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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> Engine Controls - Self-Diagnostics - EEC-V - CNG, Flex-Fuel & Gasoline >> System Tests >> Test Dd: Fuel Rail Pressure (FRP) Sensor >> Diagnostic Aids

Diagnostic Aids

NOTE: After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST  procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

Perform this test when directed by QUICK TEST. This test is intended to diagnose the following.

FRP SENSOR VOLTAGE-TO-FUEL PRESSURE CONVERSION

Volts Pressure (psi)
Natural Gas Vehicles
4.5 150
4.1 140
3.7 130
3.3 120
2.9 110
2.5 100
2.1 90
1.7 80
1.3 70
0.9 60
0.5 50
0.1 40
0.0 37.5
Except Natural Gas Vehicles
4.5 70
3.9 60
3.4 50
2.8 40
2.2 30
1.6 20
1.1 10
0.5 Zero
NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION  table of fault code setting condition.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P0190  DD11  DD11  DD15
P0191  DD16  DD16  DD16
P0192  DD1  DD1  DD15
P0193  DD7  DD7  DD15
P1168 (Natural Gas)      DD16
P1169 (Natural Gas)      DD16

  1. 1) DTC P0192: Verify DTC With FRP PID

    This DTC indicates FRP voltage signal is less than self-test minimum. Possible causes for this fault are:
    • FRP Signal Is Shorted To SIG RTN Or PWR GND
    • FRP Circuit Is Open
    • Low Fuel Pressure
    • Faulty FRP Sensor
    • Faulty PCM

    Ensure vehicle has fuel (natural gas vehicles). Turn ignition switch to ON position. Using scan tool, access FRP PID from PID/DATA MONITOR & RECORD menu. If PID voltage is less than .2 volt, go to next step (natural gas vehicles) or step  3) (all other models). If PID voltage is .2 volt or more, go to step  13).

  2. 2) Check Fuel Pressure (Natural Gas Vehicles)

    Install fuel pressure gauge. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Start engine and observe fuel pressure. If fuel pressure is more than 50 psi (345 kPa), go to next step. If fuel pressure is 50 psi (345 kPa) or less, go to TEST HB .
    NOTE: Fuel Rail Pressure (FRP) sensor may also be known as Injection Pressure (IP) sensor.

  3. 3) Generate Opposite Signal

    Turn ignition switch to OFF position. Disconnect FRP sensor connector. On CNG vehicles, connect a jumper wire between FRP sensor harness connector FRP SIGNAL and VREF terminals. See Fig 1 or Fig 2 . On all other vehicles, if scan tool communication problem exists, disconnect jumper wire and go to step  24). Turn ignition switch to ON position. Using scan tool, select FRP V PID from PID/DATA MONITOR & RECORD menu. If FRP V PID voltage is more than 4.6 volts, replace FRP sensor. If FRP V PID voltage is 4.6 volts or less, disconnect jumper wire and go to next step.

  4. 4) Measure VREF Voltage

    With FRP sensor disconnected, turn ignition switch to ON position. Measure voltage between VREF terminal and SIG RTN terminal at FRP sensor harness connector. See Fig 1 or Fig 2 . If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, reconnect sensor and go to TEST C .
    Fig 1: Identifying Fuel Rail Pressure (FRP) Sensor Circuits & Connector Terminals (Natural Gas Vehicles)
    G00013253Courtesy of FORD MOTOR CO.
    Fig 2: Identifying Fuel Rail Pressure (FRP) Sensor Circuits & Connector Terminals (All Other Models)
    G99J02112Courtesy of FORD MOTOR CO.

  5. 5) Check FRP Circuit For Open

    Turn ignition switch to OFF position. Leave FRP sensor disconnected. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between of FRP circuit between FRP sensor harness connector terminal and PCM harness connector terminal. See Fig 1 or Fig 2 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in FRP circuit.

