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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 747 (Engine Controls - Pinpoint Tests - 6.0L Diesel (99P E-Series & 99P F450/550)) >> Pinpoint Test AG: Accelerator Pedal Position (APP) Sensor >> Test Procedure

Test Procedure

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2004 Ford RV Cutaway, 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
  1. AG1 PRELIMINARY DIAGNOSIS 
    • Perform visual inspection.
    • Connect the scan tool.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record freeze frame data.
    • Clear all DTCs.
    • Perform the KOEO On-Demand Self-Test.

    ARE ANY DTCS RETRIEVED? 

    Yes No
    For DTC P2122, P2127, P2132: Go to  AG2.
    For DTC P2123, P2128, P2133: Go to  AG8.    		 UNABLE to duplicate condition. CHECK for loose connections, damaged or corroded pins. WIGGLE harness attempting to recreate fault. REFER to SYMPTOM CHARTS - 6.0L DIESEL .
  2. AG2 DIAGNOSTIC TROUBLE CODE (DTC) P2122/P2127/P2132 
    NOTE: Refer to the PCM and component connector pin numbers, Figure, Figure and Figure, at the beginning of this pinpoint test.
    • Possible causes:
      • APP not seated correctly
      • APP sensor
      • open in signal circuit
      • signal circuit shorted to ground
      • PCM
    • Key on.
    • Access PIDs APP1, APP2, APP3.
    • Press the accelerator pedal while observing voltage reading on scan tool.
    • Observe PID while pressing the accelerator pedal.

    DO ALL SIGNAL VALUES CHANGE WHEN THE ACCELERATOR IS PRESSED? 

    Yes No
    Unable to duplicate condition. CHECK for loose connections, damaged or corroded pins. WIGGLE harness attempting to recreate fault. REFER to SYMPTOM CHARTS - 6.0L DIESEL . Go to  AG3.
  3. AG3 CHECK VREF SENSOR CIRCUITS 
    • Key off.
    • Disconnect the APP sensor C2040.
    • Key on.
    • Measure the voltage between the APP sensor C2040 pins, harness side as follows:
    Vehicle Pin Pin
    F-Super Duty / Excursion 4 9
    E-Series 7 1

    IS THE VOLTAGE BETWEEN 4.5-5.5 VOLTS? 

    Yes No
    Go to  AG4. REPAIR open in VREF or signal return circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  4. AG4 CHECK SECONDARY VREF AND SIGNAL RETURN CIRCUITS 
    • Measure the voltage between the APP sensor C2040 pins, harness side as follows:
      Vehicle Pin Pin
      F-Super Duty / Excursion 5 10
      E-Series 6 3

    IS THE VOLTAGE BETWEEN 4.5-5.5 VOLTS? 

    Yes No
    Go to  AG5. REPAIR open in secondary VREF or signal return circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  5. AG5 CHECK APP SENSOR OPERATION 
    • Install a 5 amp fused jumper wire between the APP sensor C2040 pin 4 (F-Super Duty/Excursion) or pin 7 (E-Series), harness side and the suspect APP sensor circuit, harness side.
    • Access APP PID values.

    IS THE VOLTAGE OF THE SUSPECT SIGNAL CIRCUIT BETWEEN 4.5-5.5 VOLTS? 

    Yes No
    INSTALL a new APP sensor assembly. RESTORE the vehicle. CLEAR DTCs and RETEST the system. Go to  AG6.
  6. AG6 CHECK APP SENSOR SIGNAL FOR AN OPEN 
    • Key off.
    • Disconnect the PCM body harness connector.
    • Measure the resistance of faulted signal circuit between the PCM body harness connector and APP harness connector.

    IS THE RESISTANCE LESS THAN 5 OHMS? 

    Yes No
    Go to  AG7. REPAIR open in faulted APP signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  7. AG7 CHECK FAULTED APP SENSOR SIGNAL FOR A SHORT TO GROUND 
    • Measure the resistance of the faulted signal circuit between the APP harness connector and ground.

    IS THE RESISTANCE GREATER THAN 10,000 OHMS? 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR the DTCs and RETEST the system REPAIR short to ground in faulted APP signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  8. AG8 DIAGNOSTIC TROUBLE CODE (DTCs) P2123/P2128/P2133 
    NOTE: Refer to the PCM and component connector pin numbers, Figure, Figure and Figure, at the beginning of this pinpoint test.
    • Possible causes:
      • signal shorted to voltage
      • signal return open
      • APP sensor
      • PCM
    • Key on.
    • Access APP PID volts.
    • Slowly press the accelerator pedal while observing the voltage reading.

