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Test HX: Evaporative Emission Monitor & System: 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
P0443  HX2  HX2  HX1
P0452  HX26  HX26  HX26
P0453  HX33  HX33  HX33
P0457      HX43
P0460  HX76  HX76  HX76
P1450      HX18
P1451  HX65  HX65  HX65
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) Continuous Memory DTC P0443: Inspect EVAP Canister Purge Valve Circuit For Intermittent Failure
    DTC P0443 is set when EVAP Monitor test fails due to EVAP canister purge valve circuit signal reading outside minimum or maximum allowable calibrated parameters for a specified duty cycle PCM detects. Possible causes are:
    • VPWR Circuit Open
    • EVAP Canister Purge Valve Circuit Open, Or Shorted To GND Or VPWR
    • Faulty EVAP Canister Purge Valve
    • Faulty PCM

    Repeat KOEO ON-DEMAND SELF-TEST and KOER ON-DEMAND SELF-TEST . If DTC P0443 is present in KOEO or KOER ON-DEMAND self-test, go to next step. If DTC P0443 is present in Continuous Memory only, check for intermittent faults. Go to TEST Z, step 1) . If no faults are indicated, replace PCM.

    2. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    Fig 1: Identifying EVAP Canister Purge Valve Circuits & Connector Terminals
    G00013279Courtesy of FORD MOTOR CO.

  2. 2) KOEO & KOER DTC P0443: Check VPWR Voltage To EVAP Canister Purge Valve
    Turn ignition switch to OFF position. Disconnect EVAP canister purge valve connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and VPWR circuit at EVAP canister purge valve harness connector. See Fig 1. 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.
    3. NOTE: EVAP canister purge valve resistance reading must be taken with engine cooled down.

  3. 3) Check EVAP Canister Purge Valve Resistance
    Turn ignition switch to OFF position. Ensure EVAP canister purge valve is disconnected. Using a DVOM, measure resistance between EVAP canister purge valve terminals. If resistance is 30-38 ohms, go to next step. If resistance is not 30-38 ohms, replace EVAP canister purge valve. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair.

  4. 4) Check EVAP Canister Purge Valve Circuit For Open In Harness

    Ensure ignition switch is turned to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Using a DVOM, measure resistance of EVAP CANISTER PURGE VALVE circuit between PCM harness connector and EVAP canister purge valve harness connector. See Figure or Figure, and Fig 1 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in EVAP CANISTER PURGE VALVE circuit.

  5. 5) Check EVAP Canister Purge Valve Circuit For Short To PWR GND In Harness

    Disconnect scan tool from DLC. Using a DVOM, measure resistance between negative battery terminal and EVAP CANISTER PURGE VALVE circuit at PCM harness connector. If resistance is 10 k/ohms or less, repair short to PWR GND in EVAP CANISTER PURGE VALVE circuit. If resistance is more than 10 k/ohms, go to next step.

  6. 6) Check EVAP Canister Purge Valve Circuit For Short To VPWR In Harness

    Turn ignition switch to ON position. Using a DVOM, measure resistance between negative battery terminal and EVAP CANISTER PURGE VALVE circuit at PCM harness connector. If voltage is more than 10.5 volts, repair short to VPWR in EVAP CANISTER PURGE VALVE circuit. If voltage is 10.5 volts or less, replace PCM.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 6) to step 18). No test procedures have been omitted.
    7. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: Some components may need to be removed to gain access and diagnose EVAP components. For removal and installation procedures, see appropriate REMOVAL, OVERHAUL & INSTALLATION article.

  7. 18) Continuous Memory DTC P1450: Check For Visual Causes Of Excessive Fuel Tank Vacuum
    DTC P1450 is set when PCM EVAP running loss monitor detects excessive fuel tank vacuum with engine running (not at idle). Possible causes are:
    • Blocked Or Kinked EVAP Canister Tube Or EVAP Canister Purge Outlet Tube (Between Fuel Tank, EVAP Canister Purge Valve & EVAP Canister
    • Fuel Filler Cap Stuck Closed (No Vacuum Relief)
    • Contaminated Fuel Vapor Elbow On EVAP Canister
    • Restricted EVAP Canister
    • Canister Vent (CV) Solenoid Stuck Open
    • Plugged CV Solenoid Filter
    • EVAP Canister Purge Valve Stuck Open
    • Open In VREF Circuit (In Harness Near FTP Sensor, FTP Sensor Or PCM)
    • Faulty Fuel Tank Pressure (FTP) Sensor

    Check for kinks or bends in fuel vapor hoses/tubes. Visually inspect EVAP canister inlet port, CV solenoid filter and canister vent hose for contamination or debris. Check CV solenoid filter for blockage or contamination. Repair as necessary and go to next step. If no faults are found, go to next step.

