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Test L: Tonneau Cover Is Inoperative

WARNING: This page is about a different car, the 2002 Lincoln Blackwood. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, right of steering column. Using NGS tester, retrieve continuous DTCs. Clear DTCs. Perform Central Security Module (CSM) self-test. If no DTCs are retrieved, go to next step. If DTCs are retrieved, go to TEST "L" DTC INDEX  table.
    TEST "L" DTC INDEX

    DTC Go To Step
    B2415  31
    B2417  35
    B2418  15
    B2419 or B2420  17
    B2421  12
    B2422  8
    B2423  6
    B2424  37
    B2430  40
    B2542  27
    B2552  11
    B2755, B2757, Or B2748  19
    B2760, B2762, Or B2752  23
    C1123  12
  2. Disconnect tonneau cover control switches C943 and C944. Measure resistance between harness connectors C943 terminal No. 4 and C944 terminal No. 4 (both Black wires). See Fig 1. If each resistance is less than 5 ohms, go to next step. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  3. Disconnect TCM harness connector C4054c. Measure resistance between TCM harness connector C4054c terminal No. 2 (White/Red wire) and harness connectors C943 and C944 terminal No. 3 (Violet wire). Measure resistance between TCM harness connector C4054c terminal No. 3 (Pink/Light Green wire) and harness connectors C943 and C944 terminal No. 3 (Pink/Light Green wire). See Figure and Fig 1 . If each resistance is less than 5 ohms, replace appropriate tonneau cover switch. See TONNEAU COVER CONTROL SWITCHES  under REMOVAL & INSTALLATION. If any resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  4. Disconnect tonneau cover lock-out switch harness connector C3029. Measure resistance between TCM harness connector C4054c terminal No. 2 (White/Red wire) and harness connector C3029 terminal No. 1 (White/Red wire). See Figure. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open in White/Red wire and test system operation.
  5. Measure the resistance between tonneau cover control switch harness connector C943 and C944 terminals No 2 and No. 3 and tonneau cover lock-out switch harness connector C3029 terminal No. 2 (both Violet wires). See Figure and Fig 1 . If each resistance is less than 5 ohms, replace tonneau cover lock-out switch and test system operation. If either resistance is greater than 5 ohms, repair open in Violet wire and test system operation. See WIRING DIAGRAMS .
  6. Disconnect TCM harness connector C4054c. Measure resistance between harness connector C4054c terminal No. 3 (Pink/Light Green wire) and ground. See Figure. If resistance is greater than 10 k/ohms, go to step  45. If resistance is less than 10 k/ohms, go to next step.
  7. Disconnect tonneau cover switch harness connectors C943 and C944. Measure resistance between harness connector C4054c terminal No. 3 (Pink/Light Green wire) and ground. See Fig 1. If resistance is greater than 10 k/ohms, replace appropriate tonneau cover switch and test system operation. If resistance is less than 10 k/ohms, repair open in Pink/Light Green wire and test system operation.
    8. NOTE: Ensure the tonneau cover lock-out switch is not in the valet position.
  8. Disconnect TCM harness connector C4054c. Measure resistance between TCM harness connector C4054c terminal No. 2 (White/Red wire) and ground. See Figure. If resistance is greater than 10 k/ohms, go step  45. If resistance is less than 10 k/ohms, go to next step.
  9. Disconnect tonneau cover switch harness connectors C943 and C944. Measure resistance between harness connector C4054c terminal No. 2 (White/Red wire) and ground. If resistance is greater than 10 k/ohms, replace appropriate tonneau cover switch and test system operation. If resistance is less than 10 k/ohms, repair open in White/Red wire and test system operation.
  10. Disconnect tonneau cover lock-out switch harness connector C3029. Measure resistance between harness connector C4054c terminal No. 2 (White/Red wire) and ground. If resistance is greater than 5 ohms, replace tonneau cover lock-out switch. If resistance is less than 10 k/ohms, repair short to ground in White/Red wire and test system operation.
  11. Disconnect TCM harness connector C4054a. Measure resistance between harness connector C4054a terminal No. 4 (Red wire) and ground. See Figure. If battery voltage is present, go to step  45. If battery voltage is not present, repair open in Red wire and test system operation. See WIRING DIAGRAMS .
  12. Disconnect TCM harness connector C4054d. Measure voltage between harness connector C4054d terminal No. 1 (Gray/Black wire) and ground. See Figure. If any voltage is present, repair short to voltage in Gray/Black wire and test system operation. If no voltage is present, go to next step.
  13. Measure resistance between harness connector C4054d terminal No. 1 (Gray/Black wire) and ground. If resistance is greater than 10 k/ohms, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Gray/Black wire and test system operation.
