Ford - E 150 - Workshop Manual - 2011 - 2014

2011-2014 Ford E-Series and F-Series Products Liquid Propane Autogas Fuel System (3rd Generation) Includes: E-150/E-250/E-350 Cargo Van/Wagon E-150/E-250/E-350 Extended Range Cargo Van/Wagon E-450 Custom Body F-250/F-350/F-450/F-550/F-650 F-53/F-59 Revision History -AA Initial Release 2/2013 -AB Revised 5/2013 -AC Revised 7/2013 -AD Revised 11/2013 -AE Revised 3/2014 -AF Revised 8/2014 DIAGNOSTIC MANUAL P-01B101-AF TABLE OF CONTENTS SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Installation, Garaging and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Purging and Venting (Tanks and Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 About Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 System and Diagnostic Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Diagnostic Trouble Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Flow Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Bleed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Tank Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Fuel Rail Pressure Control Module Supply Solenoid and Wiring . . . . . . . . . . . . . . . . . . . . . .12 SRM, CAN Bus Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Electronic Fuel Pump Relay (A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Integrated Pressure Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 DIAGNOSTIC TESTS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 No Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Slow Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Over Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Engine Cranks, No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Engine Stumble, Stall, Rough Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Excess Flow Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Maximum Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Supply Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Fuel System Fails to Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Fuel Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Fuel Level Indication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Tank Solenoid Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Fuel Rail Pressure Control Module Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Integrated Pressure Temperature Sensor Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Fuel Pump Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Fuel Pump Control Module Electrical Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Smart Relay Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Fuel Level Sender Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Fuel Level Interface Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Manual Solenoid Activation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 E-150/250/350 Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 E-150/250/350 Extended Range Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .54 E-450 Custom Body Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . .55 Page iii TABLE OF CONTENTS F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .56 F-650 Chassis Cab Wiring Harness and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . .57 F-450/550 Roush Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F-650 Chassis Cab, Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 F-53/59 Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness . . . . . . . .61 E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness . . . . . . . . .62 E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . .63 E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness . . . . . . . . . .64 E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness . . . . . . . . . .65 E-450 Stripped Chassis CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . .67 F-250/350 Pickup, F-450/550 and F-650, Tank Solenoid Harness Electrical Schematic . . . .68 F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . .69 F-250/350 Pickup, FTPT Jumper Harness Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . .70 F-650 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 F-650 Fuel Tank Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 F-650 Underhood Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 F-53/59 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 F-53/59/250/350/450 Rear Frame Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .75 F-53/59/250/350/450 Underhood Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . .76 F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . .77 Page iv INTRODUCTION INTRODUCTION Page 1 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. 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 2.2% and 9.6%, propane will burn in the presence of an ignition source at 940°F (504°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. Page 2 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. 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 −44°F (−42°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. INTRODUCTION Installation, Garaging and Training Chapter 11 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 7.3.1, General, and 7.3.2, Purging of NFPA 58, 2008 edition. Refer to NFPA 58, Local Codes and Proper Training for specific information relating to safe venting of LPG. Paragraph 11.2 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: [email protected], or [email protected]. Page 3 TROUBLESHOOTING TROUBLESHOOTING Page 4 TROUBLESHOOTING DIAGNOSTIC TROUBLE CODES About Diagnostic Trouble Codes DTCs, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com. 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 Acronym or Abbreviation Description BS Bleed Solenoid CAN Controller Area Network DTC Diagnostic Trouble Code EFPR Electronic Fuel Pump Relay ERFS Electronic Returnless Fuel System EVAP Evaporative FCS Flow Control Solenoid FLIM Fuel Level Interface Module FLS Fuel Level Sender FP Fuel Pump FPCM Fuel Pump Control Module FRP Fuel Rail Pressure FRPCM Fuel Rail Pressure Control Module FTS Fuel Temperature Sensor GRD Ground HEGO Heated Exhaust Gas Oxygen IC Instrument Cluster IPTS Integrated Pressure Temperature Sensor KOEO Key On Engine Off KOER Key On Engine Running LPA Liquid Propane Autogas MAF Mass Air Flow OEM Original Equipment Manufacturer OPD Overfill Protection Device PCM Powertrain Control Module PID Parameter Identification PWR GND Power Ground SIG RTN Signal Return SRM Smart Relay Module SS Supply Solenoid TS Tank Solenoid VMV Vapor Management Valve VPWR Voltage Power VREF Voltage Reference WOT Wide Open Throttle Page 5 TROUBLESHOOTING 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 P009F Fuel Pressure Relief Control Stuck On P0148 Fuel Delivery Error P0171 System Too Lean (Bank 1) P0172 System Too Rich (Bank 1) P0174 System Too Lean (Bank 2) P0175 System Too Rich (Bank 2) P0182 Fuel Temperature Sensor (A) Circuit Low P0183 Fuel Temperature Sensor (A) Circuit High P0190 Fuel Pressure Sensor A Circuit P0192 Fuel Pressure Sensor A Circuit Low P0193 Fuel Pressure Sensor A Circuit High P025A Fuel Pump Control Module Circuit Range/Performance A P027A Fuel Pump Control Module Circuit Range/Performance B P03xx Misfire P0460 Fuel Level Sender A Circuit P0461 Fuel Level Sender A Circuit Range/Performance P0462 Fuel Level Sender A Circuit Low P0463 Fuel Level Sender A Circuit High P0627 Fuel Pump A Control Circuit Open P116E Exceeded Maximum Pressure P2067 Fuel Level Sensor B Circuit Low P2068 Fuel Level Sensor B Circuit High P2195 Heated Exhaust Gas Oxygen Sensor Stuck P2197 Heated Exhaust Gas Oxygen Sensor Stuck P25B1 Fuel Level Sensor B Stuck P2632 Fuel Pump B Control Circuit Open P2665 Supply Solenoid Circuit Fault P26B3 Fuel Shutoff Valve A Control Circuit Performance/Stuck Off P26B5 Fuel Shutoff Valve B Function Check U0108 Lost Communication with Alternative Fuel Control Module U0109 Lost Communication with Fuel Pump Control Module A U016C Lost Communication with Fuel Pump Control Module B U0309 Alt Fuel Module-Wrong SRM Page 6 TROUBLESHOOTING Calibration Release OBD Summary Chart OEM MY HDE MY Cert OBD Class Detail Chart 2011 N/A Fed Only PBGD-Ax & Bx OBD II E-Series 5.4L Group 2012 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group 2013 N/A Fed PBGD-Ax & Bx OBD II E-Series 5.4L Group FED OBD Identifier 2013 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group Fuel Pump Codes Added 2012 N/A 50S Only PCDH-Ax & Bx OBD II F-Series 6.2L Group 2013 N/A Fed PCDH-Cx & Dx OBD II F-Series 6.2L Group Fuel Pump Codes Added 2013 N/A 50S PCDH-Ax & Bx OBD II F-Series 6.2L Group Fuel Pump Codes Added 2011 2011 Fed PBJC-Bx & Dx Non-OBD (EMD) E-Series 6.8L HDE OBD I / EMD Level 2012 2012 50S PBJC-Ax & Cx Non-OBD (EMD) E-Series 6.8L HDE OBD I / EMD Level 2013 2013 50S PDJC-Ax & Bx EMD+ E-Series 6.8L HDE Cat Monitor Added 2012 2011 Fed PCEB-Ax Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2012 2012 Fed PCEB-Ax Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2013 2012 Fed PCEB-Ax Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2013 2013 50S PDEB-Ax EMD+ F-Series 6.8L HDE Cat Monitor Added 2013 2012 Fed PCEB-Sx Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2013 2013 50S PDEB-Sx EMD+ F-Series 6.8L HDE Cat Monitor Added 2013 2012 Fed PCEB-Mx Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2013 2013 50S PDEB-Mx EMD+ F-Series 6.8L HDE Cat Monitor Added 2012 2012 Fed PCFB-Ax Non-OBD (EMD) F-Series 6.8L HDE OBD I / EMD Level 2013 2013 50S PDFB-Ax EMD+ F-Series 6.8L HDE Cat Monitor Added Vehicle E-Series F-250/F-350 E-450 F-450/F-550 F-59 (Step Van) F-53 (Motorhome) F-650 Calibration Comments (03P150) FED OBD Identifier Note: HDE MY - Heavy Duty Engine Model Year (Some HD products have different engine certifications within the vehicle model year.) Page 7 TROUBLESHOOTING Calibration Release OBD Summary Chart E-Series 5.4L Group E-150/E-250/E-350 F-Series 6.2L Group F-250/F-350 2012 50S 2013 Fed 2013 50S 2012 50S 2013 Fed 2013 50S Fuel Shutoff Valve A Control Circuit Open 1 1 1 1 1 1 P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1 1 1 P009B Fuel Pressure Relief Control Circuit Open 2 2 2 2 2 2 P009E Fuel Pressure Relief Control Performance Stuck Off 2 2 2 2 2 2 P009F Fuel Pressure Relief Control Stuck On 2 2 2 2 2 2 P0148 Fuel Delivery Error 1 1 1 1 1 1 P0171 System Too Lean (Bank 1) 2 2 2 2 2 2 P0172 System Too Rich (Bank 1) 2 2 2 2 2 2 P0174 System Too Lean (Bank 2) 2 2 2 2 2 2 P0175 System Too Rich (Bank 2) 2 2 2 2 2 2 P0182 Fuel Temperature Sensor (A) Circuit Low 2 2 2 2 2 2 P0183 Fuel Temperature Sensor (A) Circuit High 2 2 2 2 2 2 P0190 Fuel Pressure Sensor A Circuit 2 2 2 2 2 2 P0192 Fuel Pressure Sensor A Circuit Low 2 2 2 2 2 2 P0193 Fuel Pressure Sensor A Circuit High 2 2 2 2 2 2 P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 2 1 2 2 P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2 P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 2 1 2 2 P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2 P03xx Misfire 2 2 2 2 2 2 P0460 Fuel Level Sender A Circuit 2 2 2 2 2 2 P0461 Fuel Level Sender A Circuit Range/Performance 2 2 2 2 2 2 P0462 Fuel Level Sender A Circuit Low 2 2 2 2 2 2 P0463 Fuel Level Sender A Circuit High 2 2 2 2 2 2 P0627 Fuel Pump A Control Circuit Open 1 1 2 1 2 2 P116E Exceeded Maximum Pressure 1 1 1 1 1 1 P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2 