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Test Kc: Fuel Shutoff Valve Relay: Testing

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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
P0230  KC1  KC1  KC40
P0231  KC20  KC20  KC35
P0232  KC10  KC10  KC30
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) For KOEO & KOER Only DTC P0230: Check VPWR Voltage To FSV Relay
    DTC P0230 is set when FSV output is commanded ON (grounded) and excessive current draw is detected on FSV circuit; or when FSV output is commanded OFF, voltage is not detected on FSV circuit (PCM expects VPWR voltage on FSV circuit to FSV relay coil). Possible causes are:
    • Open Or Shorted Fuel Shutoff Valve (FSV) Circuit
    • Open VPWR Circuit To FSV Relay
    • Faulty FSV Relay
    • Faulty PCM

    Turn ignition switch to OFF position. Remove FSV relay. On Crown Victoria, FSV relay is located in left rear of engine compartment, in relay center. On Econoline and Pickup, FSV relay is located in left front of engine compartment, in battery junction box. On all models, turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and FSV relay cavity No. 86 (VPWR circuit). See Figure. 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 between PCM power relay and FSV relay.

  2. 2) Check FSV Relay

    Turn ignition switch to OFF position. Using a DVOM, measure resistance between FSV relay terminals No. 85 and 86. See Figure. Resistance should be 40-120 ohms. Also, measure resistance between FSV relay terminal No. 85 and terminals No. 30 and 87. Resistance should be more than 10 k/ohms. If resistance is not as specified, replace FSV relay. If resistance is as specified, go to next step.

  3. 3) Check FSV Circuit For Short To PWR In Harness

    Ensure ignition switch is turned to OFF position. Disconnect PCM connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and FSV relay cavity No. 85 (FSV circuit). If voltage is less than one volt, go to next step. If voltage is one volt or more, repair short to PWR in FSV circuit.

  4. 4) Check FSV Circuit For Short To Ground In Harness

    Turn ignition switch to OFF position. Disconnect scan tool from Data Link Connector (DLC). Using a DVOM, measure resistance between negative battery terminal and FSV relay cavity No. 85 (FSV circuit). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in FSV circuit.

  5. 5) Check For Open FSV Circuit

    Ensure ignition switch is turned to OFF position and PCM connector is disconnected. Inspect connector for loose, damaged or corroded terminals. Using a DVOM, measure resistance of FSV circuit between FSV relay cavity No. 85 and PCM harness connector terminal No. 80. See PCM CONNECTOR IDENTIFICATION and Figure. If resistance is 5 ohms or more, repair open in FSV circuit. If resistance is less than 5 ohms and KOEO DTC P0231 or P0232 is also present with DTC P0230, go to next step. If resistance is less than 5 ohms and specified DTCs are not present, replace PCM.
    6. NOTE: Test steps  6) and  7) check FSV circuit in PCM. To perform, FSVF PID must be monitored with scan tool. FSVF PID will indicate NO when no fault is detected, and YES when a fault is detected.

  6. 6) Check FSV Primary Circuit Inside PCM
    Reconnect PCM harness connector and reinstall FSV relay. Connect scan tool to DLC. Turn ignition switch to ON position. DO NOT start engine. Using scan tool, access FSVF PID from PID/DATA MONITOR & RECORD menu. If FSVF PID value indicates YES (fault is present), replace PCM. If FSVF PID value indicates NO (no fault present), go to next step.
    7. NOTE: Scan tool must be connected to a reliable power source (such as directly to vehicle battery) with ignition switch in START position. Also, ensure vehicle battery is fully charged.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 7) to step 10). No test procedures have been omitted.

  7. 7) Check FSV Primary Circuit In PCM (While Cranking Engine)
    While cranking engine, observe FSVF PID. If FSVF PID value indicates YES (fault present) during cranking, replace PCM. If FSVF PID value indicates NO (no fault present) during cranking, FSV primary circuit is okay in harness and PCM. If DTC P0231 is present, go to step  20). If DTC P0232 is present, go to step  10).
    8. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: Fuel Shutoff Valve (FSV) relay may also be referred to as fuel valve relay (Crown Victoria) or fuel pump relay (all others).

  8. 10) For KOEO & KOER Only DTC P0232: Attempt To Start Engine
    DTC P0232 indicates PCM detected high FSVM circuit voltage when fuel shutoff valves were commanded off. Possible causes are:
    • Inertia Fuel Shutoff (IFS) Switch Open Or Not Reset
    • Open Circuit Between Fuel Shutoff Valve (FSV) Relay & FSVM Connection To FSV PWR Circuit
    • Poor FSV Ground
    • Internal Open In FSV
    • FSV Secondary Circuits Shorted To PWR
    • FSV Relay Contacts Always Closed
    • Open FSVM Circuit Between PCM & Connection To FSV PWR Circuit
    • Faulty PCM (Engine Will Start)

    Attempt to start engine. If engine starts, go to next step. If engine does not start, go to step  15).

