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Test Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2005 Ford RV Cutaway, 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
  1. AG1 PRELIMINARY DIAGNOSIS 
    • Carry out a visual inspection.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record the freeze frame data.
    • Clear all DTCs.
    • Carry out the KOEO on-demand self-test.

    Are any DTCs retrieved? 

    Yes No
    For DTCs P2122, P2127, P2132, GO to  AG2.
    For DTCs P2123, P2128, P2133, GO to  AG8.
    For DTCs P2138, P2139, P2140, GO to  AG13.
    For DTC P2104, GO to  AG16.    		 UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists.
  2. AG2 DIAGNOSTIC TROUBLE CODES (DTCS) P2122, P2127, AND P2132 
    NOTE: Refer to Figure, Figure and/or Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • APP not seated correctly
      • APP sensor
      • open in signal circuit
      • signal circuit shorted to ground
      • PCM
    • Key ON.
    • Access the APP1, APP2, and APP3 PIDs.
    • Monitor the APP sensor PIDs while applying and releasing the accelerator pedal.

    Do all signal values change when the accelerator is applied and released? 

    Yes No
    UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists. GO to  AG3.
  3. AG3 CHECK THE VREF SENSOR CIRCUITS 
    • Key OFF.
    • Disconnect the APP sensor C2040.
    • Key ON.
    • Measure the voltage between the APP sensor C2040 pins, harness side as follows:
    Vehicle Pin Pin
    F-Super Duty / E-Series 7 1
    Excursion 4 9

    Is the voltage between 4.5 - 5.5 volts? 

    Yes No
    GO to  AG4. REPAIR an open in the VREF or signal return circuit. CLEAR the DTCs. REPEAT the self-test.
  4. AG4 CHECK THE SECONDARY VREF AND SIGNAL RETURN CIRCUITS 
    • Measure the voltage between the APP sensor C2040 pins, harness side as follows:
    Vehicle Pin Pin
    F-Super Duty / E-Series 6 3
    Excursion 5 10

    Is the voltage between 4.5 - 5.5 volts? 

    Yes No
    GO to  AG5. REPAIR an open in the secondary VREF or the signal return circuit. CLEAR the DTCs. REPEAT the self-test.
  5. AG5 CHECK THE APP SENSOR OPERATION 
    • Install a 5 amp fused jumper wire between the APP sensor C2040 pin 7 (F-Super Duty/E-Series) or pin 4 (Excursion), harness side and the suspect APP sensor circuit, harness side.
    • Access the applicable APP PID.

    Is the voltage of the suspect signal circuit between 4.5 - 5.5 volts? 

    Yes No
    INSTALL a new APP sensor assembly. CLEAR the DTCs. REPEAT the self-test. GO to  AG6.
  6. AG6 CHECK THE APP SENSOR SIGNAL FOR AN OPEN 
    • Key OFF.
    • Disconnect the PCM body harness connector.
    • Measure the resistance between the APP sensor suspect signal circuit, harness side and the PCM body harness connector suspect signal circuit, harness side.

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  AG7. REPAIR the open in the suspect APP signal circuit. CLEAR the DTCs. REPEAT the self-test.
  7. AG7 CHECK THE SUSPECT APP SENSOR SIGNAL FOR A SHORT TO GROUND 
    • Measure the resistance between the APP sensor suspect signal circuit, harness side and ground.

    Is the resistance greater than 10,000 ohms? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. REPAIR the short to ground in the suspect APP signal circuit. CLEAR the DTCs. REPEAT the self-test.
  8. AG8 DIAGNOSTIC TROUBLE CODES (DTCS) P2123, P2128, AND P2133 
    NOTE: Refer to Figure, Figure and/or Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • signal shorted to voltage
      • signal return open
      • APP sensor
      • PCM
    • Key ON.
    • Access the APP1, APP2, and APP3 PIDs.
    • Slowly apply and release the accelerator pedal while monitoring the PID values.

    Do all the signal values change when the accelerator is applied and released? 

    Yes No
    UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists. GO to  AG9.
  9. AG9 SIMULATE THE OPPOSITE SIGNAL 
    • Key OFF.
    • Disconnect the APP sensor electrical connector.
    • Key ON.
    • Access the APP1, APP2, and APP3 PIDs.

    Do all PID signal values read 0 volts? 

    Yes No
    GO to  AG12. GO to  AG10.
  10. AG10 CHECK THE APP SIGNAL CIRCUITS FOR A SHORT TO VOLTAGE 
    • Key OFF.
    • Disconnect the PCM body harness connector.
    • Key ON.
    • Measure the voltage of the APP sensor suspect signal circuit, harness side and ground.

    Is the voltage less than 0.2 volts? 