  14. Disconnect PCM harness connector C175. Measure resistance between TCM harness connector C4054d terminal No. 1 and PCM harness connector C175 terminal No. 68 (Gray/Black wires). See Figure and Fig 2 . If resistance is less than 5 ohms, go step  45. If resistance is more than 5 ohms, repair open in Gray/Black wire and test system operation.
  15. Disconnect TCM harness connector C4054d. Measure resistance between ground and harness connector C4054d terminals No. 5 (White/Yellow wire), and No. 13 (Orange/Light Green wire). See Figure. If each resistance is greater than 10 k/ohms, go to step  45. If either resistance is less than 10 k/ohms, go to next step.
  16. Disconnect tonneau cover motor harness connector C4053b. Measure resistance between ground and harness connector C4054d terminals No. 5 (White/Yellow wire) and No. 13 (Orange/Light Green wire). If each resistance is greater than 10 k/ohms, replace left side tonneau cover motor and test system operation. See POWER TONNEAU COVER MOTOR  under REMOVAL & INSTALLATION. If resistance is less than 10 k/ohms, repair short to ground in appropriate wire and test system operation. See WIRING DIAGRAMS .
  17. Disconnect TCM harness connector C4054d. Disconnect tonneau cover motor harness connector C4053b. Measure resistance between ground and harness connector terminals No. 3 (White/Light Green wire) and No. 12 (White/Black wire). If each resistance is greater than 10 k/ohms, go to next step. If either resistance is less than 10 k/ohms, repair short to ground in appropriate wire and test system operation. See WIRING DIAGRAMS .
  18. Measure resistance between TCM harness connector C4054d terminal No. 3 and tonneau cover motor harness connector C4053b terminal No. 3 (White/Light Green wires). Measure resistance between TCM harness connector C4054d terminal No. 11 and tonneau cover motor harness connector C4053b terminal No. 4 (White/Black wires). See Figure. If each resistance is less than 5 ohms, replace left side tonneau cover motor and test system operation. See POWER TONNEAU COVER MOTOR  under REMOVAL & INSTALLATION. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  19. Disconnect TCM harness connector C4054b. Disconnect tonneau cover lift motor C4053a. Measure voltage between ground and TCM harness connector C4054b terminals No. 4 (Tan/Red wire) and No. 5 (White/Orange wire). See Figure. If any voltage is present, repair short to voltage in appropriate wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, go to next step.
  20. Measure resistance between ground and TCM harness connector C4054b terminals No. 4 (Tan/Red wire) and No. 5 (White/Orange wire). If each resistance is greater than 10 k/ohms, go to next step. If either resistance is less than 10 k/ohms, repair short to ground in appropriate wire and test system operation. See WIRING DIAGRAMS .
  21. Measure resistance between TCM harness connector C4054b terminal No. 4 and left side tonneau cover lift motor harness connector C4053a terminal No. 1 (Tan/Red wires). Measure resistance between TCM harness connector C4054b terminal No. 5 and left side tonneau cover lift motor harness connector C4053a terminal No. 2 (White/Orange wires). See Figure. If each resistance is less than 5 ohms, go to next step. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  22. Reconnect TCM harness connector C4054b. Connect NGS tester to DLC connector. Using NGS tester, command left tonneau cover motor OPEN and CLOSED. Measure voltage between left side tonneau cover lift motor harness connector C4053a terminals No. 1 and 2. If battery voltage is present when commanding tonneau cover motor OPEN and CLOSED, replace tonneau cover motor. See POWER TONNEAU COVER MOTOR  under REMOVAL & INSTALLATION. If battery voltage is not present while commanding tonneau cover motor OPEN and CLOSED, go to step  45.
  23. Disconnect TCM harness connector C4054b. Disconnect right side tonneau cover lift motor harness connector C4057a. Measure voltage between ground and TCM harness connector C4054b terminals No. 1 (White/Pink wire) and No. 7 (Tan/Light Blue wire). See Figure. If any voltage is present, repair short to voltage in appropriate wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, go to next step.
  24. Measure resistance between ground and TCM harness connector C4054b terminals No. 1 (White/Pink wire) and No. 7 (Tan/Light Blue wire). If each resistance is greater than 10 k/ohms, go to next step. If either resistance is less than 10 k/ohms, repair short to ground in appropriate wire and test system operation.
  25. Measure resistance between TCM harness connector C4054b terminal No. 1 and right side tonneau cover lift motor harness connector C4057a terminal No. 2 (White/Pink wires). Measure resistance between TCM harness connector C4054b terminal No. 7 and right side tonneau cover lift motor harness connector C4057a terminal No. 1 (Tan/Light Blue wires). See Figure. If each resistance is less than 5 ohms, go to next step. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  26. Reconnect TCM harness connector C4054b. Connect NGS tester to DLC connector. Using NGS tester, command right tonneau cover motor OPEN and CLOSED. Measure voltage between right side tonneau cover lift motor harness connector C4057a terminals No. 1 and 2. See Figure. If battery voltage is present while commanding motor OPEN and CLOSED, replace tonneau cover motor and test system operation. See POWER TONNEAU COVER MOTOR  under REMOVAL & INSTALLATION. If battery voltage is not present while commanding motor OPEN and CLOSED, go to step  45.