  9. 11) Check If PWR Is Always Being Supplied To FSV PWR Circuit

    Turn ignition switch to OFF position. Ensure all accessories are off. Disconnect scan tool from DLC. Disconnect PCM connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and PCM harness connector terminal No. 40 (FSVM). If voltage is 1.5 volts or more, go to next step. If voltage is less than 1.5 volts, go to step  13).

  10. 12) Check For FSV Relay Contacts Always Closed

    Turn ignition switch to OFF position. Ensure all accessories are off. Remove FSV relay. On Crown Victoria, FSV relay is located in left rear of engine compartment, in relay center. On Econoline and Pickup, FSV relay is located in left front of engine compartment, in battery junction box. On all models, turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and PCM harness connector terminal No. 40 (FSVM). If voltage is less than 1.5 volts, replace FSV relay. If voltage is 1.5 volts or more, repair short to PWR in FSVM or FSV PWR circuit.

  11. 13) Check For Open FSVM Circuit Between PCM & FSV Relay

    Turn ignition switch to OFF position. Remove FSV relay. On Crown Victoria, FSV relay is located in left rear of engine compartment, in relay center. On Econoline and Pickup, FSV relay is located in left front of engine compartment, in battery junction box. On all models, measure resistance between PCM harness connector terminal No. 40 and FSV relay cavity No. 87 (FSV PWR circuit). See Figure. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in FSVM circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 13) to step 15). No test procedures have been omitted.

  12. 15) Check IFS Switch

    Turn ignition switch to OFF position. Disconnect Inertia Fuel Shutoff (IFS) switch. Ensure IFS switch is reset. Using a DVOM, measure resistance between IFS switch terminals (Dark Green/Yellow and Pink/Black wires in harness). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, reset or replace IFS switch.

  13. 16) Check For Open FSV PWR Circuit Between IFS Switch & FSV Relay

    Remove FSV relay. On Crown Victoria, FSV relay is located in left rear of engine compartment, in relay center. On Econoline and Pickup, FSV relay is located in left front of engine compartment, in battery junction box. On all models, measure resistance of FSV PWR circuit between FSV relay cavity No. 87 and IFS switch harness connector. See Figure and Figure . If resistance is less than 5 ohms, reconnect FSV relay and go to next step. If resistance is 5 ohms or more, repair open in FSV PWR circuit between IFS switch and FSVM connection to circuit.

  14. 17) Check FSV PWR Circuit Resistance To Ground Through Fuel Shutoff Valves

    Using a DVOM, measure resistance between chassis ground and FSV PWR circuit to fuel solenoid shutoff valves at IFS harness connector. If resistance is less than 10 ohms, fault cannot be identified at this time. Ensure previous test step results are okay. If results are okay, ignore DTC P0232 at this time. Reconnect IFS switch and go to appropriate symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - CNG, FLEX-FUEL & GASOLINE article. If resistance is 10 ohms or more, repair open in FSV PWR circuit between IFS switch and common splice between fuel tank solenoid valves, or in individual fuel solenoid shutoff valve circuits to ground. See WIRING DIAGRAMS .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 17) to step 20). No test procedures have been omitted.
    15. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  15. 20) For KOEO & KOER Only DTC P0231: Attempt To Start Engine
    If DTC P0230 is also present and has not been diagnosed, go directly to step  1) to check primary fuel shutoff valve circuit fault. DTC P0231 indicates PCM commanded FSV ON and B+ voltage is not detected on Fuel Shutoff Valve Monitor (FSVM) circuit. Possible causes are:
    • Open B+ Circuit To FSV Relay
    • Open FSV PWR Circuit Between FSV Relay & Connection To FSVM Circuit
    • Faulty FSV Relay
    • Faulty PCM

    Attempt to start engine. If engine does not start, go to next step. If engine starts, turn ignition switch to OFF position. Disconnect PCM connector and go to step  13).

  16. 21) Check B+ Voltage To Fuel Shutoff Valve Relay

    Turn ignition switch to OFF position. Remove FSV relay. On Crown Victoria, FSV relay is located in left rear of engine compartment, in relay center. On Econoline and Pickup, FSV relay is located in left front of engine compartment, in battery junction box. On all models, measure voltage between negative battery terminal and FSV relay cavity No. 30 (B+ circuit). See Figure. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check B+ circuit fuse to FSV relay. If fuse is blown, check for short to ground in FSV PWR or B+ circuit. If fuse is okay, repair open in B+ circuit.

  17. 22) Check For Open FSV PWR Circuit Between FSV Relay & FSVM Splice

    Using a DVOM, measure resistance between chassis ground and FSV relay cavity No. 87 (FSV PWR circuit). If resistance is less than 10 ohms, replace FSV relay. If resistance is 10 ohms or more, repair open in FSV PWR circuit between FSVM splice and FSV relay.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 22) to step 30). No test procedures have been omitted.
    18. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 30) to step 35). No test procedures have been omitted.