  8. 19) Check FTP Voltage

    Turn ignition switch to OFF position. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID voltage is not 2.4-2.8 volts with fuel filler cap installed, turn ignition switch to OFF position and go to next step. If FTP V PID voltage is 2.4-2.8 volts with fuel filler cap installed, check for possible intermittent condition causing DTC P1450. Go to TEST Z, step 1) . If circuit is okay, check for blocked or plugged EVAP system. Perform TEST C: DTC P1450: EXCESSIVE VACUUM DETECTED IN FUEL TANK in SYSTEM TESTS (EVAPORATIVE EMISSION) to check for blocked EVAP system condition. Repair as necessary.

  9. 20) Check Fuel Tank Pressure Sensor FTP V PID (Fuel Filler Cap Removed)

    Remove fuel filler cap. Turn ignition switch to ON position. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID voltage is not 2.4-2.8 volts, turn ignition switch to OFF position and go to next step. If FTP V PID voltage is 2.4-2.8 volts with fuel filler cap removed, check for blocked or plugged EVAP system. Perform appropriate testing for DTC P1450. See EVAPORATIVE EMISSIONS DIAGNOSTIC TROUBLE CODE DEFINITIONS . Repair as necessary.

  10. 21) Check For Other DTCs

    Check for other 3-wire sensor KOEO, KOER or Continuous Memory DTCs that may be present with DTC P1450. Perform KOEO ON-DEMAND SELF-TEST , KOER ON-DEMAND SELF-TEST and CONTINUOUS MEMORY SELF-TEST . If any other DTCs are present along with DTC P1450, perform appropriate system test, see DIAGNOSTIC TROUBLE CODE DEFINITIONS , and repair as necessary. If no other DTCs are present, turn ignition switch to OFF position and go to next step.

  11. 22) Check VREF From PCM To FTP Sensor

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between VREF and SIG RTN circuits at FTP sensor harness connector. See Fig 2 or Fig 3 . If voltage is not 4-6 volts, go to next step. If voltage is 4-6 volts, turn ignition switch to OFF position and replace FTP sensor. See FUEL TANK PRESSURE SENSOR under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article. Clear DTCs and perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair. After test is complete, repeat QUICK TEST . If Continuous Memory DTC P1450 is still present, perform TEST C: DTC P1450: EXCESSIVE VACUUM DETECTED IN FUEL TANK in SYSTEM TESTS (EVAPORATIVE EMISSION). Repair as necessary.
    Fig 2: Identifying FTP Sensor Circuits & Connector Terminals (Escort)
    G00013280Courtesy of FORD MOTOR CO.
    Fig 3: Identifying FTP Sensor Circuits & Connector Terminals (All Others)
    G00013281Courtesy of FORD MOTOR CO.

  12. 23) Check For Open VREF & SIG RTN Circuits Between PCM & FTP Sensor

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Using a DVOM, measure resistance of VREF and SIG RTN circuits between PCM harness connector and FTP sensor harness connector. See Fig 2 and Fig 3 . If both resistance measurements are less than 5 ohms, replace PCM. If either resistance measurement is 5 ohms or more, repair open in VREF or SIG RTN circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 23) to step 26). No test procedures have been omitted.
    13. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  13. 26) KOEO, KOER & Continuous Memory DTC P0452: Check For FTP Sensor Connector Contamination
    DTC P0452 is set when PCM detects Fuel Tank Pressure (FTP) sensor input signal drops below minimum allowable parameter of less than .22 volt. Possible causes are:
    • Contaminated FTP Sensor Connector
    • Faulty Powertrain Control Module (PCM)
    • FTP Circuit Shorted To GND Or SIG RTN
    • Faulty FTP Sensor

    Turn ignition switch to OFF position. Visually inspect FTP sensor connector for liquid fuel contamination. Check for submerged FTP sensor in liquid fuel (tank mounted type only). Repair as necessary and adjust fuel tank overfill. If FTP sensor connector is okay, go to next step.

