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Pinpoint Test E: Electronic Pressure Control (EPC) Solenoid

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to TRANSAXLE VEHICLE HARNESS CONNECTOR  for the transaxle vehicle harness connector illustration.
NOTE: Refer to TRANSAXLE INTERNAL HARNESS DIAGRAM  for the transaxle internal harness diagram illustration.
  1. E1 ELECTRONIC DIAGNOSTICS 
    • Check to make sure the transaxle harness connector is fully seated, terminals are engaged in connector and in good condition before proceeding.
    • Connect the diagnostic tool.
    • Carry out KOEO Test until continuous DTCs have been displayed.
    • Enter Output Test Mode (OTM).
    • Select the mode ALL ON. PUSH START to turn outputs ON. PUSH STOP to turn outputs OFF.
    • Does the vehicle enter Output Test Mode (OTM)? 

      Yes 

      REMAIN in Output OTM. GO to E2.

      No 

      PRESS START. If the vehicle does not enter OTM, refer to INTRODUCTION - CNG, FLEX-FUEL & GASOLINE .

  2. E2 CHECK THE ELECTRICAL SIGNAL OPERATION 
    CAUTION: Do not pry on the connector. This will damage the connector and could result in a transaxle concern. Pull up on the connector harness.
    • Disconnect: Transaxle Vehicle Harness Connector.
    • Use a mirror to inspect both ends of the connector for damage or pushed out pins, corrosion, loose wires and missing or damaged seals.
    • Connect a VOM positive lead to VPWR pin 7 and the negative test lead to the solenoid circuit pin 10 of the transaxle vehicle harness connector.
      Fig 1: Checking Electrical Signal Operation
      G03244458Courtesy of FORD MOTOR CO.
    • Place the VOM on the 20 volt scale.
    • While observing the VOM, press start and stop to cycle solenoid output ON and OFF.
    • Does the suspect solenoid output voltage change at least 0.5 volt? 

      Yes 

      GO to  E5.

      No 

      GO to E3

  3. E3 CHECK THE CONTINUITY OF THE SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS 
    • Key in OFF position.
    • Disconnect: Powertrain Control Module (PCM).
    • Inspect for damaged or pushed out pins, corrosion or loose wires.
    • Install the EEC-V Control System Breakout Box.
    • Measure the resistance between the powertrain control module (PCM) signal test pin 71 at the EEC-V Control System Breakout Box and the EPC PWR circuit pin 7 at the transaxle vehicle harness connector.
    Fig 2: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (1 Of 2)
    G03244459Courtesy of FORD MOTOR CO.
    • Measure the resistance between the PCM signal test pin 81 at the EEC-V Control System Breakout Box and the EPC signal pin 10 at the transaxle harness connector.
      Fig 3: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (2 Of 2)
      G03244460Courtesy of FORD MOTOR CO.
    • Is each resistance less than 5 ohms? 

      Yes 

      GO to E4.

      No 

      REPAIR the open circuit(s). REMOVE the EEC-V Control System Breakout Box. CONNECT all of the components. ERASE the codes and REPEAT the On -Board Diagnostic Tests.

  4. E4 CHECK THE HARNESS FOR SHORT TO POWER AND GROUND 
    • Disconnect: Transaxle Harness Connector.
    • Measure the resistance between the EPC circuit PCM test pin 81 and pin 71 at the EEC-V Control System Breakout Box.
      Fig 4: Checking Harness For Short To Power And Ground (1 Of 2)
      G03244461Courtesy of FORD MOTOR CO.
    • Measure the resistance between the EPC circuit PCM test pin 81 and test pins 24, 25, 51, 76, 77, 91 and 103 at the EEC-V Control System Breakout Box.
      Fig 5: Checking Harness For Short To Power And Ground (2 Of 2)
      G03244462Courtesy of FORD MOTOR CO.
    • Is each resistance greater than 10,000 ohms? 

      Yes 

      GO to E5.

      No 

      REPAIR the short circuit(s). REMOVE the EEC-V Control System Breakout Box. RECONNECT all of the components. ERASE the codes and REPEAT the On -Board Diagnostic Tests.

  5. E5 TRANSMISSION FUNCTIONAL TEST 
    CAUTION: Do not pry on the connector. This will damage the connector and could result in a transaxle concern. Pull up on the connector harness.
    • Connect: PCM.
    • Install a line pressure gauge at the line tap on the transaxle case.
    • Disconnect: Transaxle Vehicle Harness.
    • Connect: Transmission Tester.
    • Set Bench/Drive switch to DRIVE mode.
    • Rotate Gear Select switch to first gear position.
      NOTE: LED will turn GREEN when EPC solenoid activates and turn OFF when deactivated. LED will turn RED if an ACTIVATED solenoid/harness is shorted to battery positive. LED will remain off if an ACTIVATED solenoid/harness is shorted to ground or no continuity (open circuit).
    • Carry out Dynamic Testing - Engine ON, EPC Solenoid Functional Test. Refer to the transmission tester manual.
    • Observe line pressure on the gauge while pressing EPC switch (engine must be running).
    • Does the EPC (GREEN LED) activate when EPC switch is pressed and line pressure drops? 