  6. 6) Check FRP Circuit For Short To PWR GND Or SIG RTN

    On LS, measure resistance between PCM connector terminals No. C49 and No. C17 (SIG RTN). On all other models, measure resistance between PCM connector terminals No. 63 and No. 91 (SIG RTN). Measure resistance between ground and PCM connector terminal C49 (LS) or terminal No. 63 (all other models). If any resistance reading is 10 k/ohms or less, repair short circuit. If both resistance readings are more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  7. 7) DTC P0193: Check FRP V PID Value

    This DTC indicates FRP voltage signal is more than self-test maximum. Possible causes for this fault are:
    • FRP Signal Is Shorted To VREF Or PWR
    • High Fuel Pressure
    • Faulty FRP Sensor
    • Faulty PCM

    Turn ignition switch to ON position. Using scan tool, select FRP V sensor from PID/DATA MONITOR & RECORD menu. On natural gas vehicles, if PID voltage is more than 4.5 volts, go to step  9). On all other models, if PID voltage is more than 4.8 volts, go to next step. On all models, if PID voltage is not as specified, fault may be intermittent. Go to step  14).

  8. 8) Check Fuel Rail Pressure (FRP) Sensor For Leaks

    Remove vacuum hose from FRP sensor. Inspect sensor and vacuum hose for fuel. If any fuel is present, replace FRP sensor. If no fuel is present, go to step  10).

  9. 9) Check Fuel Pressure (Natural Gas Vehicles)

    Install fuel pressure gauge. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Start engine and observe fuel pressure. If fuel pressure is more than 150 psi (1034 kPa), go to TEST HB . If fuel pressure is 150 psi (1034 kPa) or less, go to next step.

  10. 10) Generate Opposite FRP Signal

    Turn ignition switch to OFF position. Disconnect FRP sensor connector. Connect jumper wire between FRP sensor harness connector FRP and SIG RTN terminals. See Fig 1 or Fig 2 . Turn ignition switch to ON position. Using scan tool, select FRP V PID from PID/DATA MONITOR & RECORD menu. If scan tool communication problem is present, disconnect jumper wire and go to step  24). If FRP V PID voltage is less than .2 volt, replace FRP sensor. If FRP V PID voltage is .2 volt or more, go to step  12).
    11. NOTE: Before performing this step, check for, and repair any fuel system external leaks and verify fuel level.

  11. 11) DTC P0190
    Possible causes for this fault are:
    • VREF Open Circuit
    • VREF Sensor Is Open

    Disconnect FRP sensor connector. Turn ignition switch to ON position. Measure voltage between VREF and SIG RTN terminals at FRP sensor harness connector. If voltage is 4-6 volts, go to step  13). If voltage is not 4-6 volts, go to next step.

  12. 12) Check For Open Circuit

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance of FRP, SIG RTN and VREF circuits between appropriate FRP sensor harness connector terminal and PCM harness connector terminal. See Fig 1 or Fig 2 . If all resistance measurements are less than 5 ohms, go to next step. If any resistance measurement is 5 ohms or more, repair open in affected FRP, SIG RTN or VREF circuit.

  13. 13) Measure FRP Sensor Resistance

    Measure resistance between FRP and SIG RTN terminals at FRP sensor. Measure resistance between FRP and VREF terminals at FRP sensor. If any resistance is not 30,000-40,000 ohms, replace FRP sensor. If both resistance readings are 30,000-40,000 ohms, proceed as follows:
    • If Continuous Memory DTC P0190 is present, go to step  15).
    • If DTC P0192 is present, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    • If DTC P0193 is present, go to next step.

  14. 14) Check FRP Circuit For Short To VREF Or VPWR

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure between PCM harness connector FRP and VREF terminals. See Fig 1 or Fig 2 . Measure resistance between PCM harness connector FRP and VPWR terminals. See PCM VPWR TERMINAL IDENTIFICATION  table. If both resistance measurements are more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If either resistance measurement is 10 k/ohms or less, repair short in affected circuit.
    PCM VPWR TERMINAL IDENTIFICATION

    Application PCM Terminal No.
    Contour, Cougar & Mystique 2.0L A/T 71 & 97
    LS A32 & A33
    All Other Models 71

  15. 15) Check For Intermittent Fault

    Reconnect FRP sensor connector. Turn ignition switch to ON position. Using scan tool, select FRP V PID from PID/DATA MONITOR & RECORD menu. Observe PID voltage for fault while tapping on FRP sensor. Wiggle and bend wiring harness and connector between sensor and PCM. Fault will be indicated by a sudden change in PID voltage. If fault is indicated, isolate and repair as necessary. If fault is not indicated, symptom is intermittent and cannot be located at this time. Go to TEST Z  for additional test procedures.
    16. NOTE: On CNG models, if vehicle is a no-start, go to TEST HB .