    14. NOTE: FTP sensor input with no pressure/vacuum on fuel tank (filler cap open or not open) should be 2.37-2.97 volts.

  14. 27) Check For Low FTP Sensor Voltage
    Turn ignition switch to OFF position. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage by backprobing between FTP and SIG RTN circuits at PCM harness connector. See Figure or Figure, and Fig 2 or Fig 3 . If voltage measurement on DVOM or FTP V PID value is less than .22 volt, go to next step. If voltage is .22 volt or more, DTC P0452 is intermittent. Check for intermittent faults. Go to TEST Z, step 1) .

  15. 28) Check Opposite Induced High FTP Signal

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Connect a jumper wire between VREF and FTP circuits at FTP sensor harness connector. Turn ignition switch to ON position.
    NOTE: If a scan tool communication concern exists, remove jumper wire and go to next step.

    Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage by backprobing between FTP and SIG RTN circuits at PCM harness connector. If voltage measurement on DVOM or FTP V PID value is 4-6 volts, replace FTP sensor. See FUEL TANK PRESSURE SENSOR under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair. If voltage measurement on DVOM or FTP V PID value is not 4-6 volts, remove jumper wire and go to next step.

  16. 29) Check Voltage Between VREF & SIG RTN Circuits At FTP Sensor

    Ensure ignition switch is turned to ON position. Using a DVOM, measure voltage between VREF and SIG RTN circuits at FTP sensor harness connector. See Fig 2 or Fig 3 . If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, VREF voltage is out of range. Go to TEST C, step 1) .

  17. 30) Check FTP Circuit For Short To SIG RTN Or PWR GND In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Disconnect scan tool from DLC. Using a DVOM, measure resistance between FTP circuit, and SIG RTN circuit at PCM harness connector, and battery negative cable. If both resistance measurements are more than 10 k/ohms, replace PCM. If either resistance measurement is 10 k/ohms or less, repair short to SIG RTN or PWR GND circuit in FTP circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 30) to step 33). No test procedures have been omitted.
    18. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: FTP sensor input with no pressure or vacuum on fuel tank should be 2.37-2.97 volts.

  18. 33) KOEO, KOER & Continuous Memory DTC P0453: Check For High FTP Sensor Voltage
    DTC P0453 is set when PCM detects Fuel Tank Pressure (FTP) sensor input signal exceeds maximum allowable parameter of 4.5 volts. Possible causes are:
    • FTP Circuit Open
    • VREF Shorted To VPWR
    • Faulty Powertrain Control Module (PCM)
    • FTP Circuit Shorted To VREF Or VPWR
    • SIG RTN Circuit Open
    • Faulty FTP Sensor

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage by backprobing between FTP and SIG RTN circuits at PCM harness connector. See Figure or Figure, and Fig 2 or Fig 3 . If voltage measurement on DVOM or PID voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, DTC P0453 is intermittent. Check for intermittent faults. Go to TEST Z, step 1) .

  19. 34) Check FTP Circuit For Short To VPWR

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and FTP circuit at FTP sensor harness connector. See Fig 2 or Fig 3 . If voltage is 10.5 volts or less, go to step  36). If voltage is more than 10.5 volts, a short to VPWR exists. Go to next step.

  20. 35) Check FTP Circuit For Short To VPWR Circuit In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and FTP circuit at PCM harness connector. See Figure or Figure, and Fig 2 or Fig 3 . If voltage is more than 10.5 volts, repair short to VPWR in FTP circuit. If voltage is 10.5 volts or less, replace PCM.

  21. 36) Check Opposite Induced Low FTP Signal

    Turn ignition switch to OFF position. Connect a jumper wire between SIG RTN and FTP circuits at FTP sensor harness connector. Turn ignition switch to ON position.
    NOTE: If a scan tool communication concern exists, remove jumper wire and go to step  41).

    Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage by backprobing between FTP and SIG RTN circuits at PCM harness connector. See Figure or Figure, and Fig 2 or Fig 3 . If voltage measurement on DVOM or FTP V PID value is less than .1 volt, remove jumper wire and go to next step. If voltage measurement on DVOM or FTP V PID value is .1 volt or more, unable to induce opposite signal. Go to step  39).

  22. 37) Check For In Range Voltage Between VREF & SIG RTN Circuits At FTP Sensor

    Ensure ignition switch is in ON position. Using a DVOM, measure voltage between VREF and SIG RTN circuits at FTP sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, VREF voltage is out of range. Go to TEST C, step 1) .

  23. 38) Check FTP Circuit For Short To VREF In Sensor Or Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure voltage between FTP and VREF circuits at PCM harness connector (both VREF terminals on 150-pin PCM). See PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. If resistance is more than 10 k/ohms, replace FTP sensor. See FUEL TANK PRESSURE SENSOR under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair. If resistance is 10 k/ohms or less, repair short to VREF in FTP circuit.

  24. 39) Check FTP Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure resistance of FTP circuit between PCM harness connector and FTP sensor harness connector. See Figure or Figure, and Fig 2 or Fig 3 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in FTP circuit.

  25. 40) Check For Open SIG RTN Circuit Between PCM & FTP Sensor

    Ensure ignition switch is turned to OFF position. Using a DVOM, measure resistance of SIG RTN circuit between PCM harness connector and FTP sensor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in SIG RTN circuit.

  26. 41) Check FTP Circuit For Short To VREF In PCM

    Ensure ignition switch is turned to OFF position and PCM is disconnected. Using a DVOM, measure resistance between FTP and VREF circuits at PCM harness connector (both VREF terminals on 150-pin PCM). See PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. If resistance is more than 10 k/ohms, replace PCM. If resistance is 10 k/ohms or less, repair short to VREF in FTP circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 41) to step 43). No test procedures have been omitted.
    27. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 43) to step 65). No test procedures have been omitted.

  27. 43) Continuous Memory DTC P0457: Check For Missing Or Leaking Fuel Filler Cap
    DTC P0457 is set when PCM detects a fuel tank pressure decreases more than 7 in. H2 O within 30 seconds after refueling, or excessive purge (fuel vapor) flow more than .06 lb. per minute. Possible causes are:
    • Fuel Filler Cap Not Installed After Refueling (CHECK FUEL CAP Indicator May Be Illuminated)
    • Fuel Filler Cap Loose Or Cross-Threaded

    Check for missing, loose or cross-threaded fuel filler cap. Repair, reinstall or replace fuel filler cap as necessary. Perform PCM RESET PROCEDURE under CLEARING CODES under SELF-DIAGNOSTIC SYSTEM to clear DTCs. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair. After test is complete, repeat QUICK TEST . If DTC P0455 is present, perform TEST B: DTC P0455: MAJOR LEAK OR NO FLOW DETECTED IN EVAP SYSTEM under SYSTEM TESTS (EVAPORATIVE EMISSION). If a concern with fuel filler cap was not found, perform PCM RESET PROCEDURE under CLEARING CODES under SELF-DIAGNOSTIC SYSTEM to clear DTCs. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) to verify repair. After test is complete, repeat QUICK TEST . If DTC P0455 is present, perform TEST B: DTC P0455: MAJOR LEAK OR NO FLOW DETECTED IN EVAP SYSTEM under SYSTEM TESTS (EVAPORATIVE EMISSION). Otherwise, inform vehicle operator that it is important to immediately install fuel filler cap after every refueling.

    28. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    Fig 4: Identifying CV Solenoid Circuits & Connector Terminals
    G00035605Courtesy of FORD MOTOR CO.

  28. 65) KOEO, KOER & Continuous Memory DTC P1451: Check VPWR Voltage To CV Solenoid
    DTC P1451 is set when PCM detects EVAP Control System Canister Vent (CV) solenoid circuit signal falls below minimum or exceeds maximum allowable parameters for a specified CV duty cycle. Possible causes are:
    • VPWR Circuit Open
    • CV Solenoid Circuit Open, Or Shorted To Chassis GND, PWR GND Or VPWR
    • Faulty CV Solenoid
    • Faulty PCM

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Disconnect CV solenoid connector. Connect a test light between CV and VPWR circuits at CV solenoid harness connector. See Fig 4. Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. See OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS. Using scan tool commands, attempt to open and close CV solenoid driver. Select ALL OFF mode. Observe test light while cycling START button ON and OFF. If test light illuminates and then go off, go to next step. If test light is always off, go to step  67). If test light is always illuminated, go to step  70).