P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2 P2632 Fuel Pump B Control Circuit Open 1 1 2 1 2 2 P2665 Supply Solenoid Circuit Fault 1 1 1 1 1 1 P26B3 Fuel Shutoff Valve A Control Circuit Performance/ Stuck Off 1 1 1 1 1 1 P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1 1 1 U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2 2 2 U016C Lost Communication with Fuel Pump Control Module B 1 1 2 1 2 2 U0309 Alt Fuel Module-Wrong SRM 2 2 2 2 2 2 Code Descriptions P0005 0 Code not present 1 DTC – non MIL 2 DTC – MIL (two trips) Page 8 TROUBLESHOOTING Calibration Release OBD Summary Chart E-Series 6.8L HDE Group E-450 F-Series 6.8L HDE Group F-450/550/650/53/59 Code Descriptions 2012 50S 2013+ 50S 2012 50S 2013+ 50S P0005 Fuel Shutoff Valve A Control Circuit Open 1 1 1 1 P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1 P009B Fuel Pressure Relief Control Circuit Open 1 2 2 2 P009E Fuel Pressure Relief Control Performance Stuck Off 1 2 2 2 P009F Fuel Pressure Relief Control Stuck On 0 0 0 0 P0148 Fuel Delivery Error 1 1 1 1 P0171 System Too Lean (Bank 1) 2 2 2 2 P0172 System Too Rich (Bank 1) 2 2 2 2 P0174 System Too Lean (Bank 2) 2 2 2 2 P0175 System Too Rich (Bank 2) 2 2 2 2 P0182 Fuel Temperature Sensor (A) Circuit Low 1 2 2 2 P0183 Fuel Temperature Sensor (A) Circuit High 1 2 2 2 P0190 Fuel Pressure Sensor A Circuit 1 2 2 2 P0192 Fuel Pressure Sensor A Circuit Low 1 2 2 2 P0193 Fuel Pressure Sensor A Circuit High 1 2 2 2 P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 1 1 P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1 P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 1 1 P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1 P03xx Misfire 1 1 1 1 P0460 Fuel Level Sender A Circuit 1 1 1 1 P0461 Fuel Level Sender A Circuit Range/Performance 0 0 0 0 P0462 Fuel Level Sender A Circuit Low 1 1 1 1 P0463 Fuel Level Sender A Circuit High 1 1 1 1 P0627 Fuel Pump A Control Circuit Open 1 1 1 1 P116E Exceeded Maximum Pressure 1 1 1 1 P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 P2632 Fuel Pump B Control Circuit Open 1 1 1 1 P2665 Supply Solenoid Circuit Fault 1 1 1 1 P26B3 Fuel Shutoff Valve A Control Circuit Performance/ Stuck Off 1 1 1 1 P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1 U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2 U016C Lost Communication with Fuel Pump Control Module B 1 1 1 1 U0309 Alt Fuel Module-Wrong SRM 2 2 2 2 0 Code not present 1 DTC – non MIL 2 DTC – MIL (two trips) Page 9 TROUBLESHOOTING Flow Control Solenoid P0090 — Fuel Pressure Regulator Circuit Open Description FCS circuit fault. SRM monitors FCS circuit for open and short circuit faults. Possible Causes 앫 Short to voltage 앫 Water in the harness connector 앫 Open power circuit 앫 GND circuit 앫 Low battery voltage 앫 Corrosion 앫 Incorrect connections 앫 Damaged FCS coil 앫 Blown fuse Symptom Fuel pressure in the rail does not change when commanded. Extended fuel rail flush time. Diagnostic Aid Check the FRPCM and SRM electrical connector for damage, corrosion and water intrusion. Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Bleed Solenoid P009E/P26B3 — Fuel Pressure Relief Control Performance Stuck Off Description Fuel rail failed to bleed. The PCM measures fuel rail pressure on key-up to determine if fuel rail has been properly bled. Possible Causes 앫 BS did not open 앫 FRPCM check valve leaked (P26B3) 앫 FRPCM supply solenoid leaked (P26B3) 앫 Bleed port (bleed rate restrictor in outlet to VMV) clogged 앫 EVAP line kinked 앫 Blown fuse Symptom Fuel pressure present in the fuel rail after bleed event should have occurred; this may result in hard starts. Diagnostic Aid Check that FRPCM bleeds fuel from rail. Leaks to FRPCM can also trigger a fault. Action Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures. P009F — Fuel Pressure Relief Control Stuck On Description Bleed solenoid stuck open. While the engine is running, the PCM seals the EVAP system and checks for a rise in pressure. If pressure in the EVAP system exceeds the threshold, a fault is set. Possible Causes 앫 Short to GRD 앫 Armature stuck in post 앫 Solenoid seal compromised Symptom There is a potential for fuel odor. Diagnostic Aid — Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Page 10 TROUBLESHOOTING P009B — Fuel Pressure Relief Control Circuit Open Description Bleed solenoid circuit fault. The SRM monitors bleed solenoid circuit for open and short circuit faults. Possible Causes 앫 Short to voltage 앫 Water in the harness connector 앫 Open power circuit 앫 Open GND circuit 앫 Low battery voltage 앫 Corrosion 앫 Incorrect connections 앫 Damaged BS coil Symptom Fuel rail bleed system does not operate correctly. There is a potential for fuel odor or hard start. Diagnostic Aid Check the FRPCM and SRM electrical for damage, corrosion and water intrusion. Action 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 TS circuit fault. The SRM monitors tank solenoid circuit for open and short circuit faults. Possible Causes 앫 Short to voltage 앫 Water in the harness connector 앫 Open power circuit 앫 Open GND circuit 앫 Low battery voltage 앫 Corrosion 앫 Incorrect connections 앫 Damaged TS coil 앫 Blown fuse Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail. Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Action Refer to the Tank Solenoid Electrical Check procedure in Diagnostic Tests and Procedures. Page 11 TROUBLESHOOTING Fuel Rail Pressure Control Module Supply Solenoid and Wiring P26B5 — Fuel Shutoff Valve B Function Check Description 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. Possible Causes 앫 Electrical fault 앫 Damaged SS coil 앫 Damaged SS armature 앫 Excess flow valve tripped 앫 Tank solenoid stuck closed 앫 Tank manual valve closed 앫 Fuel pumps not powering on 앫 Blown fuse Symptom Vehicle does not start. The pumps run (or may not) but no pressure builds in the fuel rail. Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures. P2665 — Supply Solenoid Circuit Fault Description FRPCM supply solenoid circuit fault. SRM monitors supply solenoid circuit for open and short circuit faults. Possible Causes 앫 Short to voltage 앫 Water in the harness connector 앫 Open power circuit 앫 Open GND circuit 앫 Low battery voltage 앫 Corrosion 앫 Incorrect connections 앫 Damaged SS coil 앫 Blown fuse Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail. Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures. Page 12 TROUBLESHOOTING SRM, CAN Bus Circuit Wiring U0108 — Lost Communication with Alternative Fuel Control Module Description 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. Possible Causes 앫 Wiring between the SRM and PCM 앫 SRM lacks power 앫 Blown fuse Symptom Rough idle. Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Check for power at the SRM. Action Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures. U0309 — Alternate Fuel Module-Wrong SRM Description Alternate Fuel Module (SRM) is not broadcasting over vehicle communication link the expected SRM module identifier. A U0309 code should only be expected during initial build or during service replacement of the SRM module. Possible Causes 앫 Incorrect SRM was installed into the vehicle for initial build or during service of the SRM 앫 Loss of CAN communications between the SRM and PCM Symptom 앫 MIL light 앫 Fuel gage may not read full or empty correctly Diagnostic Aid 앫 Verify to latest calibration 앫 Verify SRM part number is correct for vehicle type and tank 앫 Verify that no other DTCs are set related to CAN communications 앫 Inspect CAN harness for connection issues and integrity Action Replace SRM to correct type or fix any CAN communication DTCs or wiring/connection concerns. Fuel System P0148 — Fuel Delivery Error Description LPA system is operating in vapor space. At least one bank is lean at WOT. Possible Causes 앫 Severely restricted fuel filter 앫 Severely restricted fuel supply line 앫 Damaged or worn fuel pump 앫 Damaged or contaminated MAF sensor 앫 Excess flow valve tripped 앫 TS or SS closed 앫 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. Page 13 TROUBLESHOOTING P116E — Maximum Pressure Description 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. Possible Causes 앫 Operating the vehicle in high ambient conditions 앫 Vehicle operated in a low voltage condition Symptom Vehicle hesitation, stall, rough idle, misfire or no start. Diagnostic Aid The P116E 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. Action Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures. P0171, P0174 — System Too Lean (Bank 1 and Bank 2 respectively) Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes 앫 The LPA system was operated in the vapor region 앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom — Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. P0172, P0175 — System Too Rich (Bank 1 and Bank 2 respectively) Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes 앫 The LPA system was operated in the vapor region 앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom — Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. P03xx — Misfire Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes 앫 The LPA system was operated in the vapor region 앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom — Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Page 14 TROUBLESHOOTING Heated Exhaust Gas Oxygen Sensor P2195, P2197 — Heated Exhaust Gas Oxygen Sensor Stuck Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes 앫 The LPA system was operated in the vapor region 앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom — Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure. Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures. Electronic Fuel Pump Relay (A/B) U0109, U016C — Lost Communication with Fuel Pump Control Module A/B Description The SRM repeats the signal from the second EFPR to the PCM over the CAN bus. The PCM monitors this communication. If there is a lack of communication for a long enough period of time, a fault is set. Possible Causes 앫 Wire fault between the EFPR and SRM 앫 Wire fault between SRM and PCM 앫 No power to the EFPR 앫 SRM fault 앫 CAN bus fault 앫 Blown fuse 앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom — Diagnostic Aid — Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure and also the Smart Relay Module Electrical Test procedure in Diagnostic Tests and Procedures. P025A, P027A — Fuel Pump Control Module Circuit Range/Performance Description 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. Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes. Symptom Poor starts, rough idle, hesitation/surge. Diagnostic Aid — Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures. Page 15 TROUBLESHOOTING Integrated Pressure Temperature Sensor P0182 — Fuel Temperature Sensor (A) Circuit Low Description The SRM reads the IPTS and passes the voltage reading over the CAN to the PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes 앫 CAN bus fault between the SRM and PCM 앫 Wiring fault between IPTS and SRM 앫 Short in harness 앫 VREF open or short 앫 Low ambient temperature operation 앫 Incorrect harness connection 앫 Damaged IPTS (or FTS) 앫 IPTS failure 앫 SRM failure Symptom — Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short. Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P0183 — Fuel Temperature Sensor (A) Circuit High Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes 앫 CAN bus fault between the SRM and PCM 앫 Wiring fault between IPTS and SRM 앫 Open circuit 앫 Open or short to voltage in harness 앫 Incorrect harness connection 앫 Damaged IPTS (FTS) 앫 IPTS failure 앫 SRM failure Symptom — Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short. Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 16 TROUBLESHOOTING P0190 — Fuel Pressure Sensor A Circuit Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes 앫 CAN bus fault between the SRM and PCM 앫 Wiring fault between IPTS and SRM 앫 VREF open in harness 앫 VREF open in sensor 앫 Vacuum leaks 앫 IPTS failure 앫 SRM failure Symptom — Diagnostic Aid VREF should be between 4–6 volts. Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P0192 — Fuel Pressure Sensor A Circuit Low Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes 앫 CAN bus fault between the SRM and PCM 앫 Wiring fault between IPTS and SRM 앫 IPTS FRP signal short to SIG RTN or PWR GND 앫 Damaged IPTS (or FRP) 앫 IPTS failure 앫 SRM failure Symptom — Diagnostic Aid A FRP PID value during ignition ON, engine OFF, or ignition ON, engine running is less than 0.3 volt. This indicates a concern is present. Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. P0193 — Fuel Pressure Sensor A Circuit High Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle. Possible Causes 앫 CAN bus fault between the SRM and PCM 앫 Wiring fault between IPTS and SRM 앫 IPTS FRP signal short to VREF or VPWR 앫 IPTS (or FRP) open signal 앫 Damaged IPTS (or FRP) 앫 IPTS failure 앫 SRM failure Symptom — Diagnostic Aid Verify the FRP PID value to determine open or short. Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures. Page 17 TROUBLESHOOTING Fuel Level Sender P0460 — Fuel Level Sender A Circuit Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the FLS and the SRM and not the IC. Symptom — Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM. Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures. P0461 — Fuel Level Sender A Circuit Range/Performance Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information. Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the sender and the SRM and not the IC. Symptom — Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM. Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures. P0462 (P2067) — Fuel Level Sender A (B) Circuit Low Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value. Possible Causes 앫 Fuel level sender wiring shorted to ground 앫 Damaged Fuel Level Sender 앫 Smart Relay Module Symptom P0462 — Fuel gauge may read empty all the time P2067 — Fuel gauge will only show primary tank Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster. Action Refer to the following tests located later in this manual. 앫 SRM Electrical Test 앫 Fuel Level Sender Test 앫 Fuel Level Interface Module Page 18 TROUBLESHOOTING P0463 (P2068) — Fuel Level Sender A (B) Circuit High Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value. Possible Causes 앫 Fuel level sender wiring is disconnected or shorted to above 5 volts 앫 Damaged Fuel Level Sender 앫 Smart Relay Module Symptom P0463 — Fuel gauge may read full all the time P2068 — Fuel gauge will only show primary tank Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster. Action Refer to the following tests located later in this manual. 앫 SRM Electrical Test 앫 Fuel Level Sender Test 앫 Fuel Level Interface Module P25B1 — Fuel Level Sensor B Stuck Description Failed transfer of fuel from secondary tank B to primary tank A. Failure code sets if a transfer is not detected by sender movement in 3 transfer attempts. Possible Causes Secondary tank transfer failure causes: 앫 Tank supply solenoid did not open 앫 Manual valve closed 앫 Excess flow valve trips on transfer attempts 앫 Blown fuse 앫 Electrical fault or relay failure that supplies the tank solenoid or pumps 앫 SRM hardware failure 앫 Sender arm stuck 앫 Sender signal out of range 앫 Fuel transfer line between secondary and primary tank kinked or plugged 앫 High differential of pressure when the primary tank greater than ~60 psi over secondary tank (typically caused by higher temperatures in the primary tank) Primary tank transfer failure causes: 앫 Faulty transfer OPD connected to transfer line Symptom 앫 Fuel indication is only based on primary tank sender 앫 Customer does not achieve expected driving range 앫 Short fuel fills (only adds fuel to primary tank) 앫 Cluster fuel gauge may indicate inconsistent behavior Diagnostic Aid Check all electrical connectors and voltage supply to the secondary tank valve and fuel pumps. Verify that the secondary tank sender voltages (or resistances) are in the expected range. Verify that no other primary or secondary tank out-of-range codes are set (P0462, P0463, P2067, P2068). Action Refer to the Secondary Tank – Fuel Will Not Transfer Troubleshooting. Page 19 TROUBLESHOOTING 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. 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. Page 20 TROUBLESHOOTING DIAGNOSTIC TESTS AND PROCEDURES General Information Expected Fuel Tank Pressure — On a tank at ambient temperature conditions, the following pressures can be expected: Pressure (psi) 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 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information regarding the tools required. Method 1 — Install a 0–500 psi (0–3447 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 2 — If a 0–500 psi (0–3447 kPa) fuel pressure gauge is not available, fuel rail pressure can be used to infer fuel tank pressure. Refer to Method 1 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. Temperature (°F) Min. Nominal Max. 0 15 25 35 5 19 29 39 10 23 33 43 15 28 38 48 20 33 43 53 25 38 48 58 30 43 53 63 35 49 59 69 40 55 65 75 45 62 72 82 50 69 79 89 55 77 87 97 60 84 94 104 65 93 103 113 70 102 112 122 75 111 121 131 80 121 131 141 Measuring Fuel Rail Pressure — Fuel rail pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual for more information regarding the tools required. Method 1 — 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 1 Powertrain Data. Then locate and select FRP (pressure) from PID selection table. Method 2 — Empty the fuel rails and fuel lines. Refer to the Fuel Line Purging Procedure in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information. Using the Jiffy-Tite disconnect tool, 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 0–500 psi (0–3447 kPa) fuel pressure gauge to the service port on the adapter. Record the value. 85 131 141 151 90 142 152 162 95 153 163 173 100 165 175 185 105 178 188 198 110 191 201 211 115 205 215 225 120 219 229 239 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 two operating speeds. The pump operates in low speed mode at idle and during moderate fuel flow/part throttle driving. Once a fuel demand threshold is met, typically during wide open throttle (WOT) operation, the pump is switched to high speed. The pump is also operated at high speed during the pre-start flush sequence. Page 21 TROUBLESHOOTING 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 150 psi (1034 kPa) and pressure in the rail is measured at 200 psi (1379 kPa), the rail is running at 50 psi (345 kPa) over tank. Condition Pump Speed Pressure Over Tank Engine Off Off <10 Idle Low >30 Part Throttle Low <25 Part Throttle High >25 WOT High >25 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 P116E or P0148 code. No Fill Step Procedure Action 1 Inspect vehicle to check for kinked fill lines. Are fill lines kinked? Yes — Replaced kinked fill lines. No — Go to Step 2. 2 Determine the location of the overflow protection device (OPD). Is the OPD located in the end cap of the fuel tank? Yes — Go to Step 3. No — Go to Step 6. 3 Check the fuel gauge in the instrument cluster. Is the gauge indicating less than 1/4 full? Yes — Go to Step 4. No — Go to Step 6. 4 Check to see if the OPD is being activated. 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. b. 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. 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 10 gal (38 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? Yes — Diagnostic is complete. No — Go to Step 6. 6 Check the fuel gauge in the instrument cluster. Is the gauge indicating more than 1/2 full? Yes — Go to Step 7. No — Go to Step 11. 7 Reverse direction of vehicle at the pump and try to fill the vehicle. Does the vehicle fuel tank fill? Yes — Vehicle not on level ground. Diagnostic is complete. No — Drive vehicle until fuel gauge indicates less than 1/2 full and go to Step 8. Page 22 TROUBLESHOOTING Step Procedure Action 8 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Yes — Go to Step 9. No — Go to Step 11. 9 Open bleeder valve. Does liquid fuel vent? Yes — Go to Step 10. No — Go to Step 12. 10 Check fuel gauge. Does fuel gauge read full? Yes — Diagnostic complete. No — Refer to Fuel Level Indication Check. 11 Check for sufficient fill station pressure. Yes — Go to Step 12. No — Fill station may not be providing enough pressure to fill. Go to Step 19. a. b. 12 Connect pressure gauge service tool to the fuel tank bleeder valve and record pressure. 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 20 psi (138 kPa) greater than tank pressure? Check body side fuel fill valve; it may be stuck closed. a. b. c. 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. Attempt to push open the piston in the fill valve to determine if it is stuck closed. Yes — Replace body-side fill valve and go to Step 13. No — Replace filter in the fuel fill line and go to Step 15. Is the fill valve piston stuck closed? 13 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Yes — Diagnostic is complete. No — Go to Step 14. 14 Replace the filter in the fuel fill line and then attempt to fill the vehicle fuel tank. Does the vehicle fuel tank fill? Yes — Diagnostic is complete. No — Go to Step 16. 15 Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Yes — Diagnostic is complete. No — Go to Step 16. 16 Replace the OPD valve in the vehicle fuel tank. Is the OPD valve located in the end cap of the fuel tank? Yes — Go to Step 17. No — Go to Step 18. 17 Attempt to fill the vehicle fuel tank as follows: Yes — Diagnostic is complete. No — Call ROUSH CleanTech Customer Service at 800-597-6874. 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. a. 18 b. Install a fuel fill pressure tester on the fill valve and close the ball valve. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 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? Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Yes — Diagnostic is complete. No — Call ROUSH CleanTech Customer Service at 800-597-6874. Page 23 TROUBLESHOOTING Step 19 Procedure Fill station is not providing enough pressure to fill. a. b. 20 Vehicle fuel tank is at a higher pressure. a. b. 21 Higher pressure is likely caused by heavy vehicle usage heating the fuel. 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. b. 22 Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature. Is the vehicle fuel tank pressure greater than 20 psi (138 kPa) over the nominal expected pressure? Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. 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 20 psi (138 kPa) greater than fuel tank pressure? Attempt to fill the vehicle fuel tank. Does the fuel tank fill? Action Yes — Go to Step 20. No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 12. When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 21. Yes — Go to Step 22. No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 22. Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Yes — Diagnostic is complete. No — Go to Step 12. Slow Fill Step Procedure Action 1 Inspect vehicle to check for kinked fill lines. Are fill lines kinked? Yes — Replaced kinked fill lines. No — Go to Step 2. 2 Determine flow rate at which the vehicle fuel system fills. Yes — System fill rate is OK; diagnostic is complete. No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 3. a. b. c. 3 b. 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 (345 kPa) greater than fuel tank pressure? Check fuel fill valve; it may not be opening completely. b. c. Page 24 Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle. c. a. 5 Is the fill station pump flow rate at least 6 gal (23 L) per minute? Measure and compare vehicle fuel tank and fill station pressures. a. 4 Time the fill station pump for 10 seconds and record the number of gallons dispensed. Multiply the gallons dispensed by six to determine the flow rate in gallons per minute. 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. Attempt to push open the piston in the fill valve to determine if it is opening completely. Piston should travel 1/4 inch. Yes — Go to Step 4. No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 11. 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. Is the fill valve piston opening completely? Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal (23 L) per minute? Yes — Diagnostic is complete. No — Go to Step 6. TROUBLESHOOTING Step Procedure Action 6 Replace the filter in the fuel fill line. Does the vehicle fuel tank fill at greater than six gal (23 L) per minute? Yes — Diagnostic is complete. No — Go to Step 7. 7 Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal (23 L) per minute? Yes — Diagnostic is complete. No — Go to Step 8. 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? Yes — Go to Step 9. No — Go to Step 10. 9 Attempt to fill the vehicle fuel tank as follows: Yes — Diagnostic is complete. No — Call ROUSH CleanTech Customer Service at 800-597-6874. 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. a. b. Install a fuel fill pressure tester on the fill valve and close the ball valve. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 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? 10 Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal (23 L) per minute? Yes — Diagnostic is complete. No — Call ROUSH CleanTech Customer Service at 800-597-6874. 11 Fill station is not providing enough pressure to fill. Yes — Go to Step 12. No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 2. a. b. 12 Vehicle fuel tank is at a higher pressure. a. b. 13 Higher pressure is likely caused by heavy vehicle usage heating the fuel. 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. b. 14 Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature. Is the vehicle fuel tank pressure greater than 20 psi (38 kPa) over the nominal expected pressure? Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure. 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 (345 kPa) greater than fuel tank pressure? Attempt to fill the vehicle fuel tank. Does the fuel tank fill at greater than six gal (23 L) per minute? When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 13. Yes — Go to Step 14. No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 14. Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Yes — Diagnostic is complete. No — Go to Step 4. Page 25 TROUBLESHOOTING Over Fill Step 1 Procedure Suspect overfill because fuel fill volumes achieved during refueling exceed the rated fuel capacity or excessive vehicle range between refueling. a. b. 2 3 b. 4 Check to determine if the vehicle is level using the vehicle frame as reference. Does the vehicle sit level? Locate the American Society of Mechanical Engineers (ASME) inspection plate on the fuel tank. a. b. 5 Listen at valve to verify propane vapor is venting. Is propane vapor venting? Park the vehicle at the refueling station. a. Yes — Go to Step 2. No — Drive vehicle until gauge reads below 1/4 tank. Check the fuel gauge. Is the gauge reading below 1/2 tank? Open bleeder valve located on the tank or remotely mounted on the vehicle. a. b. Action Yes — Go to Step 3. No — Bleeder valve is not functioning properly. Replace the valve. Yes — Go to Step 4. No — Using a jack, raise the vehicle to obtain a level condition. Then, go to Step 4. With the value recorded, go to Step 5. Note the tank water capacity listed on the plate. Multiply the listed capacity by 0.05 (5%) and record the value. Refuel the vehicle as follows: Yes — Record the volume of fuel dispensed and then go to Step 6. 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. 6 a. b. Verify that the ignition is in the OFF position. 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? Resume filling until the dispensing pump stops automatically. a. b. 7 Page 26 Record the total volume of fuel dispensed and subtract the amount from the volume recorded in Step 5. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4? 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. TROUBLESHOOTING Step 8 Procedure Refuel the vehicle as follows: Action 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. 9 a. b. Verify that the ignition is in the OFF position. 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? Resume filling until the dispensing pump stops automatically. a. b. Record the volume of fuel dispensed and subtract the amount from the volume recorded in Step 8. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4? Yes — Tank does not overfill. Diagnostic is complete. No — Tank is overfilling. Replace the fuel tank assembly. Engine Does Not Crank Step Procedure Action 1 Is battery voltage above 10 volts? Yes — Go to Step 2. No — Determine cause of low battery voltage. 2 Verify that the smart relay module (SRM) has communication. Yes — Go to Step 3. No — Go to the Smart Relay Module Electrical Test procedure. Can fuel rail pressure and temperature be read with a scan tool? 3 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 800-597-6874. Page 27 TROUBLESHOOTING Engine Cranks, No Start For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step 1 Procedure Verify the following: a. b. Is there fuel in the tank of at least 1/8 tank or more? (add fuel if necessary). Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 10 volts? Action Yes — Go to Step 2. No — Correct fault and retry. 2 Check for diagnostic trouble codes (DTC). Are any codes present? Yes — Go to Step 3. No — Go to Step 4. 3 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. 4 Check fuel pressure. Yes — Go to Step 11. No — Go to Step 5. a. 5 b. Measure and record fuel rail and fuel tank pressure, Key ON Engine OFF (KOEO). While monitoring fuel pressure, attempt to start engine. c. Record the highest pressure observed. d. Does fuel pressure rise 25 psi (172 kPa) before engine crank? Check fuel pump operation. a. 6 b. 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. 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 2 amps should be recorded on both fuel pump circuits. c. Do fuel pumps draw current? Check excess flow valve (XFV). a. b. Turn ignition key to the OFF position. Close the manual shutoff valve on tank. c. Wait 1 minute and then slowly open manual shutoff valve. d. Measure and record fuel pressure, using a scan tool, at integrated pressure temperature sensor (IPTS). e. Is problem resolved? 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 10. Yes — Go to Step 11. No — Go to Step 7. 7 Check ROUSH fuel pump (FP) fuse. Is fuse intact and OK? Yes — Go to Step 8. No — Determine the cause of the short and repair; replace the fuse. Diagnostic is complete. 8 Check the tank solenoid (TS) and supply solenoid (SS) fuses. Yes — Determine the cause of the short and repair; replace the fuse. No — Go to Step 9. Page 28 a. b. Locate the TS fuse (E3-E4) and check its condition. Locate the SS fuse (F1-F2) and check its condition. c. Are the fuses blown? TROUBLESHOOTING Step 9 Procedure Verify that there is power and proper grounding at the tank solenoid (TS) and supply solenoid (SS) wiring circuits. a. 10 b. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure. Is +12 volts present at the TS connector? c. Is +12 volts present at the SS connector? Verify that there is power and proper grounding in the wiring circuit to the tank. a. b. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Pump Electrical Check procedure. Is +12 volts present at the FP1 connector? c. Is +12 volts present at the FP2 connector? Action 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 12. No — Check for an open(s) in the wiring circuits and repair. 11 Integrated Pressure Temperature Sensor Rationality Yes — Refer to the Integrated Pressure Does temperature and pressure make sense to verification procedure? Temperature Sensor Electrical Check. No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor. 12 Check wiring. a. 13 b. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information. 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. 앫 Are in-tank fuel hoses and quick-connect fittings connected and in good condition? Yes — Replace harness. No — Go to Step 13. Yes — Replace fuel pump assembly. No — Replace hose assemblies as needed. Page 29 TROUBLESHOOTING Engine Stumble, Stall, Rough Idle For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step 1 Procedure Verify the following: a. b. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.) Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 11 volts with engine running? Action Yes — Go to Step 2. No — Correct the fault and retry. 2 Check for diagnostic trouble codes (DTCs). Are any codes present? Yes — Go to Step 3. No — Go to Step 4. 3 Identify the DTC. Yes — Refer to ROUSH CleanTech Diagnostic Trouble Code List. No — Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com. a. b. Is the DTC covered in the ROUSH CleanTech DTC listing for LPA-fueled vehicles? Correct all DTCs before continuing. 4 Does the problem occur only after cold start? Yes — Go to Step 6. No — Go to Step 5. 5 Determine fuel pressure. Yes — Go to Step 7. No — Go to Step 6. 6 7 a. b. Measure tank pressure with Key ON Engine OFF (KOEO). 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? Determine if the excess flow valve (XFV) is tripped. a. b. Turn OFF the engine. Wait one minute and then restart the engine. c. Is the fault condition resolved? Check fuel pump operation. a. 8 b. 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. 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 2 amps should be recorded on both fuel pump circuits. c. Do fuel pumps draw current? Verify that there is power and proper grounding in the wiring circuit to the tank. a. Page 30 b. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. Is +12 volts present at the FP1 connector? c. Is +12 volts present at the FP2 connector? Yes — Refer to the Excess Flow Valve Check procedure. No — Go to Step 7. Yes — Go to Step 11. 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. TROUBLESHOOTING Step 9 Procedure Check wiring. a. 10 Action b. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information. 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. 