  16. 16) KOEO/KOER DTC P0191
    DTC P0191 indicates FRP voltage signal is more than self-test maximum. Possible causes for this fault are:
    • High Fuel Pressure
    • Low Fuel Pressure
    • Excessive Resistance In Circuit
    • Faulty FRP Sensor
    • Low Or No Fuel

    Turn ignition switch to ON position. Ensure vehicle has at 1/8 tank of fuel. Turn ignition switch to OFF position. Release fuel pressure. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Connect pressure gauge to Schrader valve. With engine running, check fuel pressure. Fuel pressure should be within specification. See FUEL PRESSURE SPECIFICATIONS . If fuel pressure is within specification, go to next step. If fuel pressure is not within specification, go to TEST HB  (natural gas vehicles) or TEST HC  (all other models) .

  17. 17) DTC P0191, P1168 & P1169: Check FRP PID Fuel Pressure

    Turn ignition switch to ON position. Using scan tool, select FRP PID from PID/DATA MONITOR & RECORD menu. If PID psi reading is not within 10 psi of fuel pressure gauge psi reading in step  16), go to next step (natural gas vehicles) or step  19) (all other models). If PID psi reading is within 10 psi, proceed as follows:
    • If DTC P1168 or DTC P1169 is not present, repeat QUICK TEST .
    • If DTC P1168 or DTC P1169 is present, clear DTCs. Road test vehicle 3-5 minutes at a steady speed. Stop vehicle and check for Continuous Memory DTCs. If DTC P1168 or DTC P1169 is present, go to next step.

  18. 18) Check Fuel Rail Solenoid

    Using scan tool, access OUTPUT TEST MODE  under ADDITIONAL SYSTEM FUNCTIONS. While observing fuel rail solenoid, cycle output on and off several times. If solenoid clicking can be heard or felt, exit output test mode and go to next step. If no solenoid clicking can be heard or felt, go to step  22.

  19. 19) Measure VREF Voltage

    Disconnect FRP sensor connector. Turn ignition switch to ON position. Measure voltage between VREF terminal and SIG RTN terminal at FRP sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, reconnect sensor and go to TEST C .

  20. 20) Check FRP Circuit For Excessive Resistance

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between FRP terminal at FRP sensor harness connector and PCM connector terminal C40 (LS) or terminal No. 63 (all other models). Measure resistance between SIG RTN terminal at FRP sensor harness connector and PCM connector terminal No. 91 (SIG RTN). Measure resistance between VREF terminal at FRP sensor harness connector and PCM connector terminal C20 (LS) or terminal No. 90 (all other models). If all resistance readings are less than 5 ohms, go to next step. If any resistance reading is 5 ohms or more, repair open circuit.

  21. 21) Monitor FRP Circuit With Scan Tool

    Turn ignition switch to ON position. Using scan tool, select FRP V PID from PID/DATA MONITOR & RECORD menu. If PID voltage is less than .2 volt (natural gas vehicles) or more than 4.8 volts (all other models), replace FRP sensor. If PID voltage is not as specified, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    22. NOTE: When in output test mode, voltage measurement must be made within 7 seconds of activating test mode.

  22. 22) Check Voltage At Fuel Rail Solenoid
    Disconnect fuel rail solenoid connector. Using scan tool, access OUTPUT TEST MODE  under ADDITIONAL SYSTEM FUNCTIONS. Turn all outputs ON. Measure voltage between VPWR circuit terminal (Pink/Black wire) at fuel rail solenoid harness connector and negative battery terminal. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit.

  23. 23) Check Ground Circuit

    Measure resistance between ground circuit terminals at fuel rail solenoid harness connector and negative battery terminal. If resistance is less than 5 ohms, replace fuel rail solenoid. If resistance is 5 ohms or more, repair open circuit.

  24. 24) Check VREF Voltage To FRP Sensor

    Disconnect FRP sensor connector. Turn ignition switch to ON position. Measure voltage between VREF and SIG RTN circuit terminals at FRP sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, VREF is out of range. Go to TEST C .

  25. 25) Check For Shorted FRP Signal

    Disconnect scan tool from Data Link Connector (DLC). Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between PCM harness connector FRP and SIG RTN terminals, between PCM harness connector FRP and VREF terminals, and between PCM harness connector FRP terminal and battery negative terminal. See WIRING DIAGRAMS article. If all resistance measurements are more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If any resistance measurement is 10 k/ohms or less, repair short in affected circuit.
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