      Yes 

      INSTALL a new powertrain control module. INSPECT the PCM power relay. REPAIR as required.

      No 

      GO to E6.

  6. E6 CHECK THE RESISTANCE OF THE SOLENOID/HARNESS 
    NOTE: Refer to the transmission tester for terminal locations.
    • Set the Bench/Drive switch to BENCH mode.
    • Rotate the Gear Select switch to the OHMS CHECK position.
    • Connect the ohmmeter negative lead to the VPWR jack and the positive lead to the EPC jack on the tester.
      Fig 6: Checking Resistance Of Solenoid/Harness
      G03244463Courtesy of FORD MOTOR CO.
    • Record the resistance.
      NOTE: Out of specification may be caused by the internal harness or EPC solenoid concerns.
    • The resistance should be between 3.23 and 5.5 ohms.
    • Is the resistance between 3.23 and 5.5 ohms? 

      Yes 

      GO to E7.

      No 

      GO to  E8.

  7. E7 CHECK THE SOLENOID/HARNESS FOR SHORT TO GROUND 
    • Check for continuity between the BAT - jack (engine ground) and the appropriate jack with an ohmmeter or other low current tester (less than 200 milliamps).
      Solenoid Tester Jack
      EPC EPC
      VPWR
      Fig 7: Checking Solenoid/Harness For Short To Ground
      G03244464Courtesy of FORD MOTOR CO.
    • Connection should show infinite resistance (no continuity).
    • Does the connection show continuity? 

      Yes 

      GO to E8.

      No 

      Refer to DIAGNOSIS BY SYMPTOM .

  8. E8 INTERNAL ELECTRONIC DIAGNOSTICS 
    • Remove the transaxle side pan.
    • Check that the internal harness connector is fully engaged on the EPC solenoid assembly.
    • Check that the internal harness connector terminals are fully seated in the connector.
    • Inspect the connector for damage.
    • Are the above in good condition and engaged correctly? 

      Yes 

      GO to E9.

      No 

      REPAIR as required.

  9. E9 CHECK THE INTERNAL HARNESS (CONTINUITY) 
      CAUTION: Do not probe into the connector terminals. This will damage the connector and could result in a transaxle concern.
    • Disconnect the EPC solenoid.
    • Connect the positive lead from an ohmmeter to the tester EPC jack and the negative lead at the blue wire at the EPC wire connector.
      Fig 8: Checking Internal Harness (Continuity) (1 Of 2)
      G03244465Courtesy of FORD MOTOR CO.
    • Record the resistance. The resistance should be less than 0.5 ohms.
    • Connect the positive lead from an ohmmeter to the tester VPWR jack and the negative lead at the green wire at the EPC wire connector.
      Fig 9: Checking Internal Harness (Continuity) (2 Of 2)
      G03244466Courtesy of FORD MOTOR CO.
    • Record the resistance. The resistance should be less than 0.5 ohms.
    • Is the resistance for each solenoid less than 0.5 ohms? 

      Yes 

      GO to E10.

      No 

      INSTALL a new internal harness. GO to  E11.

  10. E10 CHECK THE INTERNAL HARNESS (SHORT TO GROUND) 
    • Check for continuity between BAT(-) jack (engine ground) and the appropriate wire with an ohmmeter or other low current tester (less than 200 milliamps).
      Solenoid Wire
      EPC Blue (Signal)
      Green (EPC VPWR)
      Fig 10: Checking Internal Harness (Short To Ground)
      G03244467Courtesy of FORD MOTOR CO.
    • Connection should show infinite resistance (no continuity).
    • Does the connection show continuity? 

      Yes 

      INSTALL a new internal harness. GO to E11

      No 

      GO to E11.

  11. E11 CHECK THE SOLENOID RESISTANCE 
    • Check the solenoid resistance by connecting an ohmmeter at the EPC solenoid terminals of the solenoid.
      Fig 11: Checking Solenoid Resistance
      G03244468Courtesy of FORD MOTOR CO.
    • Record the resistance. The resistance should be between 3.23 and 5.5 ohms.
    • Is the resistance for each solenoid betweeen 3.23 and 5.5 ohms? 

      Yes 

      GO to E12.

      No 

      INSTALL a new EPC solenoid.

  12. E12 CHECK THE SOLENOID FOR SHORT TO GROUND 
    • Check for continuity between BAT(-) jack (engine ground) and the appropriate terminal with an ohmmeter or other low current tester (less than 200 milliamps).
      Solenoid Terminal
      D EPC +/-
      Fig 12: Checking Solenoid For Short To Ground
      G03244469Courtesy of FORD MOTOR CO.
    • Connection should show infinite resistance (no continuity).
    • Does the connection show continuity? 

      Yes 

      INSTALL a new EPC solenoid.

      No 

      Refer to DIAGNOSIS BY SYMPTOM .

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