    DO ALL SIGNAL VALUES CHANGE WHEN THE ACCELERATOR IS PRESSED? 

    Yes No
    Unable to duplicate condition. CHECK for loose connections, damaged or corroded pins. WIGGLE harness attempting to recreate fault. REFER to SYMPTOM CHARTS - 6.0L DIESEL . Go to  AG9.
  9. AG9 INDUCE OPPOSITE FAILURE 
    • Key off.
    • Disconnect the APP sensor electrical connector.
    • Key on.
    • Access APP PID volts.

    DO ALL PID SIGNAL VALUES READ 0 VOLTS? 

    Yes No
    INSTALL a new APP sensor assembly. RESTORE the vehicle. CLEAR DTCs and RETEST the system. Go to  AG10.
  10. AG10 CHECK APP SIGNAL CIRCUITS FOR A SHORT TO VOLTAGE 
    • Key off.
    • Disconnect the PCM body harness electrical connector.
    • Key on.
      • Measure the voltage of faulted signal circuit between the APP harness connector and ground.

    IS THE VOLTAGE LESS THAN 0.2 VOLTS? 

    Yes No
    Go to  AG11. REPAIR short to voltage in faulted APP signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  11. AG11 CHECK APP SIGNAL CIRCUITS FOR A SHORT TO GROUND 
    • Key off.
    • Measure the resistance of faulted signal circuit between the APP harness connector and ground.

    IS THE RESISTANCE GREATER THAN 10,000 OHMS? 

    Yes No
    Go to  AG12. REPAIR short to ground in the faulted signal circuit. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  12. AG12 CHECK APP SIGNAL RETURN CIRCUITS FOR AN OPEN 
    • Measure the resistances between the PCM connector, harness side and the APP sensor C2040, harness side as follows:
      RESISTANCE MEASUREMENT SPECIFICATIONS - AG12

      Vehicle PCM Connector Pin APP Sensor Connector Pin
      F-Super Duty / Excursion C1381a 33 C2040 9
      F-Super Duty / Excursion C1381a 20 C2040 10
      E-Series C176a 33 C2040 1
      E-Series C176a 20 C2040 3

    ARE THE RESISTANCES LESS THAN 5 OHMS? 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR DTCs and RETEST the system. REPAIR open in signal return circuit in question. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  13. AG13 DIAGNOSTIC TROUBLE CODES (DTCs) P2138/P2139/P2140 
    NOTE: Refer to the PCM and component connector pin numbers, Figure, Figure and Figure, at the beginning of this pinpoint test.
    • Possible causes:
      • APP sensor
      • PCM
      • high circuit resistance
    • Clear all DTCs.
    • Perform the On-Demand Self-Test.

    ARE DTCS P2138, P2139 OR P2140 PRESENT? 

    Yes No
    Go to  AG14. If other DTCs are present, Go to the appropriate pinpoint test procedure. If no DTCs are present, attempt to recreate fault. ROAD TEST the vehicle. RERUN On-Demand Self-Test. If no DTCs are retrieved, RESTORE the vehicle. System OK.
  14. AG14 CHECK ACCELERATOR PEDAL ASSEMBLY FOR BINDING 
    • Press the accelerator pedal slowly to the floor and release.

    DOES THE ACCELERATOR PEDAL MOVE TO THE FLOOR AND RETURN WITHOUT BINDING? 

    Yes No
    Go to  AG15. INSTALL a new APP sensor assembly. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
  15. AG15 CHECK APP SENSOR SIGNAL VOLTAGE RANGES 
    • Key on.
    • Access and monitor APP sensor 1, 2, and 3 PIDs.
    • Press the accelerator pedal slowly to the floor and release.
    PID VOLTAGE SPECIFICATIONS

    Pedal Position APP1 APP2 APP3
    CT 3.92-4.17 1.37-1.62 0.82-1.07
    WOT 0.53-0.78 3.93-4.18 3.38-3.63

    ARE THE PID VOLTAGES WITHIN THE RANGE SPECIFIED IN THE 

    Yes No
    INSTALL a new PCM. RESTORE the vehicle. CLEAR DTCs and RETEST the system. INSTALL a new APP sensor assembly. RESTORE the vehicle. CLEAR DTCs and RETEST the system.
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