  29. 66) Check CV Solenoid Resistance

    Turn ignition switch to OFF position. Using a DVOM, measure resistance between CV solenoid terminals. If resistance is 48-65 ohms, fault is unable to be duplicated at this time. Go to TEST Z, step 1) . If resistance is not 48-65 ohms, replace CV solenoid. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) at EVAP test port to verify leak did not occur during component replacement. Perform OBD-II DRIVE CYCLE PROCEDURE under DRIVE CYCLE PROCEDURE. Ensure EVAP MONITOR PROCEDURE is performed.

  30. 67) Check For Open VPWR Circuit Between CV Solenoid & Power Relay

    Using a DVOM, measure voltage between negative battery cable and VPWR circuit at CV solenoid harness connector. See Fig 4. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 ohms or less, repair open in VPWR circuit.

  31. 68) Check VPWR Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance of VPWR circuit between CV solenoid harness connector and VPWR fuse to power relay (vehicles with 150-pin PCM), or PCM harness connector (all others). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in VPWR circuit.

  32. 69) Check CV Circuit For Open In Harness

    Using a DVOM, measure resistance of CV circuit between PCM harness connector and CV solenoid harness connector. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in CV circuit.

  33. 70) Check CV Circuit For Short To PWR GND In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Disconnect scan tool from DLC. Using a DVOM, measure resistance between negative battery terminal and CV circuit at CV solenoid harness connector. See Fig 4. If resistance is more than 10 k/ohms, reconnect scan tool to DLC and go to next step. If resistance is 10 k/ohms or less, repair short to PWR GND in CV circuit.

  34. 71) Check CV Circuit For Short To PWR Or Chassis Ground In Harness

    Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and CV circuit at PCM harness connector. If voltage is less than one volt, turn ignition switch to OFF position and replace PCM. If voltage is one volt or more, turn ignition switch to OFF position and repair short to VREF, VPWR or chassis ground in CV circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 71) to step 76). No test procedures have been omitted.
    35. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: On Blackwood, Econoline 4.6L and 5.4L, Escape, Excursion, Expedition, Explorer, Focus, LS, Mountaineer, Mustang, Navigator, Pickup 4.6L and 5.4L (including Lightning 5.4L SC), Thunderbird, Town Car and Windstar, for fuel level indicator or Rear Electronic Module (REM) diagnosis, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.

  35. 76) KOEO, KOER & Continuous Memory DTC P0460: Check Fuel Tank Level
    This DTC is set when PCM detects Fuel Level Input (FLI) circuit signal falls below minimum or exceeds maximum allowable calibrated parameters for a specified fuel fill percentage in fuel tank. Possible causes are:
    • Empty Fuel Tank
    • Fuel Pump Module (FPM) Stuck Open
    • Incorrectly Installed Fuel Gauge
    • Faulty Fuel Gauge Or Instrument Cluster
    • CASE GND Circuit Open Or Shorted To VPWR
    • FLI Circuit Open, Or Shorted To CASE GND, PWR GND Or VPWR
    • Faulty PCM
    • Overfilled Fuel Tank
    • Fuel Pump Module (FPM) Stuck Closed
    • Faulty Fuel Pump

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Note fuel gauge reading. Using scan tool, access FLI PID from PID/DATA MONITOR & RECORD menu. Both fuel gauge and FLI PID readings should be between slightly more than 1/3 (33 percent for FLI PID) and 3/4 (75 percent for FLI PID) filled. If gauge and FLI PID readings are as specified, go to step  78). If gauge and FLI PID readings are not as specified, check fuel tank for leaks. Repair as necessary. If fuel tank is okay, check for faulty fuel pump-to-fuel gauge circuit fuse. Proceed as follows:

    • If fuse is blown and DTC P0460 is not present, check for CASE GND short to VPWR circuit. Go to TEST X, step 1) (Escort and Mustang), or go to TEST B, step 1) (all others).
    • If fuel gauge is inoperative and DTC P0460 is not present, go to appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT and diagnose fuel gauge concern.
    • If fuse is okay and DTC P0460 is present, go to next step.

