vehicles LF headlamp mounting bracket and secure using supplied metal screws torqued to Nm. P6FB-0F00-CB 5

102 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Route RMST harness GRAY wire to the hood open switch, use the RCT CAN harness grommet to reach the engine compartment. Route the wire clear of sharp edges and excessive heat producing components and terminate at the hood open safety switch. Use wire splice procedure B outlined earlier in this manual to connect RMST harness GRAY wire to hood safety switch unterminated BLACK wire. If more wire length is required see unused circuits on RMST harness at RH kick panel. P6FB-0F00-CB 6

103 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Secure hood open switch ground eyelet to bracket outlined below. Remove the finish from the vehicle surface for an electrical contact. Use a self taping screw from RMST kit to secure the ground eyelet to the vehicle as marked below. If more wire length is needed see the RMST harness for unused circuits at RH kick panel. Apply rustproofing compound PM-A or equivalent. LF HEADLIGHT P6FB-0F00-CB 7

104 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750. Install the orange warning label under hood on drivers side of cowl side panel.. Return to vehicles interior to connect the antenna to the RMST module.! P6FB-0F00-CB 8

105 Programming Module Settings ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750. Prepare the system for programing. The RMST harness LED must be visible to complete this step. The RMST override button must be accessible. The RMST starter-fob must be accessible. The brake pedal must be accessible. Close vehicles hood and doors before proceeding.. Press and hold the brake pedal and position ignition key to RUN 5. Hold the RMST override button for 0 seconds. Listen for the horn to honk times indicating the learn mode is active. Release brake pedal and override button. 6. Tap the RMST override button. Listen for the horn to honk times indicating first program bank is active. 7. Tap the RMST override button again. Listen for the horn to honk 5 times indicating second program bank is active. 8. Press and release the brake pedal. Listen for the horn to honk time indicating option of the second program bank. Press and release the brake pedal 6 more times to step the system into option Quickly press start-fob button to turn OFF the LED for option The system is now programmed.. Remove ignition key.. Test the system before continuing the installation. P6FB-0F00-CB 9

106 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750. Remove all fir trees and connectors from the mounting bracket located in the LH kick panel.. Remove the two mounting nuts using a mm socket and set them aside. P6FB-0F00-CB 0

107 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Align the RMST module on the bracket as shown. 6. Mark the locations of the mounting tabs using a transfer punch then remove the bracket from the vehicle. 7. Drill a pilot hole in the marked locations followed by a clearance hole using a #7 drill bit. 5 7 P6FB-0F00-CB

108 ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 Installation (continued) 8. Using the M nut and bolt combination, supplied with the kit, mount the RMST module to the bracket. Torque the fasteners to - Nm. ISO View P6FB-0F00-CB

109 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Reinstall the modified bracket using the OEM fasteners. Secure the top connector () into the OEM location on the bracket. Secure the mid connector () with a zip-tie to the exposed RMST hole using a zip-tie. Secure the bottom connector () to the OEM harness using a zip-tie. Connect zip-tie here Use zip-tie to connect to main wiring harness P6FB-0F00-CB

110 Installation (continued) ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/ Retain the RMST electrical harness to the OEM harness using the zip-ties in the kit.. Reinstall the interior pieces removed in earlier steps.. Install the yellow DTC disclaimer label on drivers knee bolster near diagnostic port. P6FB-0F00-CB

111 Troubleshooting ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 Several safety checks are performed when attempting to start the engine remotely. If any of the input signals are present that should not be the system responds with a series of horn chirps. The table below outlines the possible causes. CHIRPS PROBLEM Chirp DNA-9 not programmed (not used on F-650/750) Chirps BRAKE is pressed or HOOD is open Chirps DOORS open (not used on F-650/750) Chirps TACH not programmed 5 Chirps Vehicle KEY is in the ignition 6 Chirps RMST is in SERVICE/VALET mode NOTE: If remote start module is in SERVICE/VALET mode it can be deactivated by following these steps. Turn vehicles ignition to ON Hold the brake pedal Tap the remote start system transmitter times. P6FB-0F00-CB 5

112 REFERENCE SECTION Kit contents ROUSH CleanTech Liquid Propane Autogas Fuel System: Ford F-650/750 ALJ-9G67-AA 7LJ-5K60-AA A B C D W7J-9G66-AA W7J-560-AA YLZ-9G90-AA E F G H P6FB-0F00-CB 6