  27. Disconnect TCM harness connector C4054d. Disconnect tonneau cover clutch harness connector C4053b and C4053c. Measure voltage between ground and TCM harness connector C4054d terminals No. 7 (Light Green/Yellow wire), No. 8 (Pink/Light Green wire), No 15 (White/Light Blue wire), and No. 16 (Orange/Light Blue wire). If any voltage is present, repair short to voltage in appropriate wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, go to next step.
  28. Measure resistance between ground and TCM harness connector C4054d terminals No. 7 (Light Green/Yellow wire) and No. 8 (Pink/Light Green wire). If each resistance is greater than 10 k/ohms, go to next step. If either voltage is less than 10 k/ohms, repair short to ground in appropriate wire and test system operation. See WIRING DIAGRAMS .
  29. Measure resistance between TCM harness connector C4054d and tonneau cover clutch harness connectors C4057b (right) and C4053c (left) as indicated. See TONNEAU COVER CLUTCH CIRCUIT IDENTIFICATION  table. See Figure. If each resistance is less than 5 ohms, go to next step. If any resistance is greater than 5 ohms, repair open in appropriate wire and test system operation.
    TONNEAU COVER CLUTCH CIRCUIT IDENTIFICATION

    TCM Connector C4054d Terminal No. Wire Color Tonneau Cover Clutch Connector/Terminal No.
    7 Light Green/Yellow C4053c/2
    8 Pink/Light Green C4057b/2
    15 White/Light Blue C4053c/1
    16 Orange/Light Blue C4057b/1
  30. Reconnect TCM harness connector C4054d. Connect NGS tester to DLC connector. Using NGS tester, command tonneau cover clutch to ENGAGE and DISENGAGE. Measure voltage between right side tonneau cover clutch harness connector C4057b terminals No. 1 (Orange/Light Blue wire) and No. 2 (Pink/Light Green wire). Measure voltage between left tonneau cover clutch harness connector C4053c terminals No. 1 (White/Light Blue wire) and No. 2 (Light Green/Yellow wire). See Figure. If battery voltage is present while commanding either tonneau cover clutch to ENGAGE and DISENGAGE, replace appropriate tonneau cover motor and test system operation. See POWER TONNEAU COVER MOTOR  under REMOVAL & INSTALLATION. If battery voltage is not present while both commanding tonneau cover clutch to ENGAGE and DISENGAGE, go to step  45.
  31. Disconnect tonneau cover safety strip harness connectors C4059 (passenger's side) and C4060 (driver's side). Disconnect TCM harness connector C4054c. Measure voltage between TCM harness connector C4054c terminal No. 8 (Light Green/Red wire) and ground. If any voltage is present, repair short to voltage in Light Green/Red wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, go to next step.
  32. Measure resistance between TCM harness connector C4054c terminal No. 8 and driver side safety strip harness connector C4060 terminal No. 1 (Light Green/Red wires). Measure resistance between TCM harness connector C4054c terminal No. 8 and passenger side safety strip harness connector C4059 terminal No. 1 (Light Green/Red wires). If each resistance is less than 5 ohms, go to next step. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  33. Measure resistance between TCM harness connector C4054c terminal No. 17 and driver side safety strip harness connector C4060 terminal No. 2 (Black/Orange wires). Measure resistance between TCM harness connector C4054c terminal No. 17 and passenger side safety strip harness connector C4059 terminal No. 2 (Black/Orange wires). See Figure. If each resistance is less than 5 ohms, go to next step. If either resistance is greater than 5 ohms, repair open in appropriate wire and test system operation. See WIRING DIAGRAMS .
  34. Measure resistance between driver side safety strip terminals No. 1 and 2 (component side). Measure resistance between passenger side safety strip terminals No. 1 and 2 (component side). If both resistances are approximately 5000 ohms, go to step  45. If either resistance not approximately 5000 ohms, replace appropriate tonneau cover safety strip and test system operation.
  35. Disconnect tonneau cover safety strip harness connector C4059 (passenger's side) and C4060 (driver's side). Disconnect TCM harness connector C4054c. Measure resistance between ground and TCM harness connector C4054c terminal No. 8 (Light Green/Red wire). If resistance is greater than 10 k/ohms, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Light Green/Red wire and test system operation. See WIRING DIAGRAMS .