  36. 77) Check For Inadequate Fuel Level

    Turn ignition switch to ON position. Observe both fuel gauge and FLI PIDs. If fuel level is less than 1/3 (33 percent on FLI PID), add 2-3 gallons of fuel to fuel tank. If fuel level is more than 3/4 (75 percent on FLI PID), drain 2-3 gallons of fuel from fuel tank. If fuel gauge or FLI PID value does not increase or decrease as fuel is added or drained, go to step  79). If either fuel gauge or FLI PID value increases or decreases as fuel is added or drained, clear DTCs. Road test vehicle and repeat QUICK TEST . If DTC P0460 is still present, go to next step.

  37. 78) Check FLI Circuit Voltage

    Start engine and allow to idle. Using scan tool, access FLI V PID from PID/DATA MONITOR & RECORD menu. If FLI V PID voltage is not 1.23-2.25 volts, go to next step. If FLI V PID voltage is 1.23-2.25 volts, go to step  87) (Continental), or go to step  86) (all others).

  38. 79) Check Fuel Pump Module Resistance

    Turn ignition switch to OFF position. Disconnect fuel pump module connector. Using a DVOM, measure resistance between FLI and CASE GND circuits at fuel pump module connector (at pigtail). See Fig 5-Fig 9 . If resistance is 15-160 ohms, go to next step. If resistance is not 15-160 ohms, check for stuck fuel level float on fuel pump. Repair as necessary. If float moves freely, replace fuel pump module.
    Fig 5: Identifying Fuel Pump Module Circuits & Connector Terminals (Continental, Crown Victoria, Explorer Sport, Explorer Sport Trac, Grand Marquis, Ranger - Except 3.0L Flex Fuel, Sable & Taurus)
    G00077825Courtesy of FORD MOTOR CO.
    Fig 6: Identifying Fuel Pump Module Circuits & Connector Terminals (Cougar)
    G00035606Courtesy of FORD MOTOR CO.
    Fig 7: Identifying Fuel Pump Module Circuits & Connector Terminals (Escort)
    G99B02622Courtesy of FORD MOTOR CO.
    Fig 8: Identifying Fuel Pump Module Circuits & Connector Terminals (Econoline)
    G00013286Courtesy of FORD MOTOR CO.
    Fig 9: Identifying Fuel Pump Module Circuits & Connector Terminals (Ranger 3.0L Flex Fuel)
    G00013287Courtesy of FORD MOTOR CO.

  39. 80) Check FLI Circuit Voltage At Fuel Pump Module

    Reconnect all connectors. Disconnect appropriate instrument cluster connector to fuel gauge. For instrument cluster connector location and removal and installation, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Turn ignition switch to ON position. Using a DVOM, measure voltage by backprobing between FLI circuit at fuel pump module harness connector and negative battery terminal. If voltage is more than 5 volts, go to next step. If voltage is 5 volts or less, go to step  82).

  40. 81) Check FLI Circuit For Short To VPWR In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure voltage between negative battery terminal and FLI circuit at fuel pump module harness connector. If voltage is more than 10.5 volts, repair short to VPWR in FLI circuit. If voltage is 10.5 volts or less, replace PCM.

  41. 82) Check FLI Circuit For Short To PWR GND In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance between negative battery terminal and FLI circuit at PCM harness connector. If resistance is more than 10 k/ohms, go to step  84) (Continental), or go to next step (all others). If resistance is 10 k/ohms or less, repair short to PWR GND in FLI circuit.

  42. 83) Check FLI Circuit For Short To CASE GND In Harness

    Using a DVOM, measure resistance between CASE GND and FLI circuits at PCM harness connector. If resistance is more than 10 k/ohms, go to step  85). If resistance is 10 k/ohms or less, repair short between FLI and CASE GND circuits.

  43. 84) Check FLI Circuit For Short To CASE GND In Harness (Continental)

    Using a DVOM, measure resistance between Virtual Image Instrument Cluster (VIC) harness connectors terminal No. 4 (FLI) and terminals No. 27 (fuel logic ground), and No. 28 (fuel level return). See Fig 5 and Fig 10 . If both resistances are more than 10 k/ohms, go to next step. If either resistance is 10 k/ohms or less, repair short between affected circuits.
    Fig 10: Identifying Virtual Image Instrument Cluster Harness Connector Terminals (Continental)
    G97C28607Courtesy of FORD MOTOR CO.

