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Home >> Ford >> 1996 >> Aerostar Van Window >> Repair and Diagnosis >> External Pages >> Different car >> Section 199 (Engine Controls - Tests W/Codes - 7.3L Diesel - EEC-IV) >> Pinpoint Tests >> Pinpoint Test S: Glow Plugs & Relay >> Diagnostic Aids

Diagnostic Aids

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  1. 1) DTC 0380: Check If Glow Plugs Are On Continuously

    This DTC indicates that PCM has detected a glow plug relay control circuit malfunction. Possible causes for this DTC are:
    • Short to power.
    • Open or grounded circuit.
    • Faulty glow plug relay.
    • Faulty Powertrain Control Module (PCM).

    Disconnect glow plug relay connector. Relay is located on top of engine. Turn ignition on. Measure voltage between ground and Red/Light Green wire at glow plug relay connector. If battery voltage is present, go to next step. If battery voltage is not present, check for blown fuse "U" (Econoline), or fuse No. 22 (Pickup). If fuse is okay, locate and repair open in Red/Light Green wire between power distribution box in engine compartment and glow plug relay. If fuse is blown, locate and repair short to ground in Red/Light Green wire between power distribution box in engine compartment and glow plug relay.

  2. 2) Check Relay Coil Resistance

    Turn ignition off. Measure resistance between glow plug relay terminals "A" (Purple/Orange wire terminal) and "B" (Red/Light Green wire terminal). If resistance is 5-15 ohms, go to next step. If resistance is not 5-15 ohms, replace relay. Clear DTCs, and repeat QUICK TEST .

  3. 3) Check Purple/Orange Wire For Short To Power

    Turn ignition off. Disconnect PCM 104-pin connector, and inspect for damaged pins, corrosion and loose wires. Repair as necessary. Install Breakout Box (014-00950), leaving PCM disconnected. Measure voltage between ground and test pin No. 101 at breakout box. If battery voltage is present, locate and repair short to ground in Purple/Orange wire. Clear DTCs, and repeat QUICK TEST . If battery voltage is not present, go to next step.

  4. 4) Check Purple/Orange Wire For Short To Ground

    Turn ignition off. Measure resistance between ground and Purple/Orange wire at glow plug relay wiring harness connector. If resistance is less than 5 ohms, locate and repair short to ground in Purple/Orange wire. Clear DTCs, and repeat QUICK TEST . If resistance is 5 ohms or more, go to next step.

  5. 5) Check Purple/Orange Wire For Open

    Measure resistance of Purple/Orange wire between glow plug relay wiring harness connector and test pin No. 101 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs, and repeat QUICK TEST . If resistance is 5 ohms or more, locate and repair open in Purple/Orange wire between PCM and glow plug relay connector. Clear DTCs, and repeat QUICK TEST .
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