  36. Measure resistance between driver side safety strip terminals No. 1 and 2 (component side). Measure resistance between passenger side safety strip terminals No. 1 and 2 (component side). If both resistances are approximately 5000 ohms, go to step  45. If either resistance not approximately 5000 ohms, replace appropriate tonneau cover safety strip and test system operation.
  37. Connect NGS tester to DLC connector. Using NGS tester monitor driver and passenger side tonneau cover latch engaged switch PIDs while tonneau cover is in open and closed positions. If PIDs agree with tonneau cover positions, go to step  45. If driver side PID does not agree with tonneau cover position, go to step  40. If passenger side PID does not agree with tonneau cover position, go to next step.
  38. Turn ignition switch to LOCK position. Disconnect TCM harness connector C4054c. Disconnect passenger side tonneau cover latch harness connector C4055. Measure resistance between TCM harness connector C4054c terminal No. 5 and passenger side latch harness connector C4055 terminal No. 3 (Dark Blue/White wires). Also measure resistance between TCM harness connector C4054c terminal No. 5 and ground. See Figure. If resistance is less than 5 ohms between connectors and greater than 10 k/ohms to ground, go to next step. If resistance is not as specified, repair open or short to ground in Dark Blue/White wire and test system operation. See WIRING DIAGRAMS .
  39. Turn ignition switch to ON position. Measure voltage between TCM harness connector C4054c terminal No. 5 (Dark Blue/White wire) and ground. If any voltage is present, repair short to voltage in Dark Blue/White wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, replace passenger side tonneau cover latch assembly and test system operation. See TONNEAU COVER LATCH  under REMOVAL & INSTALLATION.
  40. Turn ignition switch to LOCK position. Disconnect TCM harness connector C4054c. Disconnect driver side tonneau cover latch harness connector C4056. Measure resistance between TCM harness connector C4054c terminal No. 4 and driver side latch harness connector C4055 terminal No. 3 (Dark Green/Violet wires). Also measure resistance between TCM harness connector C4054c terminal No. 4 and ground. See Figure. If resistance is less than 5 ohms between connectors and greater than 10 k/ohms to ground, go to next step. If resistance is not as specified, repair open or short to ground in Dark Green/Violet wire and test system operation. See WIRING DIAGRAMS .
  41. Turn ignition switch to ON position. Measure voltage between TCM harness connector C4054c terminal No. 4 (Dark Green/Violet wire) and ground. If any voltage is present, repair short to voltage in Dark Green/Violet wire and test system operation. See WIRING DIAGRAMS . If no voltage is present, replace driver side tonneau cover latch assembly and test system operation. See TONNEAU COVER LATCH  under REMOVAL & INSTALLATION.
  42. Turn ignition switch to ON position. Using NGS tester or equivalent, monitor tonneau cover release latches while opening and closing the tonneau cover. If passenger side tonneau cover release latch PID agrees with tonneau cover position, go to next step. If passenger side tonneau cover release latch PID does not agree with tonneau cover position, go to step  44.
  43. Turn ignition switch to LOCK position. Disconnect TCM harness connector C4054c. Disconnect driver side tonneau cover latch harness connector C4056. Measure resistance between TCM harness connector C4054c terminal No. 6 and driver side latch harness connector C4055 terminal No. 1 (Dark Green/White wires). Also measure resistance between TCM harness connector C4054c terminal No. 6 and ground. See Figure. If resistance is less than 5 ohms between connectors and greater than 10 k/ohms to ground, go to step  45. If resistance is not as specified, repair open or short to ground in Dark Green/White wire and test system operation. See WIRING DIAGRAMS .
  44. Turn ignition switch to LOCK position. Disconnect TCM harness connector C4054c. Disconnect passenger side tonneau cover latch harness connector C4056. Measure resistance between TCM harness connector C4054c terminal No. 2 and passenger side latch harness connector C4055 terminal No. 1 (Violet/White wires). Also measure resistance between TCM harness connector C4054c terminal No. 2 and ground. See Figure. If resistance is less than 5 ohms between connectors and greater than 10 k/ohms to ground, go to next step. If resistance is not as specified, repair open or short to ground in Dark Green/White wire and test system operation. See WIRING DIAGRAMS .
  45. Ensure ignition switch is in LOCK position. Disconnect all CSM harness connectors. CSM is located behind instrument panel, left of steering column. Check for backed out or corroded terminals. Repair terminals as necessary. Connect all CSM harness connectors. Check operation of power door lock system. If problem still exists, replace CSM. See CENTRAL SECURITY MODULE  under REMOVAL & INSTALLATION. If problem does not exist, clear all DTCs and perform CSM self-test.
Fig 1: Identifying Power Tonneau Cover Control Switches Harness Connectors C943 & C944 Terminals
G97I28546Courtesy of FORD MOTOR CO.
Fig 2: Identifying PCM Harness Connector C175 Terminals
G97C28771Courtesy of FORD MOTOR CO.
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