  44. 85) Check FLI Circuit For Open In Harness

    Using a DVOM, measure resistance of FLI circuit between PCM harness connector, fuel pump module connector (pigtail), and instrument cluster connector. See Fig 5-Fig 9 . For instrument cluster connector and terminal identification, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If both resistance measurements are less than 10 ohms, go to step  87) (Continental), or go to next step (all others). If either resistance measurement is 10 ohms or more, repair open in FLI circuit.

  45. 86) Check CASE GND Circuit For Open In Harness

    Turn ignition switch to OFF position. Ensure PCM is disconnected. Using a DVOM, measure resistance of CASE GND circuit between PCM harness connector, fuel pump module connector (pigtail), and instrument cluster harness connector fuel gauge ground terminal. See Fig 5-Fig 9 . If either resistance measurement is 10 ohms or more, repair open in CASE GND circuit. If both resistance measurements are less than 10 ohms, perform fuel gauge symptom diagnosis. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair or replace fuel gauge as necessary. Clear DTCs and repeat QUICK TEST . If DTC P0460 is still present, replace PCM.

  46. 87) Check CASE GND Circuit For Open In Harness (Continental)

    Turn ignition switch to OFF position. Disconnect PCM connector. Using a DVOM, measure resistance of CASE GND circuit between PCM harness connector terminal No. 25 and Virtual Image Instrument Cluster (VIC) harness connector terminal No. 27 (fuel logic ground). Also, measure resistance between CASE GND circuit at fuel pump module connector (pigtail) and VIC harness connector terminal No. 28 (fuel level return). See Fig 5 and Fig 10 . If either resistance measurement is 10 k/ohms or more, repair open circuit. If both resistance measurements are 10 k/ohms or less, check fuel gauge and circuits. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair or replace fuel gauge as necessary. Clear DTCs and repeat QUICK TEST . If DTC P0460 is still present, replace PCM.
    47. NOTE: Perform test step  88) when directed from WARNING INDICATOR LIGHTS symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - GASOLINE & NGV article.

  47. 88) CHECK FUEL CAP Indicator Always ON (No DTCs)
    Turn ignition switch to OFF position. Disconnect PCM connector(s). Turn ignition switch to ON position. If CHECK FUEL CAP indicator light is off, replace PCM. If CHECK FUEL CAP indicator is still illuminated, PCM is not grounding the CHECK FUEL CAP indicator circuit and causing CHECK FUEL CAP indicator to illuminate. Check for short to ground in CHECK FUEL CAP indicator circuit between instrument cluster and PCM. See PCM CHECK FUEL CAP INDICATOR CIRCUIT TERMINAL IDENTIFICATION  table. See WIRING DIAGRAMS article. Repair as necessary.
    PCM CHECK FUEL CAP INDICATOR CIRCUIT TERMINAL IDENTIFICATION

    Application PCM Terminal No.
    Crown Victoria & Grand Marquis 20
    Escort 79
    Focus 46
    Pickup F150 (Except NGV) 70
    Sable, Taurus, Explorer Sport, Explorer Sport Trac & Ranger 82
    48. NOTE: Perform test step  89) when directed here from WARNING INDICATOR LIGHTS symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - GASOLINE & NGV article.

  48. 89) CHECK FUEL CAP Indicator Always OFF (No DTCs)
    Turn ignition switch to OFF position. Disconnect CHECK FUEL CAP indicator circuit harness connector at instrument cluster. See WIRING DIAGRAMS article. Disconnect PCM connector(s). Using a DVOM, measure resistance of CHECK FUEL CAP indicator circuit between CHECK FUEL CAP indicator circuit at instrument cluster harness connector and PCM harness connector. See PCM CHECK FUEL CAP INDICATOR CIRCUIT TERMINAL IDENTIFICATION  table. See Figure and Figure . If resistance is 5 ohms or more, repair open circuit. If resistance is less than 5 ohms, check fuel cap indicator bulb. If bulb is okay, replace PCM.
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