    Yes No
    GO to  AG11. REPAIR the short to voltage in the suspect APP signal circuit. CLEAR the DTCs. REPEAT the self-test.
  11. AG11 CHECK THE APP SIGNAL CIRCUITS FOR A SHORT TO GROUND 
    • Key OFF.
    • Measure the resistance of the APP sensor suspect signal circuit, harness side and ground.

    Is the resistance greater than 10,000 ohms? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. REPAIR the short to ground in the suspect APP signal circuit. CLEAR the DTCs. REPEAT the self-test.
  12. AG12 CHECK THE APP SIGNAL RETURN CIRCUITS FOR AN OPEN 
    • Measure the resistances between the PCM connector, harness side and the APP sensor C2040, harness side as follows:
      Vehicle PCM Connector Pin APP Sensor Connector Pin
      F-Super Duty C1381a 33 C2040 1
      F-Super Duty C1381a 20 C2040 3
      Excursion C1381a 33 C2040 9
      Excursion C1381a 20 C2040 10
      E-Series C176a 33 C2040 1
      E-Series C176a 20 C2040 3

      Are the resistances less than 5 ohms? 

      Yes No
      INSTALL a new APP sensor assembly. CLEAR the DTCs. REPEAT the self-test. REPAIR the open in the signal return circuit in question. CLEAR the DTCs. REPEAT the self-test.
  13. AG13 DIAGNOSTIC TROUBLE CODES (DTCs) P2138, P2139, AND P2140 
    NOTE: Refer to Figure, Figure and/or Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • APP sensor
      • PCM
      • high circuit resistance
    • Clear all the DTCs.
    • Carry out the on-demand self-test.

    Are DTCs P2138, P2139, or P2140 present? 

    Yes No
    GO to  AG14. UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists.
  14. AG14 CHECK THE ACCELERATOR PEDAL ASSEMBLY FOR BINDING 
    • Apply the accelerator pedal slowly to the floor and release.

    Does the accelerator pedal move to the floor and return without binding? 

    Yes No
    GO to  AG15. INSTALL a new APP sensor assembly. CLEAR the DTCs. REPEAT the self-test.
  15. AG15 CHECK THE APP SENSOR SIGNAL VOLTAGE RANGES 
    • Key ON.
    • Access and monitor the APP1, APP2, and APP3 PIDs.
    • Apply the accelerator pedal slowly to the floor and release.
    Pedal Position APP1 APP2 APP3
    Closed Throttle 3.43 - 4.69 1.13 - 1.88 0.64 - 1.28
    Wide Open Throttle (E-Series) 0.73 - 1.28 3.03 - 4.55 2.59 - 3.89
    Wide Open Throttle (F-Super Duty / Excursion) 0.39 - 0.97 3.45 - 4.71 2.95 - 4.10

    Are the PID voltages within the range specified in the table? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. INSTALL a new APP sensor assembly. CLEAR the DTCs. REPEAT the self-test.
  16. AG16 DIAGNOSTIC TROUBLE CODE P2104 
    NOTE: Refer to Figure, Figure and/or Figure for PCM and component connector pin numbers at the beginning of this pinpoint test.
    • Possible causes:
      • APP sensor
      • APP track 2 and 3 circuits shorted
      • PCM
    • Key ON, engine OFF.
    • Access and monitor the APP2 and APP3 PIDs.
    • Slowly apply and release the accelerator pedal while observing the PID voltage values.
    Pedal Position APP2 APP3
    Closed Throttle 1.13 - 1.88 0.64 - 1.28
    Wide Open Throttle (E-Series) 3.03 - 4.55 2.59 - 3.89
    Wide Open Throttle (F-Super Duty / Excursion) 3.45 - 4.71 2.95 - 4.10

    Are the PID voltage values within the range specified in the table? 

    Yes No
    UNABLE to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the fault. REPAIR as necessary. REFER to SYMPTOM CHARTS - 6.0L DIESEL if a driveability concern exists. GO to  AG17.
  17. AG17 CHECK THE APP SENSOR 
    • Key OFF.
    • Disconnect the APP sensor.
    • Measure the resistance between the APP sensor pin 2, component side and the APP sensor pin 8, component side.

    Is the resistance between 2,700 and 6,500 ohms? 

    Yes No
    GO to  AG18. INSTALL a new APP sensor assembly. CLEAR the DTCs. REPEAT the self-test.
  18. AG18 CHECK THE APP SENSOR SIGNAL CIRCUITS 
    • Disconnect the PCM body harness electrical connector.
    • Measure the resistance between the APP sensor pin 2, harness side and the APP sensor pin 8, harness side.

    Is the resistance greater than 10,000 ohms? 

    Yes No
    INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
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