앫 Are in-tank fuel hoses and quick-connect fittings connected and in good condition? Yes — Replace harness. No — Go to Step 10. Yes — Replace fuel pump assembly. No — Replace hose assemblies as needed. 11 Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. Yes — Go to Step 12. No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor. 12 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com. — 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 1 Procedure Verify fuel supply line pressure prior to cranking engine. a. b. Read fuel rail pressure and tank pressure. Energize bleed solenoid until rail pressure is at least 50 psi (345 kPa) below tank pressure. If rail is bled, skip to Step D. c. Let pressure stabilize for 1 minute. d. Open the supply solenoid. e. Read fuel rail pressure and tank pressure. f. Does fuel rail pressure jump to tank pressure? Action Yes — Check is OK. No — Repair the leak in the fuel supply line. Page 31 TROUBLESHOOTING 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 P116E code is set. While this Step 1 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. Procedure Measure tank pressure and tank surface temperature. Is tank pressure more than 15 psi (103 kPa) over expected tank pressure? Action 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 1 Procedure Verify the following: a. b. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.) Is the tank supply manual shutoff valve fully OPEN? c. Is battery voltage above 10 volts? Action Yes — Go to Step 2. No — Correct fault and retry. 2 Check for diagnostic trouble codes (DTC). Are any codes present? Yes — Go to Step 3. No — Go to Step 4. 3 Is the DTC identified on the ROUSH liquid propane autogas DTC list? Yes — Refer to Diagnostic Trouble Code List. No — Refer to the Ford service manual DTC chart. 4 Check fuel pressure. Yes — Go to Step 11. No — Go to Step 5. a. Page 32 b. Measure and record fuel rail pressure and fuel tank pressure at Key ON Engine OFF (KOEO). While monitoring fuel pressure, attempt to start engine. c. Record the highest pressure observed. d. Does fuel pressure rise 20 psi (138 kPa) before engine crank? TROUBLESHOOTING Step 5 Procedure Check fuel pump operation. a. 6 b. 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. 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 2 amps should be recorded on both fuel pump circuits. a. Do fuel pumps draw current? Check XFV. a. b. Turn OFF engine. Wait 1 minute and then restart engine. c. Measure and record fuel rail pressure and fuel tank pressure. d. Is problem resolved? Action 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 10. Yes — Go to Step 11. No — Go to Step 7. 7 Check ROUSH FP fuse. Is fuse intact and OK? Yes — Go to Step 8. No — Determine the cause of the short and repair; replace the fuse. 8 Check the TS and SS fuses. Yes — Determine the cause of the short and repair; replace the fuse. No — Go to Step 9. 9 a. b. Locate the TS fuse (E3-E4) and check its condition. Locate the SS fuse (F1-F2) and check its condition. c. Are the fuses blown? Verify that there is power and grounding in the TS and SS wiring circuits. a. 10 b. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure. Is +12 volts present at the TS connector? c. Is +12 volts present at the SS connector? Verify that there is power and grounding in the wiring circuit to the tank. a. b. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. Is +12 volts present at the FP1 connector? c. Is +12 volts present at the FP2 connector? 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 12. No — Check for an open/short in the wiring circuit and repair. 11 Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? Yes — Go to Step 12. No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor. 12 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com. — Page 33 TROUBLESHOOTING Fuel System Fails to Bleed Step 1 Procedure Check for diagnostic trouble codes (DTC). a. 2 3 4 5 Check for oil contamination at vapor port/EVAP line. a. Disconnect EVAP line from vapor port. b. Is oil present in EVAP line or vapor port? Determine if fault condition repeats. a. b. START the engine and allow it to run for a few minutes. 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 15 minutes. f. Does fuel rail pressure drop more than 20 psi (138 kPa)? Verify vapor port function. a. b. Disconnect the EVAP line from the FRPCM port. 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? 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. Is there propane flowing from the port? d. 6 Verify that wiring is in good condition and functioning. a. b. 7 Page 34 Perform wiring checks of the FRPCM harness. Is the wiring OK? Check for a kinked EVAP line. a. b. 8 Are both DTC 26B3 and P009E present? Inspect the EVAP line between the FRPCM and EVAP canister. Are there kinks in the line? Check for leaks to the FRPCM. a. b. START the engine and allow it to run for a few minutes. 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 (345 kPa). Refer to the Manual Solenoid Activation Procedure. e. De-energize bleed solenoid. f. Disconnect the FRPCM and wait 120 minutes. g. Measure fuel rail pressure and fuel tank pressure. h. Does fuel rail pressure rise more than 10 psi (69 kPa)? Action Yes — Go to Step 8. No — Go to Step 2. Yes — Replace vapor port and perform Step 3. No — Go to Step 3. Yes — Potential intermittent fault. Return vehicle to customer and see if problem persists. No — Go to Step 4. Yes — Go to Step 7. No — Go to Step 5. Yes — Replace vapor port and repeat Step 3. No — Go to Step 6. Yes — Bleed solenoid stuck closed. Replace the FRPCM. No — Repair wiring and repeat Step 3. Yes — Replace the kinked EVAP line and then repeat Step 3. 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. TROUBLESHOOTING Fuel Pressure Drop For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. Step 1 2 Procedure Verify the following: a. b. Is there fuel in the tank of at least 1/8 tank? Is the tank supply manual shutoff valve fully open? c. Is battery voltage above 10 volts? Determine fuel pressure. a. b. 3 4 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. b. Turn OFF the engine. Wait one minute and then restart the engine. c. Is the problem resolved? Check fuel pump operation. a. 5 b. 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. 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 2 amps should be recorded on both fuel pump circuits. c. Do fuel pumps draw current? Check tank solenoid (TS) and supply solenoid (SS) fuses. a. b. 6 Measure and record fuel tank pressure. Measure and record fuel rail pressure with Key ON Engine Running (KOER). Locate the TS (E3-E4) and SS (F1-F2) fuses. Are the fuses blown? Verify that there is power and ground in the wiring circuit to the tank. a. b. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure. Is +12 volts present at the FP1 connector? c. Is +12 volts present at the FP2 connector? Action Yes — Go to Step 2. No — Correct the fault condition and retry. Yes — Go to Step 4. No — Go to Step 3. Yes — Refer to the Excess Flow Valve Check procedure. No — Go to Step 4. 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. 7 Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification? See the Integrated Pressure Temperature Sensor Electrical Check procedure. Yes — Go to Step 8. No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor. 8 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com. — Page 35 TROUBLESHOOTING 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, and to the FLIM, 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 resistance or voltage outputs should be used for diagnostic purposes. Symptom Cause/Action to be taken Fuel gauge does not move on a partial fill 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. Malfunction Indicator Lamp (MIL) There is a circuit fault that has been identified by the PCM. 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. Gauge points below E This is an indication of an error state. 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. Doesn’t read full after a fill 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 36 TROUBLESHOOTING Tank Solenoid Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS PBT/ASA-GF20 1 2 32 44 18 29 3 15 6 4 1 5 3 2 4 3 5 1 2 4 3 31 5 30 E D B 44 1 2 3 3 E 1 5 A 2 4 1 FUSE BOX 5 2 4 1 F 1 15 45 46 A1 16 17 F C B A 100070a Figure 1 — Underhood Harness Connectors 2 21 30 A B C A B D C D E F 100071a Figure 2 — Rear Frame Harness Connectors 3 1 9 D C B A A B 100072a Figure 3 — Solenoid Harness Connectors Page 37 TROUBLESHOOTING PROCEDURE Step Procedure Action 1 Unplug the solenoid harness connector 9 from the tank solenoid. Go to Step 2. 2 Using a multimeter, measure resistance of the solenoid. Is the measured resistance within 6–35 ohms? Yes — Go to Step 3. No — Replace the tank solenoid. 3 Using a multimeter, measure voltage at the tank solenoid as follows: Yes — Supply circuit OK. No — Go to Step 4. a. b. With the ignition key ON, check for voltage present at pin-A, connector 9 (solenoid harness). Use the body as the reference ground. Is battery (B+) voltage present? 4 Check fuse (E3-E4, 20A) in auxiliary fuse box. Is fuse blown? Yes — Replace fuse. No — Fuse OK; go to Step 5. 5 Check relay. Is relay functioning properly? Yes — Go to Step 6. No — Replace relay. 6 Check supply circuit continuity from solenoid harness to fuse box. Yes — Go to Step 7. No — Repair supply circuit wiring. a. b. 7 Check ground circuit continuity from solenoid harness to smart relay module (SRM) connector. a. b. Page 38 Check continuity between: 앫 Pin-A, connector 9 and pin-A, connector 1 (solenoid harness) 앫 Pin-A, connector 21 and pin-A, connector 30 (rear wiring harness) 앫 Pin-A, connector 15 and cavity A5, fuse box (underhood harness) Is there good continuity in the circuit? Check continuity between: 앫 Pin-B, connector 9 and pin-B, connector 1 (solenoid harness) 앫 Pin-B, connector 21 and pin-E, connector 30 (rear wiring harness) 앫 Pin-E, connector 15 and pin-44, connector 1 (underhood harness) Is there good continuity in the circuit? Yes — Refer to the Smart Relay Module Electrical Test procedure. No — Repair ground circuit wiring. TROUBLESHOOTING 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 4 30 31 PBT/ASA-GF20 1 2 32 44 29 3 15 5 3 5 2 4 1 46 18 6 4 3 3 5 1 2 4 B 33 1 2 3 3 E 1 5 A 2 4 1 FUSE BOX 5 2 4 1 F F1-F2 45 11 46 A1 16 17 17 F E D C B A 100073a Figure 4 — Underhood Harness Connectors PROCEDURE Step Procedure Action 1 Unplug the fuel rail pressure control module (FRPCM) connector from connector 11 of underhood harness. Go to Step 2. 2 Using a multimeter, check the resistance of each solenoid. Yes — Go to Step 3. No — Replace the FRPCM if resistance for any one of the solenoids is not within the specified range. a. b. 3 Check resistance across the terminals of the FRPCM connector in sequence as follows: 앫 Supply Solenoid — Pin-A and pin-F 앫 Flow Control Solenoid — Pin-B and pin-E 앫 Bleed Solenoid — Pin-C and pin-D Is the measured resistance for each solenoid within 6–35 ohms? Check supply voltage to FRPCM solenoids. Using a multimeter, measure voltage between the terminal for each solenoid at the harness side connector 11 and ground as follows: Go to Steps 4–6. Page 39 TROUBLESHOOTING 4 Supply Solenoid — Pin-A and body ground B+ Voltage — Go to Step 5. No Voltage — Go to Step 5. 5 Flow Control Solenoid — Pin-B and body ground B+ Voltage — Go to Step 6. No Voltage — Go to Step 6 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7. 