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Test Procedure

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, 2011 Ford Fusion, 2010 Mercury Milan, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. KF1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) 

    Is DTC P0480 present? 

    Yes No
    For KOEO and KOER DTC P0480, GO to  KF2.
    For continuous memory DTC P0480, GO to  KF8.    		 For electric cooling fan(s) does not operate. GO to  KF10.
  2. KF2 CHECK FOR A MECHANICAL CONCERN WITH THE COOLING FAN MOTOR OR FOR OBSTRUCTIONS LIMITING THE COOLING FAN MOTOR OPERATION 
    • Ignition OFF.
    • CF Motor connector disconnected.
    • Rotate the fan by hand. The fan should rotate freely, with no abnormal binding. If binding is present, remove any foreign materials or install a new fan assembly as required.
    • Measure the voltage between:
    VOLTAGE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-) CF Motor Connector, Harness Side
    B+ - Pin 1 GND - Pin 2

    Is the voltage greater than 10 V? 

    Yes No
    GO to  KF4. GO to  KF3.
  3. KF3 CHECK THE VOLTAGE TO THE FAN MOTOR USING GROUND AS A REFERENCE 
    • Measure the voltage between:
    VOLTAGE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-)
    B+ - Pin 1 Ground

    Is the voltage greater than 10 V? 

    Yes No
    REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test. A B+ circuit concern is present. CHECK the condition of the related fuse/fuse links. If OK, REPAIR the open circuit. If the fuse/fuse link is damaged, CHECK the circuit for a short to ground before installing a new fuse/fuse link.
  4. KF4 CHECK THE FCV CIRCUIT(S) 
    • Connect the 1.6K ohms resistor between the FCV and B+ circuits at the CF harness connector (this simulates cooling fan circuitry).
    • Ignition ON, engine OFF.
    • Carry out the PCM KOEO self-test.

    Is DTC P0480 present? 

    Yes No
    GO to  KF5. INSTALL a new cooling fan motor. REFER to the ENGINE COOLING SYSTEM (HYBRID)
    Clear the PCM DTCs. REPEAT the self-test.
  5. KF5 CHECK THE FCV CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS 
    • Ignition OFF.
    • PCM connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
    VOLTAGE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-)
    FCV - Pin 4 Ground

    Is the voltage less than 1 V? 

    Yes No
    GO to  KF6. REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  6. KF6 CHECK THE FCV CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Ignition OFF.
    • Measure the resistance between:
    RESISTANCE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-)
    FCV - Pin 4 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to  KF7. REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  7. KF7 CHECK FOR AN OPEN CIRCUIT BETWEEN THE PCM AND FAN MOTOR 
    • Measure the resistance between:
    RESISTANCE REFERENCE CHART

    (+) PCM Connector, Harness Side (-) CF Motor Connector, Harness Side
    FCV - Pin B36 FCV - Pin 4

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KF12. REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  8. KF8 CONTINUOUS MEMORY DTC P0480: CHECK THE B+ AND GND CIRCUIT FOR AN INTERMITTENT CONCERN 
    • Ignition OFF.
    • CF Motor connector disconnected.
    • Rotate the fan by hand. The fan should rotate freely, with no abnormal binding. If binding is present, remove any foreign materials or install a new fan assembly as required.
    • Connect a non-powered test lamp between:
      CONNECTOR PINS REFERENCE CHART

      Point A CF Motor Connector, Harness Side Point B CF Motor Connector, Harness Side
      B+ - Pin 1 GND - Pin 2
    • Observe the test lamp for an indication of a concern while carrying out the following. Note that the lamp turns off when a concern is present.
      • shake, wiggle, and bend the B+ and GND circuits to the CF
      • shake, wiggle, and bend the associated fuse

    Is a concern present? 

    Yes No
    ISOLATE the concern and REPAIR as necessary.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to  KF9.
  9. KF9 CHECK THE FCV CIRCUIT(S) FOR INTERMITTENT CONCERNS 
    • PCM connector disconnected.
    • Measure the resistance between:
      RESISTANCE REFERENCE CHART

      (+) CF Motor Connector, Harness Side (-) PCM Connector, Harness Side
      FCV - Pin 4 FCV - Pin B36
    • Observe the digital multimeter (DMM) for an indication of a concern while shaking, wiggling, and bending the FCV circuit between the CF motor and the PCM. Note that resistance changes suddenly when a concern is detected.

    Is a concern present? 

    Yes No
    ISOLATE the concern and REPAIR as necessary.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to PINPOINT TEST Z .
  10. KF10 CHECK THE B+ AND GND CIRCUITS TO THE COOLING FAN MOTOR 
    • Ignition OFF.
    • CF Motor connector disconnected.
    • Rotate the fan by hand. The fan should rotate freely, with no abnormal binding. If binding is present, remove any foreign materials or install a new fan assembly as required.
    • Measure the voltage between:
    VOLTAGE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-) CF Motor Connector, Harness Side
    B+ - Pin 1 GND - Pin 2

    Is the voltage greater than 10 V? 

    Yes No
    INSTALL a new CF motor. REFER to the ENGINE COOLING SYSTEM (HYBRID)
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to  KF11.
  11. KF11 CHECK THE VOLTAGE TO THE COOLING FAN USING GROUND AS A REFERENCE 
    • Measure the voltage between:
    VOLTAGE REFERENCE CHART

    (+) CF Motor Connector, Harness Side (-)
    B+ - Pin 1 Ground

    Is the voltage greater than 10 V? 

    Yes No
    REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test. A B+ circuit concern is present. CHECK the condition of the related fuse/fuse links. If OK, REPAIR the open circuit. If the fuse/fuse link is damaged, CHECK the circuit for a short to ground before installing a new fuse/fuse link.
    Clear the PCM DTCs. REPEAT the self-test.
  12. KF12 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect all the PCM connectors.
    • Visually inspect for:
      • pushed out pins
      • corrosion
    • Connect all the PCM connectors and make sure they seat correctly.
    • Carry out the PCM self-test.
    • Verify the concern is still present.

    Is the concern still present? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) , PROGRAMMING THE VID BLOCK FOR A REPLACEMENT PCM . The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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