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Test Me: Pcm Reset: Testing

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  1. 1) Check Vehicle Battery Power Circuit

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950) and connect PCM to breakout box. Turn ignition on. Using DVOM, measure voltage between PCM power test pins No. 55, 71 and 97 and PCM ground test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are more than 10.5 volts and within one volt of each other, go to next step. If any resistance is 10.5 volts or less or not within one volt of each other, go to TEST A, step  1).

  2. 2) Check VREF Voltage

    Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is 4-6 volts, go to next step. If voltage is less than 4 volts, go to step  5). If voltage is more than 6 volts, go to step  4).

  3. 3) Check VREF & SIG RTN Circuits

    Turn ignition off. Disconnect suspect sensor connector. See Figure or Figure . Disconnect PCM from breakout box. Using DVOM, measure resistance between test pin No. 90 at breakout box and VREF circuit terminal at suspect sensor harness connector. See Figure. Using DVOM, measure resistance between test pin No. 91 at breakout box and SIG RTN circuit terminal at suspect sensor harness connector. If both resistances are less than 5 ohms, no concern is indicated at this time. Fault may be intermittent. Retest system. If either resistance is 5 ohms or more, locate and repair open in VREF or SIG RTN circuit. Retest system.

  4. 4) Check For Excess Voltage On VREF Circuit

    Disconnect PCM connector from breakout box. Turn ignition on. Using DVOM, measure voltage between negative battery terminal and test pin No. 90 at breakout box. If voltage is less than .5 volt, replace PCM. Retest system. If voltage is .5 volt or more, locate and repair short to voltage. Retest system.

  5. 5) Check SIG RTN Circuit

    Turn ignition off. Using DVOM, measure resistance between test pin No. 91 and test pins No. 25, 51, 76 (Econoline), 77 and 103 at breakout box. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, replace PCM. Retest system.

  6. 6) Check For Shorted Accelerator Pedal/Electronic Throttle Control (AP/ETC) Sensor

    Disconnect AP/ETC sensor connector. Sensor is located above accelerator pedal. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace AP/ETC sensor. Retest system.

  7. 7) Check For Shorted Camshaft Position (CMP) Sensor

    Turn ignition off. Disconnect CMP sensor connector. Sensor is located right on front of engine, above crankshaft pulley. See Figure or Figure . Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace CMP sensor.

  8. 8) Check For Shorted Injection Control Pressure (ICP) Sensor

    Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top center of engine. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace ICP sensor.

  9. 9) Check For Shorted Exhaust Backpressure (EBP) Sensor

    Turn ignition off. Disconnect EBP sensor connector. Sensor is located on top front of engine. See Figure or Figure . Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace EBP sensor.

  10. 10) Check For Shorted Manifold Absolute Pressure (MAP) Sensor

    Turn ignition off. Disconnect MAP sensor connector. MAP sensor is mounted to cowl in engine compartment. Inspect connector for damaged pins, corrosion and loose wires. Repair connector as necessary. Turn ignition on. Using DVOM, measure voltage between test pins No. 90 and 91 at breakout box. If voltage is less than 4 volts, leave sensor disconnected and go to next step. If voltage is 4 volts or more, replace MAP sensor.

  11. 11) Check VREF Circuit For Short To Ground

    Disconnect PCM connector from breakout box. Ensure all 3-wire sensors are still disconnected. Using DVOM, measure resistance between test pin No. 90 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace PCM and perform QUICK TEST . If any resistance is 10 k/ohms or less, go to next step.

  12. 12) Check PCM & Vehicle Harness Connectors

    Ensure ignition is off. Disconnect IDM 40-pin connector. IDM is located in left side of engine compartment. Inspect IDM, PCM and harness connectors for damaged, loose or pushed out terminals, or loose or poorly crimped wires. Remove valve covers. Inspect under valve cover connectors and harnesses for damage. If any connectors or terminals are damaged, repair as necessary. Retest system. If all connectors and terminals are okay, go to next step.

  13. 13) Check High Side Circuit For Short To Ground

    Disconnect both valve cover connectors on bank with fault. Using DVOM, measure resistance between suspect high side circuit at IDM connector and negative battery terminal. See Figure. If resistance is more than 10 k/ohms, fault may be intermittent. Go to next step. If resistance is 10 k/ohms or less, repair short to ground. Retest system.

  14. 14) Check Injector Circuit For Short To Ground

    Using DVOM, measure resistance between chassis ground and suspect high side circuit at IDM connector. Wiggle and bend small sections of wiring harness starting at harness closest to suspect injector harness connector and work toward IDM. A fault is indicated when resistance changes to 10 k/ohms or less. If fault is indicated, isolate intermittent short to ground and repair as necessary. Retest system. If no fault is indicated, ensure no circuit issues are present. Repair circuits as necessary and retest system. If concern still exists, replace IDM and retest system.
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