6 Bleed Solenoid — Pin-C and body ground B+ Voltage — Continue with Step 9. No Voltage — Go to Step 8 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7. 7 Check fuses (F1-F2, 10A) in auxiliary fuse box. Is a fuse blown? Yes — Replace fuse. No — Go to Step 8. 8 Check solenoid supply circuit continuity. Yes — Go to Step 9. No — Repair wiring circuit. a. b. 9 Check solenoid ground circuit continuity. a. b. Page 40 Check continuity between: 앫 Supply Solenoid — Pin-A, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box) 앫 Flow Control Solenoid — Pin-B, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box) 앫 Bleed Solenoid — Pin-C, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box) Is there good continuity in all three circuits? Check continuity in the underhood harness between: 앫 Supply Solenoid — Pin-F, connector 11 and pin-46, connector 1 at SRM 앫 Flow Control Solenoid — Pin-E, connector 11 and pin-33, connector 1 at SRM 앫 Bleed Solenoid — Pin-D, connector 11 and pin-17, connector 1 at SRM Is there good continuity in all three circuits? Yes — Refer to the Smart Relay Module Electrical Test procedure. No — Repair wiring circuit. TROUBLESHOOTING Integrated Pressure Temperature Sensor Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS Figure 5 — Underhood Harness Connectors PROCEDURE Step Procedure Action 1 Unplug the connector 8 (underhood harness) to the IPTS. Go to Step 2. 2 Check resistance of the integrated pressure temperature sensor (IPTS). Yes — Go to Step 3. No — Replace the IPTS. a. b. 3 With vehicle at ambient room temperature (20–30°C, 68–86°F) and using a multimeter, measure resistance across the IPTS terminals (between pin-1 and pin-3). Is the resistance value between 8K–12K ohms? Check circuit continuity between the IPTS and the smart relay module (SRM). a. b. Using a multimeter, check continuity in the underhood harness between: 앫 Pin-1, connector 8 and pin-40, connector 1 앫 Pin-2, connector 8 and pin-7, connector 1 앫 Pin-3, connector 8 and pin-5, connector 1 앫 Pin-4, connector 8 and pin-25, connector 1 Is there good continuity in the circuits? Yes — Refer to the Smart Relay Module Electrical Test procedure. No — Repair circuit wiring. Page 41 TROUBLESHOOTING Fuel Pump Electrical Test For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 5 12 13 24 4 1 8 5 27 B A B A 100075a Figure 6 — Rear Frame Harness Connectors 6 1 2 4A 4B A B A B 100076a Figure 7 — In-Tank Harness Connectors PROCEDURE Step 1 Procedure Check fuel pump circuit continuity. a. 2 3 b. Unplug the FPCM connector 12 for fuel pump 1. Check fuel pump circuit continuity. Using a multimeter, measure resistance between pin-5 and pin-8. c. Is resistance between 0.4–1.0 ohm? Check fuel pump circuit continuity. a. b. Unplug the FPCM connector 13 for fuel pump 2. Using a multimeter, measure resistance between pin-5 and pin-8. c. Is resistance between 0.4–1.0 ohm? Check resistance of each fuel pump. a. b. c. Page 42 Unplug the fuel pump connectors (in-tank harness) at the fuel pump assembly. Using a multimeter, measure resistance for fuel pump 1 across the terminals of the fuel pump. Is resistance between 0.4–1.0 ohm? Action Yes — Go to Step 2. No — Go to Step 3. Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure. No — Go to Step 3. Yes — Go to Step 4. No — Replace fuel pump assembly. TROUBLESHOOTING Step 4 Procedure Check resistance continued. a. b. 5 Using a multimeter, measure resistance for fuel pump 2 across the terminals of the fuel pump. Is resistance between 0.4–1.0 ohm? Check harness circuit continuity from fuel pumps to FPCM. a. b. Check continuity for pump 1, wire FPPWR, V+ across: 앫 Pin-A, connector 4A (in-tank harness) to pin-A, connector 1 (in-tank harness) 앫 Pin-A, connector 24 (rear frame harness) and pin-5, connector 12 (rear frame harness) Check continuity for pump 1, wire FPRTN, V– across: c. 앫 Pin-B, connector 4A (in-tank harness) to pin-B, connector 1 (in-tank harness) 앫 Pin-B, connector 24 (rear frame harness) and pin-8, connector 12 (rear frame harness) Check continuity for pump 2, wire FPPWR, V+ across: d. 앫 Pin-A, connector 4B (in-tank harness) to pin-A, connector 2 (in-tank harness) 앫 Pin-A, connector 27 (rear harness) and pin-5, connector 13 (rear harness) Check continuity for pump 2, wire FPRTN, V– across: e. 앫 Pin-B, connector 4B (in-tank harness) to pin-B, connector 2 (in-tank harness) 앫 Pin-B, connector 27 (rear frame harness) and pin-8, connector 13 (rear frame harness) Is there good continuity in all circuits? Action Yes — Go to Step 5. No — Replace fuel pump assembly. Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure. No — Repair circuit wiring. Page 43 TROUBLESHOOTING 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 7 E4 F A5 3 F C 2 4 5 1 5 6 4 3 3 5 1 2 4 B A 2 4 2 3 3 E 1 5 5 1 15 1 2 4 D FUSE BOX Figure 8 — Underhood Harness Connectors 8 12 13 27 1 4 4 1 5 8 8 5 30 A B C D E F A B 41 A B 100078a Figure 9 — Rear Frame Harness Connectors Page 44 D C B A 100077a A3 1 E TROUBLESHOOTING 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 www.motorcraft.com. 1 2 Check Ford FPCM circuit continuity to Ford harness. a. b. Disconnect rear frame harness connectors 1 and 12. Check for continuity in the rear frame harness across: c. 앫 Pin-1, connector 1 and pin-1, connector 12 앫 Pin-3, connector 1 and pin-3, connector 12 앫 Pin-4, connector 1 and pin-4, connector 12 앫 Pin-5, connector 1 and pin-5, connector 12 앫 Pin-6, connector 1 and pin-6, connector 12 앫 Pin-7, connector 1 and pin-7, connector 12 Is there good continuity in each circuit? Check FPCM circuit continuity to Ford harness. a. b. Disconnect rear frame harness connector 13. Check wire VPWR (V+) for continuity across: c. 앫 Pin-1, connector 13 (rear frame harness) and pin-A, connector 30 (rear frame harness) 앫 Pin-A, connector 15 (underhood harness) and cavity-A5, fuse box (underhood harness) 앫 Cavity-A3, fuse box (underhood harness) and cavity-E4, fuse box (underhood harness) Is there good continuity in each circuit? Yes — Go to Step 2. No — Repair circuit wiring. Yes — Go to Step 3. No — Repair circuit wiring. 3 Check fuse condition (E3-E4). Is the fuse blown? Yes — Replace the fuse. No — Go to Step 4. 4 Check Roush CleanTech FPCM circuit continuity to Ford harness. Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service a. Check for continuity in the rear frame harness across: Manual for functional testing of the FPCM. 앫 Pin-A, connector 30 and pin-1, connector 13 No — Repair circuit wiring. 앫 Pin-4, connector 1 and pin-4, connector 13 앫 Pin-A, connector 27 and pin-5, connector 13 앫 Pin-6, connector 1 and pin-6, connector 13 앫 Pin-B, connector 27 and pin-8, connector 13 앫 Pin-A, connector 41 and pin-7, connector 13 b. Is there good continuity in each circuit? Page 45 TROUBLESHOOTING Smart Relay Module Electrical Test For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 9 E1-E2 31 4 5 3 2 E 1 6 1 3 5 2 4 1 F FUSE BOX 1 3 PBT/ASA-GF20 5 2 4 3 5 1 31 1 2 32 44 18 29 3 15 45 46 A1 16 17 B 2 4 3 5 A 2 4 1 30 100079a 2 Figure 10 — Underhood Harness Connectors 10 5 9 7 1 A C D 14 8 F 100080a Figure 11 — CAN Harness Connectors PROCEDURE Step Procedure Action 1 Disconnect the smart relay module (SRM) connector 1 (underhood harness). Go to Step 2. 2 Check for battery voltage (B+) to the SRM. Yes — Go to Step 5. No — Go to Step 3. a. b. 3 Check for battery voltage (B+) to the SRM. a. b. Page 46 Using a multimeter, check for B+ voltage at cavity 2, connector 1. Use a body ground for reference. Is there voltage (B+)? Check circuit continuity between cavity 2, connector 1 and cavity E2, auxiliary fuse box. Is there good continuity in the circuit? Yes — Go to Step 4. No — Repair circuit wiring. TROUBLESHOOTING Step 4 Procedure Check for battery voltage (B+) to the SRM. a. b. 5 Check the SRM ground circuit for continuity. a. b. 6 b. Check condition of fuse (F5-F6, 5A) in auxiliary fuse box. Is fuse blown? E-Series Only: Check CAN harness for SRM circuit continuity. a. b. 9 Using a multimeter, check the underhood harness for continuity in the E-Series system between pin-26, connector 1 and pin-A, connector 23 and in F-Series system between pin-26, connector 1 and pin-1, connector 51/55. Is there good continuity in the circuit? Check fuse. a. b. 8 Using a multimeter, check ground at cavity 31, connector 1 (underhood harness). Use a body ground for reference. Is there good continuity? Check for active signal to SRM. a. 7 Check condition of SRM power fuse (E1-E2, 25A) in the auxiliary fuse box. Is fuse blown? Check continuity between pin-A, connector 9 and pin-12, connector 5. Is there good continuity in the circuit? Check CAN and underhood harness continuity. a. Check CAN-H(+) continuity across: 앫 Pin-28, SRM connector 1 (underhood harness) and pin-C, connector 23 (underhood harness) Action Yes — Replace fuse. No — Go to Step 5. Yes — Go to Step 6. No — Repair circuit wiring. Yes — E-Series: Go to Step 8, F-Series: Go to Step 9. No — Go to Step 7. Yes — Replace fuse. No — Repair circuit wiring Yes — Go to Step 9. No — Repair circuit wiring. Yes — Go to Step 10. No — Repair circuit wiring. 앫 Pin-C, connector 9 (CAN harness) and pin-2, connector 5 (CAN harness) b. 10 Is there good continuity in the circuits? Check CAN and underhood harness continuity. a. Check CAN-H(−) continuity across: 앫 Pin-43, SRM connector 1 (underhood harness) and pin-B, connector 23 (underhood harness) 앫 Pin-B, connector 9 (CAN harness) and pin-3, connector 5 (CAN harness) b. Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the CAN bus. No — Repair circuit wiring. Is there good continuity in the circuits? Page 47 TROUBLESHOOTING Fuel Level Sender Electrical Check For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 11 1 15 30 31 PBT/ASA-GF20 1 2 32 44 18 29 3 15 45 46 A1 16 17 3 F E Figure 12 — Underhood Harness Connectors 12 21 30 A B C A B C D D E 100082a Figure 13 — Rear Frame Harness Connectors 13 1 6 A D C B A B 100083a Figure 14 — Solenoid Harness Connectors Page 48 F D C B A 100081a TROUBLESHOOTING PROCEDURE Step Procedure Action For fuel level sender (FLS) functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes. 1 2 3 4 5 Check resistance in FLS circuit wiring. a. b. Disconnect the SRM connector 1 (underhood harness). Using a multimeter, measure the resistance between pin-3 and pin-40 of the harness connector. c. Is resistance between 24–260 ohms? Check resistance of the FLS. a. b. Disconnect the FLS connector 6 (solenoid harness). Using a multimeter, measure the resistance across the FLS connector pins. c. Is resistance between 24–260 ohms? Check circuit wiring continuity between FLS connector and SRM connector. a. b. Disconnect connector 1 of the solenoid harness. Check continuity between pin-B, connector 6 (solenoid harness) and pin-C, connector 1 (solenoid harness). c. Is there good continuity in the circuit? Check circuit wiring continuity between FLS connector and SRM connector. a. b. Disconnect connector 30 of the rear frame harness. Check continuity between pin-C, connector 21 (rear frame harness) and pin-D, connector 30 (rear frame harness). c. Is there good continuity in the circuit? Check circuit wiring continuity between FLS connector and SRM connector. a. b. 6 b. 7 b. 8 b. Yes — Go to Step 5. No — Repair circuit wiring. Yes — Go to Step 6. No — Repair circuit wiring. Yes — Go to 7. No — Repair circuit wiring. Yes — Go to Step 8. No — Repair circuit wiring. Check continuity between pin-D, connector 21 (rear frame harness) and pin-C, connector 30 (rear frame harness). Is there good continuity in the circuit? Check circuit wiring continuity between FLS connector and SRM connector. a. Yes — Go to Step 4. No — Repair circuit wiring. Check continuity between pin-A, connector 6 (solenoid harness) and pin-D, connector 1 (solenoid harness). Is there good continuity in the circuit? Check circuit wiring continuity between FLS connector and SRM connector. a. Yes — Go to Step 3. No — Replace the FLS. With SRM connector 1 and connector 15 of the underhood harness disconnected, check continuity between pin-C, connector 15 and pin-3, SRM connector 1. Is there good continuity in the circuit? Check circuit wiring continuity between FLS connector and SRM connector. a. Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure. No — Go to Step 2. Check continuity between pin-D, connector 15 (rear frame harness) and pin-40, SRM connector (underhood harness). Is there good continuity in the circuit? Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure. No — Repair circuit wiring. Page 49 TROUBLESHOOTING Fuel Level Interface Module Electrical Test For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTORS 14 15 1 35 37 30 31 PBT/ASA-GF20 1 2 32 44 18 29 3 15 2 45 30 A B C D E F 46 A1 16 9 17 B A C D 100084a Figure 15 — Underhood Harness Connectors 100085a Figure 16 — Rear Frame Harness Connectors PROCEDURE Step Procedure Action For FLIM functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes. 1 2 Check FLIM circuit wiring for continuity to SRM. a. b. Disconnect underhood harness connector 1 to SRM. Check underhood harness continuity between pin-A, connector 35 and pin-26, connector 1. c. Is there good continuity in the circuit? Check FLIM circuit wiring for continuity to SRM. a. b. 3 Check FLIM circuit wiring for continuity to SRM. a. b. 4 5 Page 50 Check underhood harness continuity between pin-B, connector 35 and pin-37, connector 1. Is there good continuity in the circuit? Check underhood harness continuity between pin-C, connector 35 and body ground. Is there good continuity in the circuit? Check FLIM circuit wiring for continuity to SRM. a. b. Disconnect underhood harness connector 15 to rear frame harness. Check underhood harness continuity between pin-D, connector 35 and pin-F, connector 15. c. Is there good continuity in the circuit? Check FLIM circuit wiring for continuity to SRM. a. b. Disconnect rear frame harness connector 9 to Ford harness. Check rear frame harness continuity between pin-F, connector 30 and pin-2, connector 9. c. Is there good continuity in the circuit? Yes — Go to Step 2. No — Repair circuit wiring. Yes — Go to Step 3. No — Repair circuit wiring. Yes — Go to Step 4. No — Repair circuit wiring. Yes — Go to Step 5. No — Repair circuit wiring. Yes — Refer to the Smart Relay Module Electrical Test procedure. No — Repair circuit wiring. TROUBLESHOOTING Manual Solenoid Activation Procedure For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics. CONNECTOR 16 17 33 30 31 PBT/ASA-GF20 1 2 FLOW CONTROL SOLENOID 46 32 44 18 29 3 15 45 A1 16 FUEL SUPPLY SOLENOID BLEED SOLENOID 46 17 17 100351a BLEED/ VAPOR PORT Figure 17 — Connector End View 100108c Figure 18 — FRPCM Solenoid Locations PROCEDURE Step Procedure Action 1 Disconnect the smart relay module (SRM) wire harness connector at the SRM. — 2 Energize the individual solenoids on the FRPCM by providing a ground to the following pins in the SRM connector: — • Pin 17 – Bleed Solenoid • Pin 33 – Flow Control Solenoid • Pin 46 – Supply Solenoid Page 51 WIRING DIAGRAMS AND SCHEMATICS WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS Page 52 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-150/250/350 Wiring Harnesses and Connector Layout APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS 8 5 1 11 27 GND R1 GND R2 23 9 35 1 PASS THRU 15 30 47 41 9 UNDER BODY LPA FUEL TANK 6 4A 7 9 4B GND 4 1 1 27 24 21 13 12 1 UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS IN-TANK HARNESS SOLENOID HARNESS Page 53 100129a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-150/250/350 Extended Range Wiring Harnesses and Connector Layout IN-VEHICLE LPA FUEL TANK 6 4A 7 9 4B 8 5 1 11 27 GND R1 GND R2 23 9 PASS THRU 35 1 15 30 9 GND 4 1 1 13 16 9 APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS 13 12 1 47 41 1B 1A 4 27 24 21 GND UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS IN-TANK HARNESS SOLENOID HARNESS IN-BED FUEL TANK JUMPER 100152a Page 54 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-450 Custom Body Wiring Harnesses and Connector Layout APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS 8 5 1 11 27 GND R1 GND R2 23 9 PASS THRU 35 1 15 30 47 41 1 12 13 GND AFT-AXLE LPA FUEL TANK 6 4A 7 9 4B 4 1 1 27 24 21 UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS IN-TANK HARNESS SOLENOID HARNESS IN-BED FUEL TANK JUMPER Page 55 100153a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS GND R2 1 8 4A 4B 1 13 12 * GND 1B 1A 4 27 24 21 GND 6 15 30 9 4 11 1 4 1 16 13 9 5 1 51 55 35 PASS THRU 9 23 9 7 + – GND R1 6 BATTERY IN-BED LPA FUEL TANK 27 1 47 41 UNDERHOOD HARNESS CAN HARNESS *FTPT Harness depends upon the Ford Fuel Tanks REAR FRAME HARNESS IN-TANK HARNESS SOLENOID HARNESS IN-BED FUEL TANK JUMPER FTPT JUMPER HARNESS 100187a Page 56 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650 Chassis Cab Wiring Harness and Connector Layout APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS FB C4 C3 C3 C1 C2 BATTERY G1 C19 C7 C6 C8 C9 C13 C13 UNDERHOOD HARNESS IN-TANK HARNESS TANK SOLENOID HARNESS FUEL TANK JUMPER HARNESS CAN HARNESS IN-TANK HARNESS (LH AND RH) 1 FUEL PUMP #1 INLINE 2-PIN 4 FUEL PUMP #2 INLINE 2-PIN 7 GROMMET UNDERHOOD HARNESS C3 UNDERHOOD/CAN INLINE CONNECTOR 2-PIN C4 SRM 46-PIN 7 T2 – T3 C11 1 C13 C13 C12 4 C19 T4 C11 1 C12 4 T1 C15 C14 C10 C16 C15 C14 C5 Page 57 + C18 C18 7 UNDERHOOD HARNESS (CONT.) C5 IPTS 4-PIN C6 FRPCM 6-PIN C7 FLIM 4-PIN C8 FORD EFPR 8-PIN C9 RCT EFPR 8-PIN C10 TO FORD INLINE CONNECTOR 8-PIN C11 UNDERHOOD/IN-TANK FP#1 INLINE (LEFT TANK) 2-PIN C12 UNDERHOOD/IN-TANK FP#2 INLINE (LEFT TANK) 2-PIN C13 TANK SOLENOID INLINE CONNECTOR (LEFT TANK) 4-PIN C14 UNDERHOOD/FUEL TANK JUMPER INLINE CONNECTOR 2, 4-PIN UNDERHOOD HARNESS (CONT.) C15 UNDERHOOD/FUEL TANK JUMPER INLINE CONNECTOR 1, 4-PIN C16 UNDERHOOD/FUEL PUMP AND SENDER INLINE CONNECTOR 4-PIN FB AUX FUSE BOX T1 PWR #1 RING TERMINAL T2 PWR #2 RING TERMINAL T3 GROUND RING TERMINAL T4 TERMINAL INSERTED IN SPLICE PACK TANK SOLENOID HARNESS (LH AND RH) C13 UNDERHOOD/TANK SOLENOID INLINE CONNECTOR 4-PIN C18 SUPPLY VALVE SOLENOID 2-PIN C19 FUEL SENDER 2-PIN FUEL TANK JUMPER HARNESS C11 FUEL TANK JUMPER/IN-TANK INLINE 1 (RIGHT TANK) 2-PIN C12 FUEL TANK JUMPER/IN-TANK INLINE 2 (RIGHT TANK) 2-PIN C13 FUEL TANK JUMPER/TANK SOLENOID INLINE (RIGHT TANK) 4-PIN C14 FUEL TANK JUMPER/UNDERHOOD INLINE 2, 4-PIN C15 FUEL TANK JUMPER/UNDERHOOD INLINE 1, 4-PIN CAN HARNESS C1 BODY MODULE 12-PIN C2 TO FORD HARNESS CONNECTOR 12-PIN C3 CAN/UNDERHOOD IN-LINE CONNECTOR 2-PIN G1 GROMMET 100254a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-450/550 Roush Wiring Harnesses (Note: This wiring harness print does not include the attachment locations for the ROUSH CleanTech tank jumper harness to the rear chassis harness.) TO ROUSH FPCM MODULE FUEL PUMP CONTROL MODULE 2 SRM TO IPTS TO FORD FPCM MODULE FUEL PUMP CONTROL MODULE 1 TO SOLENOID MODULE BATTERY POSITIVE UNDERHOOD HARNESS TO FLM REAR CHASSIS HARNESS FUSE BOX TO FORD FUEL PUMP HARNESS CONNECTOR TO REAR FRAME HARNESS MODULE GROUND TO ROUSH UNDERHOOD HARNESS FRAME GROUND TO FUEL TANK 1 PWR SYSTEM GROUND TO REAR FRAME HARNESS TO ROUSH UNDERHOOD HARNESS TO CAN HARNESS TO FORD AUX ENGINE INLINE MODULE TO FORD HARNESS FORD HARNESS CONNECTOR CONNECT TO FORD HARNESS FPCM TO FUEL TANK SENDER SOLENOID TO FUEL TANK 2 PWR CAN HARNESS TRAILER BRAKE MODULE CONNECTOR (IF EQUIPPED) TO ROUSH HARNESS TO ROUSH HARNESS FUEL TANK JUMPER HARNESS TO ROUSH HARNESS TO ROUSH HARNESS TO ROUSH HARNESS TO ROUSH HARNESS 100257a Page 58 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650 Chassis Cab, Roush Wiring Harnesses BODY MODULE (12-PIN) C1 CAN HARNESS CAN/UNDERHOOD INLINE CONNECTOR (2-PIN) C3-F TANK JUMPER HARNESS UNDERHOOD/ FUEL TANK JUMPER INLINE CONNECTOR C15 FUEL TANK JUMPER/ IN-TANK INLINE 2 (RH TANK) C12-M FORD EFPR C8 FORD HARNESS CONNECTOR (12-PIN) C2 GROMMET SRM C4 IPTS C5 UNDERHOOD/ FUEL TANK JUMPER INLINE CONNECTOR C14 ROUSH EFPR C9 FRPCM C6 UH/CAN Inline C3 IN-TANK INLINE 1 (RH TANK) C11-M UH/FORD Inline C10 FUEL TANK JUMPER/ TANK SOLENOID INLINE (RH TANK) C13-F UH/TANK JUMPER Inline 1 C15 UH/TANK JUMPER Inline 2 C14 FLIM C7 FUSE_BOX UH/TANK SOLENOID INLINE C13 (LH TANK) UNDERHOOD HARNESS GND-BATT A A R_PWR_1 R_PWR_2 C4-M C4-F FUEL SENDER (4-PIN) C19 A B UH/FORD INLINE C16 UH/IN-TANK INLINE 2 (FUEL PUMP) C12 (LH TANK) UH/IN-TANK INLINE 1 (FUEL PUMP) C11 (LH TANK) B TO SPLICE PACK (PIN D) TERMINAL Page 59 TANK SOLENOID/ UNDERHOOD INLINE (4-PIN) C13-M TANK SOLENOID HARNESS (LONG AND SHORT TANKS) A SUPPLY VALVE SOLENOID (2-PIN) C18 100255a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-53/59 Roush Wiring Harnesses Page 60 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Underhood Harness PWR_W 30 18 2 Connector E2 F6 F4 FUSE 5 FUSE 6 F3 F2 FUSE 3 FUSE 4 D5 26 29 1 E4 F3 F4 E6 F6 5A F6 3 4 SRM_PWR_1 IPTS_PWR F3 20A E3 2 46 F2 F1 D D4 D1 FUSE 1 FUSE 2 RELAY D E C KEY_PWR_2 D2 F1 25 44 F B A SUPPLY_SOL E1 F5 40 28 BLEED_SOL A4 A1 B1 E3 D3 F5 A5 43 37 TO SOLENOID MODULE TO IPTS FLOW_CNTL_ SOL E4 A3 20 36 3 SUPPLY_SOL_RTN E5 B4 17 35 2 FLOW_CNTL_SOL_RTN B5 15 34 1 TO SRM 11 8 4 17 F2 10A E5 A2 B2 B3 PWR_W_3 7 33 16 Connector BLEED_SOL_RTN C4 C1 E6 RELAY A RELAY B C2 S4 SRM_PWR E2 E1 5 1 IPTS_TEMP_OUT RELAY C PWR_W_2 15 3 Connector Connector IPTS_GND PWR_W_1 3 31 S5 F1 25A 2 46 A1 PWR_W_6 27 ELECTRICAL CENTER (FUSE BOX) C5 45 29 PBT/ASA-GF20 1 C3 44 32 31 IPTS_PRES_OUT PWR To Battery Positive RELAY A Normally Open 12V/20A Relay A3 A5 A2 A4 A1 S1 SOLENOID_PWR SRM_PWR_2 A Connector FG_RTN_SRM FG_RTN C R2 FRAME GROUND (GND_R2) D FG_SND F TANK_SOL_RTN FL_RTN_2 S3 35 B TO FUEL LEVEL BLACK BOX Connector 15 E FL_RTN_1 D FL_SND C VPWR_RI TO REAR FRAME HARNESS B VPWR_RO A Connector R1 GND3 GND1 S2 GND2 B PLUG FPM_2 A LAMP_RTN_1 PLUG FRAME GROUND (GND_R1) PLUG CAN-H_1(+) CAN-H_1(-) KEY_PWR_1 47 TO REAR FRAME HARNESS F E D C B A Connector 23 TO CAN HARNESS 100130c Page 61 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness 7 1 Connector 5 14 8 7 13 12 4 11 3 10 2 9 CONNECT TO FORD HARNESS CONNECTOR C2142 1 8 FUSE_33_2 14 5 6 D C 1 FUSE_18 CAN-H(+)_1 F E D C B A Connector 9 CONNECT TO ROUSH UNDERHOOD HARNESS A 1 8 2 PLUG 9 CAN-H(-)_1 PLUG 3 BRK_PED_POS PLUG 10 4 CAN-H(+)_2 GND CAN-H(-)_2 KEY_PWR_1 FUSE_33_1 11 5 12 6 S1 F 8 13 TOW_BRK 7 14 Connector 7 14 1 CONNECT TO TRAILER BRAKE MODULE 100131b Page 62 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Rear Frame Harness 2 5 3 4 8 5 6 7 ENS_2 1 SHIELD_3 7 GND_2 6 PLUG 5 FPC_2 8 VPWR_2 4 GND_3 PLUG 8 5 3 FPC_3 VPWR_P2 2 TO FORD FPCM MODULE (FUEL PUMP CONTROL MODULE)_1 8 PLUG FPM_2 FPM_1 PLUG 7 ENS_1 S4 30 6 GND_1 2 PLUG VPWR_RI VPWR_1 CONNECT TO FORD HARNESS FPCM 1 S1 VPWR_RI 4 S5 B C 3 S2 VPWR_RO 1 4 FPC_1 8 A Connector 5 PLUG S3 1 B Connector Connector 5 A 1 12 1 TO ROUSH