  18. 30) For Continuous Memory Only DTC P0232: Check Harness For Open Or Short To VPWR
    If Continuous Memory DTC P0230 is also present, go directly to step  40). DTC P0232 indicates PCM detected high FSVM circuit voltage when fuel shutoff valves were commanded off. Possible causes are:
    • Inertia Fuel Shutoff (IFS) Switch Open Or Not Reset
    • Open Circuit Between Fuel Shutoff Valve (FSV) Relay & FSVM Connection To FSV PWR Circuit
    • Poor FSV Ground
    • Internal Open In FSV
    • FSV Secondary Circuits Shorted To PWR
    • FSV Relay Contacts Always Closed
    • Open FSVM Circuit Between PCM & Connection To FSV PWR Circuit
    • Faulty PCM (Engine Will Start)

    Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access FSVM PID from PID/DATA MONITOR & RECORD menu. FSVM PID value should indicate OFF. Observe FSVM PID value for indication of fault while performing the following:

    • Shake, wiggle and bend FSV PWR circuit between FSV relay and fuel shutoff solenoid valves.
    • Shake, wiggle and bend fuel shutoff valve ground circuits between each fuel shutoff solenoid valve and ground.
    • Shake, wiggle and bend FSVM circuit between PCM and splice to FSV PWR circuit.
    • Lightly tap on Inertia Fuel Shutoff (IFS) switch and FSV relay to simulate road shock.

    A fault is indicated when FSVM PID value indicates ON (open or short to VPWR is detected). If any faults are found, isolate fault and repair as necessary. If no faults are found, fault cannot be duplicated at this time. Go to TEST Z, step  1).

    19. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 35) to step 40). No test procedures have been omitted.

  19. 35) For Continuous Memory Only DTC P0231: Check Fuel Shutoff Valves Secondary Circuits Between B+ Supply & FSVM Connection
    DTC P0231 indicates PCM commanded fuel pump ON and B+ voltage is not detected on Fuel Shutoff Valve Monitor (FSVM) circuit. Possible causes for this fault are:
    • Open B+ Circuit To FSV Relay
    • Open FSV PWR Circuit Between FSV Relay & Connection To FSVM Circuit
    • Faulty FSV Relay
    • Faulty PCM (Engine Will Start)

    Turn ignition switch to OFF position. Disconnect Inertia Fuel Shutoff (IFS) switch. Disconnect PCM connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Connect a jumper wire between PCM harness connector terminal No. 80 (FSV circuit) and chassis ground. Connect DVOM between PCM harness connector terminal No. 40 (FSVM circuit) and chassis ground. Turn ignition switch to ON position. FSV relay should activate and voltage on DVOM should be more than 10 volts. Observe DVOM for indication of fault while performing the following:

    • Shake, wiggle and bend B+ circuit to FSV relay.
    • Shake, wiggle and bend FSV PWR circuit between FSV relay and FSVM circuit splice.
    • Lightly tap on FSV relay to simulate road shock.
    • Check FSV relay connector for corrosion or damaged terminals.

    A fault will be indicated by sudden change in DVOM voltage. If any faults are found, isolate fault and repair as necessary. If no faults are found, fault cannot be duplicated at this time. Go to TEST Z, step  1).

    20. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  20. 40) For Continuous Memory Only DTC P0230: Check Fuel Shutoff Valve Primary Circuits
    DTC P0230 is set when FSV output is commanded ON (grounded) and excessive current draw is detected on FSV circuit; or when FSV output is commanded OFF, voltage is not detected on FSV circuit (PCM expects VPWR voltage on FSV circuit to FSV relay coil). Possible causes are:
    • Open Or Shorted Fuel Shutoff Valve (FSV) Circuit
    • Open VPWR Circuit To FSV Relay
    • Faulty FSV Relay
    • Faulty PCM

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position and wait 5 seconds. Using scan tool, access FSVF PID from PID/DATA MONITOR & RECORD menu. FSVF PID should indicate NO (PCM detects VPWR through relay coil and FSV circuit at terminal No. 80). Observe FSVF PID value for indication of fault while performing the following:

    • Shake, wiggle and bend FSV circuit between PCM harness connector terminal No. 80 and FSV relay.
    • Shake, wiggle and bend VPWR circuit between PCM power relay and FSV relay.
    • Lightly tap on FSV relay to simulate road shock.
    • Check PCM and FSV relay connectors for clean tight connection.

    If a fault is detected (open circuit), FSVF PID will indicate YES. If any faults are found, isolate fault and repair as necessary. If no faults are found, fault cannot be duplicated at this time. Go to TEST Z, step  1).

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