UNDERHOOD HARNESS 4 13 8 41 TO ROUSH UNDERHOOD HARNESS 1 SHIELD_4 Connector 4 Connector ENS_3 TO ROUSH FPCM MODULE (FUEL PUMP CONTROL MODULE)_2 D S6 SHIELD_5 E C B FG_SND 2 A B SHIELD_1 A_FPPWR_1 A Connector 21 PLUG PLUG PLUG 3 A_FPRTN_1 A B 4 SHIELD_2 A_FPRTN_2 FRAME GROUND (SHIELD) A_FPPWR_2 A_SOL_1 A_SOLRTN_1 A_FLS_1 D A_FLSRTN_1 F Connector 1 Connector 27 TO FUEL TANK_SENDER_SOLENOID TO FUEL_TANK_2_PWR 24 TO FUEL_TANK_1_PWR Connector 9 CONNECT TO FORD HARNESS FUEL PUMP MODULE Page 63 100132b WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-Series, Extended Range and E-450, E-450 Stripped Chassis, F-53/59, F-250/350, F-450/550/650 Electrical Schematic — In-Tank Harness IN-TANK HARNESS PASS THRU 1 A B A B INLINE FUEL PUMP-1 (V+) INLINE FUEL PUMP-1 (V-) FUEL PUMP-1 (V+) FUEL PUMP-1 (V-) INLINE FUEL PUMP-2 (V+) FUEL PUMP-2 (V+) INLINE FUEL PUMP-2 (V-) FUEL PUMP-2 (V-) A PUMP-1 B 4A A B 4B PUMP-2 2 100133b Page 64 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness 9 CONNECT TO THE REAR HARNESS CONNECT TO TANK SOLENOID 1 A B A SUPPLY SOLENOID V+ B SUPPLY SOLENOID V- C FUEL LEVEL SENDER V- B D FUEL LEVEL SENDER V+ A CONNECT TO FUEL LEVEL SENDER 6 100134b Page 65 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-450 Stripped Chassis CAN Harness B F D C A A C2-F C D E F CAN-H (-) CAN-H (+) KEY_PWR PLUG PLUG PLUG SP1 VDB05C VDB05A SP2 VDB04C VDB04A SP3 CBB80C CBB80A VDB05B VDB04B CBB80B CAN-H (-) CAN-H (+) KEY_PWR CAN-H (-) CAN-H (+) KEY_PWR 1 2 1 3 1 1 3 3 3 4 4 6 5 6 2 4 C1-F 4 6 C1-M 5 6 CAN-H (-) CAN-H (+) KEY_PWR CAN-H (-) CAN-H (+) KEY_PWR VDB05D VDB04D CBB80D PIN-34 PIN-21 PIN-23 100262a Page 66 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-250/350 Pickup, F-450/550 Electrical Schematic — CAN Bus Jumper Harness Connector 5 CONNECT TO FORD HARNESS CONNECTOR C2142 7 14 5 6 13 12 4 11 3 10 1 2 9 8 FUSE_18 PASS-THROUGH F PLUG E PLUG D PLUG C CAN-H(+)_2 B A CAN-H(+)_1 9 3 BRK_PED_POS 10 4 GND CAN-H(-)_2 FUSE_33 PLUG 11 5 12 6 13 TOW_BRK CONNECT TO ROUSH UNDERHOOD HARNESS 8 2 9 CAN-H(-)_1 GROMMET Connector 1 7 14 CONNECT TO TRAILER BRAKE MODULE Connector 1 100189a Page 67 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-450 Stripped Chassis, F-53/59, F-250/350 Pickup, F-450/550 and F-650 Electrical Schematic — Tank Solenoid 9 CONNECT TO REAR FRAME HARNESS CONNECT TO TANK (FUEL SUPPLY) SOLENOID 1 A A SUPPLY SOLENOID V+ B SUPPLY SOLENOID V- C D FUEL LEVEL SENDER VFUEL LEVEL SENDER V+ B B A CONNECT TO FUEL LEVEL SENDER 6 FUEL LEVEL SENDER CONNECTOR FROM TANK 100191a Page 68 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E-450 Extended Range, F-250/350 Pickup Electrical Schematic — In-Bed Fuel Tank Jumper Harness CONNECT TO TANK SOLENOID HARNESS Connector 16 CONNECT TO REAR FRAME HARNESS PUMP_1 Connector A 1A B FUEL_PUMP_1_PWR A FUEL_PUMP_1_RTN B FUEL_PUMP_2_PWR A FUEL_PUMP_2_RTN B SHIELD_1 SHIELD_3 SHIELD_2 Connector 1B A S1 B Connector CONNECT TO REAR FRAME HARNESS 13 FRAME GROUND (SHIELD) PUMP_2 CONNECT TO TANK SOLENOID HARNESS D C B A FUEL_LEVEL _SENDER RETURN TANK (FUEL SUPPLY) SOLENOID _RETURN TANK (FUEL SUPPLY) SOLENOID_POWER D C B A Connector Connector 4 9 CONNECT TO REAR FRAME HARNESS Page 69 FUEL_LEVEL _SENDER POWER CONNECT TO TANK SOLENOID HARNESS 100192a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-250/350 Pickup Electrical Schematic — FTPT Jumper Harness 3 2 1 FTP_REF FTP_REF SIGRTN SIGRTN FTP FTP 3 2 1 r Connector Connector 1 4 VERSION DEPENDS ON TANK CONFIGURATION CONNECT TO FTPT CONNECT TO FORD HARNESS (14405) C B A FTP_REF SIG_RTN FTP FTP_REF SIG_RTN FTP 3 2 1 Connector 1 Connector 6 CONNECT TO FORD HARNESS (14405) CONNECT TO FTPT 100193a Page 70 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650 CAN Harness 7 12 6 1 1 2 3 4 5 6 7 8 9 10 11 12 MSCAN(-) MSCAN(+) LAPI SBIC PBPS HIP-1 HSCAN(-) HSCAN(+) HIP-2 HIP-3 SCS NOT USED 1909A 1908A SP1909 SP1908 1 2 3 4 5 6 7 8 9 10 11 12 2181 2180 218 450 338 14 1909B 1908B 1045A 1045B 151 ZA100 12 1 7 6 C1_FORD_HARNESS_CONN C1 FORD_Gateway_Module 1909C 1908C A B C3-F Page 71 100261a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650 Fuel Tank Jumper Harness A B C11- M B A B_FPPWR_1 B B_FPRTN_1 C B_FPPWR_2 D B_FPRTN_2 C A D C14- M A B C12- M C15- F A B_SOLPWR A B B_SOLRTN B C B_FLRTN C D B_FLSND D C13_F 100264a Page 72 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-650 Underhood Harness Electrical Schematic BATTERY + R_PWR_1 PWR_W T4 1 C4-F TERMINAL C4-M T1 BATTERY + R_PWR_2 PUMP_PWR 1 T2 SEC_TANK_PUMP_1 SEC_TANK_PUMP_2 ELECTRICAL CENTER (FUSE BOX) RELAY C C5 C2 C1 PUMP_R2 C3 PUMP_PWR_3 C3 S16 B1 GND_12 A2 PWR_W_6 A3 PIN2 E1 F1 PWR_W_2 1 S12 3 FG_SND F3 PUMP_PWR_4 S17 E5 PUMP_PWR_5 FUSE_1_25A F5 FUSE 6 B F4 F3 F2 F5 D2 D5 F1 A FUSE_2_10A FUSE 3 A A FUSE_3_20A FUSE_4_20A A FUSE_5_20A FUSE 4 FUSE 2 RELAY D B PRI_FUEL_TANK B B B DEV432 A FUSE_6_5A B FUSE BOX S8 1 VPWR VPWR_1 2 PLUG 3 FUEL PUMP COMM. A_FPRTN_2 5 FUEL PUMP PWR FUEL PUMP MONITOR FORD_GND_1 ENS_1 S4 ENS_3 8 FUEL PUMP RETURN FPC_1 S5 FORD_GND_3 6 ENS S2 FPC_3 4 GND FPM_1 7 DRAIN_4 C9 ROUSH EFPR VPWR_2 4 GND_1 3 15 31 2 PIN9 PIN12 NOT USED PIN13 NOT USED 13 PIN1 PLUG 1 PIN16 PLUG PIN20 NOT USED FUEL LEVEL SENDER # 1 45 16 PIN21 NOT USED PIN22 NOT USED PIN23 NOT USED PIN24 NOT USED NOT USED NOT USED PIN39 SPARE OUTPUT_2 BLEED SOLENOID SPARE INPUT_3 NOT USED PIN30 PLUG PIN4 NOT USED PIN32 NOT USED PIN42 NOT USED PIN27 NOT USED SPARE OUTPUT_1 NOT USED FUEL LEVEL SENDER # 2 NOT USED FORD CAN+ 24 S1 39 36 BLEED_SOL 17 BLEED_SOL_RTN FLOW_SOL_RTN 29 30 A B C D E F 42 27 D C C SUPPLY_SOL FLOW_CNTL_SOL BLEED_SOL 46 A_FPRTN_1 A_FPPWR_1 DRAIN_3 STERM_1 A A B B C11 PRI FUEL PUMP 1 S6 DRAIN_2 BLEED_SOL_RTN STERM_2 FLOW_CNTL_SOL_RTN SUPPLY_SOL_RTN B PIN2 A PIN1 C12 PRI FUEL PUMP 2 B_SOL_1 B_FLSND IP_TEMP A IP_PRES IP_PWR A_FLRTN FL_RTN 41 45 C8 FORD EFPR GND_4 35 28 A_FPRTN_2 B D C6 FRPCM 4 32 44 PLUG SUPPLY _SOL FLOW_CNTL_SOL A C13 PRIMARY TANK SOLENOID HARNESS 23 43 FORD CANFUEL TANK SOLENOID SUPPLY SOLENOID FL_SND 22 40 XDRG C4 SRM MODULE B 3 21 25 XDRP +5V A A_TANK_SOL 7 FUEL RAIL PRESSURE PIN45 20 19 PIN8 GND 16 5 FUEL RAIL TEMPERATURE PIN41 14 PIN7 8 PLUG KEY ON PWR C7 FUEL LEVEL INTERFACE MODULE 12 33 FLOW CONTROL SOLENOID PWM DUTY CYCLE C FG_RTN S10 9 FUEL GAUGE SENDER SGN B A SRM_PWR_2 18 SPARE INPUT_2 PIN19 D FG_RTN_SRM SRM_PWR_1 DRAIN_1 38 NOT USED NOT USED SPARE INPUT_1 A_FPPWR_2 8 37 2 BATT+ B_FPPWR_B NOT USED 6 GND_4 PIN8 FUEL LEVEL OUTPUT (PWM) STERM_3 FPM_2 11 PIN5 7 PIN3 FUEL PUMP RETURN FUEL PUMP PWR 5 34 NOT USED NOT USED PIN38 8 26 PIN6 PIN6 5 PLUG S9 PIN11 PIN4 6 FUEL PUMP COMM. VPWR 1 31 FUEL PUMP RELAY PIN2 4 PLUG NOT_USED_1 ENS GND 6 EFPR DIAGNOSTIC FEEDBACK PIN1 2 PLUG 3 FUEL PUMP MONITOR 2 WAKE 1 C10 FORD FUEL TANK HARNESS STERM_4 7 GROUND CAN-H(+) CAN-H(-) A B 3 A B C3 CAN SUPP_SOL_RTN 2 4 S3 IP_GND 1 TEMP OUT PRESSURE OUPUT PWR GND C5 IPTS SENSOR B_FLRTN A D D C C B_FPPWR_1 A A B B B_FPPWR_2 C C B_FPRTN_1 B B D D C15 FUEL TANK JUMPER B_SOLRTN FG_RTN D4 D1 FUSE 1 F6 VPWR_P2 NOT_USED_1 A4 A1 E1 DEV434 E6 PUMP_ACTIVE S13 Page 73 E2 F4 PUMP_PWR_6 C16 FORD FUEL TANK HARNESS E3 F2 E3 E4 2 A E2 4 E4 A5 B1 FUSE 5 ENS_2 PLUG E5 A2 A3 B4 A1 VPWR_RI PLUG PIN3 B5 D3 F6 FPC_2 FORD_GND_2 PLUG PIN4 E6 A5 PWR_W_1 PIN1 B3 C4 B3 PUMP_PWR_2 S14 B2 C1 desc B2 PUMP_R1 C5 RELAY_B RELAY_C B5 S11 RELAY A RELAY B C2 PU_AC_2 S15 B_FPRTN_2 C14 FUEL TANK JUMPER S7 GND GND-BATT T3 100269a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-53/59 CAN Harness B F D C A A C2-F C D E F CAN-H (-) CAN-H (+) KEY_PWR PLUG PLUG PLUG SP1 1909C 1909A SP2 1908C 1908A SP3 298C 298A 1909B 1908B 298B CAN-H (-) CAN-H (+) KEY_PWR CAN-H (-) CAN-H (+) KEY_PWR 6 5 6 1 4 4 1 3 3 8 8 5 7 4 5 8 C1-M 8 5 C1-F 7 4 CAN-H (-) CAN-H (+) KEY_PWR CAN-H (-) CAN-H (+) KEY_PWR 1909D 1908D 298D PIN-5 PIN-4 PIN-13 100263a Page 74 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-53/59/250/350/450 Rear Frame Harness Electrical Schematic TO ROUSH FPCM MODULE (FUEL PUMP CONTROL MODULE) 4 TO FORD FPCM MODULE (FUEL PUMP CONTROL MODULE) 1 4 1 Connector Connector 13 12 TO ROUSH UNDERHOOD HARNESS INLINE CONNECTOR 8 1 4 5 8 6 8 7 1 5 2 3 4 5 8 6 7 ENS_2 SHILED_3 GND_2 PLUG FPC_2 VPWR_2 SHILED_4 GND_3 PLUG ENS_3 C FPC_3 VPWR_P2 VPWR_RI B CONNECT TO FORD FPCM HARNESS CONNECTOR PLUG FL_SRTN FPM_1 E ENS_1 F S4 6 PLUG GND_1 S3 S5 FPC_1 1 B Connector 9 4 PLUG 3 PLUG 2 1 D C B A_SOL_1 FRAME GROUND (SHIELD) B A B SHILED_1 A_FPRTN_1 A_SOLRTN_1 A_FLS_1 CONNECT TO FORD FUEL PUMP HARNESS INLINE CONNECTOR A_FLSRTN_1 RING TERMINAL GND A_FPPWR_1 SHIELD_5 S6 SHILED_2 FPM_2 A_FPPWR_2 A A_FPRTN_2 41 4 Connector 2 8 VPWR_1 S1 1 3 PLUG VPWR_RI Connector 5 4 S2 TO ROUSH UNDERHOOD HARNESS INLINE CONNECTOR 8 7 1 D 5 30 3 VPWR_RO A Connector 5 2 A A FG_SND PLUG GRAY BLACK Connector Connector 27 24 Connector 21 TO FUEL TANK JUMPER HARNESS INLINE CONNECTOR Page 75 TO FUEL TANK JUMPER HARNESS INLINE CONNECTORS 100266a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-53/59/250/350/450 Underhood Harness Electrical Schematic PWR_W 44 18 29 3 15 45 46 A1 PBT/ASA-GF20 1 2 16 2 Connector E6 E5 E4 A2 A3 E3 E2 F5 D2 F2 FUSE 3 FUSE 4 F1 D5 D4 28 44 26 29 1 2 4 46 D1 FUSE 1 A2 A4 A1 E4 KEY_PWR_2 D RELAY D PWR_W_6 Connector 51 TO FORD AUX ENGINE INLINE MODULE 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 J1 J9 J2 J10 J3 J11 J4 J12 J5 J13 J6 J14 J7 J15 J8 J16 55 TO FORD HARNESS 12C508 (C1168) S8 J1A SRM_PWR_2 1 FG_RTN_SRM 9 2 FG_RTN 10 F B A S1 SOLENOID_PWR Connector E C A1 = 85 A2 = 86 A3 = 30 A4 = 87A A5 = 87 FUSE 2 11 Initial Print A.A 20111403 SRM_PWR_1 F2 F6 3 RELAY NO CONTACT 20A@14VDC A3 FUSE 5 FUSE 6 F3 37 25 A4 A5 F4 36 40 A1 E1 D3 F6 A5 B1 35 43 BLEED_SOL B4 34 17 Connector TO SOLENOID MODULE FLOW_CNTL_SOL_RTN B5 5A 20A 33 15 IPTS_TEMP_OUT B2 B3 C1 F5 E3 31 10 TO IPTS BLEED_SOL_RTN C4 PWR_W_3 10A KEY_PWR_1 C5 RELAY A RELAY B C2 C3 S4 F1 S5 SRM_PWR E2 3 11 A B C Connector 35 TO FLIM D 4 12 5 13 GND_R2 6 FRAME GROUND 14 FG_SND 7 15 TANK_SOL_RTN 8 S3 FL_RTN_2 16 FL_RTN_1 FL_SND VPWR_RI VPWR_RO F E D C Connector 15 TO REAR FRAME HARNESS B A Connector B FPM_2 S2 GND2 GND3 GND1 RELAY C PWR_W_2 25A 7 3 IPTS_PRES_OUT ELECTRICAL CENTER (FUSE BOX) E1 5 IPTS_GND PWR_W_1 3 8 1 17 2 27 Connector 4 TO SRM SUPPLY_SOL 32 31 FLOW_CNTL_ SOL 1 SUPPLY_SOL_RTN 30 Connector IPTS_PWR PWR To Battery Positive Connector GND PLUG F PLUG E PLUG D CAN-H_1(+) CAN-H_1(-) FRAME GROUND PLUG C B A A 47 TO REAR FRAME HARNESS Connector 23 TO CAN HARNESS 100267a Page 76 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic CONNECT TO IN-TANK HARNESS INLINE CONNECTOR CONNECT TO REAR FRAME HARNESS INLINE CONNECTOR Connector A 1A B FUEL_PUMP_PWR_1 BLACK A 1B 16 B BLACK Connector Connector A FUEL_PUMP_RTN_1 B FUEL_PUMP_PWR_2 A FUEL_PUMP_RTN_2 13 B SHIELD_1 SHIELD_3 SHIELD_2 GRAY CONNECT TO REAR FRAME HARNESS INLINE CONNECTOR Connector S1 Connector GND GRAY CONNECT TO IN-TANK HARNESS INLINE CONNECTOR FRAME GROUND (SHIELD) D Connector 4 C FUEL_LEVEL _RTN B SOLENOID _RTN A SOLENOID_SPLY CONNECT TO REAR FRAME HARNESS INLINE CONNECTOR Page 77 FUEL_LEVEL _SPLY D C B Connector 9 A CONNECT TO TANK HARNESS INLINE CONNECTOR 100268a ©2014 by ROUSH CleanTech. All rights reserved. The information in this publication was accurate and effective at the time the publication was approved for publishing and is subject to change without notice or liability. ROUSH CleanTech reserves the right to revise the information herein and to make changes and discontinue production of described parts at any time.