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Testing (F150)

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford Econoline, 2002 Ford Cutaway, and 2002 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Battery must be fully charged to perform solenoid diagnostics. Ensure manual lock-down valve jackscrew on rear in-bed fuel tank solenoid valve is in open (full counterclockwise) position.

  1. Check Rear In-Bed Fuel Tank Solenoid Valve For An Open
    Turn ignition off. Connect grounding cable, venting hose assembly and fuel filler neck venting kit to vent stack and fuel fill valve assembly. See Figure and Figure . Vent stack installation must be approved by local authorities. For additional fuel tank venting information, see FUEL SYSTEM PRESSURE RELEASE in REMOVAL, OVERHAUL & INSTALLATION - F150 PICKUP - NGV article. Close manual lock-down valve jackscrew on forward in-bed fuel tank and mid fuel tank (if equipped) solenoid valve. See Figure. Tighten jackscrew(s) to 62-79 INCH lbs. (7-9 N.m). Open manual backflow valve on fuel filler valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds, then close bleed valve. Observe and record system pressure on fuel filler neck venting kit pressure gauge. If pressure is zero psi (zero kPa), go to step  3. If pressure is more than zero psi (zero kPa), go to next step.

  2. Check Rear In-Bed Fuel Tank Solenoid Valve Power Circuit For Short To Voltage

    Ensure ignition is off. Disconnect rear in-bed fuel tank solenoid valve harness connector C4123. Using DVOM, measure voltage between chassis ground and rear in-bed fuel tank solenoid valve harness connector C4123 terminal No. 1 (Pink/Black wire). See Figure. If voltage is more than 10 volts, repair short to power in Pink/Black wire. See WIRING DIAGRAMS article. Retest system for normal operation and go to step  6. If voltage is 10 volts or less, mark rear in-bed fuel tank solenoid valve as "Stuck Open". A NEW solenoid valve will be installed after diagnostics are completed. Go to step  6.
    3. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  3. Check Rear In-Bed Fuel Tank Solenoid Valve Operation
    Turn ignition off. Reconnect rear in-bed fuel tank solenoid valve harness connector C4123. Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record pressure on fuel filler neck venting kit pressure gauge. Press "Stop" button on scan tool. If pressure reading was zero psi (zero kPa) when "Start" button was pressed, go to next step. If pressure reading was more than zero psi (zero kPa) when "Start" button was pressed, mark rear in-bed fuel tank solenoid valve as "Functions Normally", then go to step  6.
    4. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  4. Check Rear In-Bed Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect rear in-bed fuel tank solenoid valve harness connector C4123. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Using DVOM, measure voltage between chassis ground and rear in-bed fuel tank solenoid valve harness connector C4123 terminal No. 1 (Pink/Black wire). See Figure. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire. See WIRING DIAGRAMS article. Retest system for normal operation and go to step  6.

  5. Check Rear In-Bed Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and rear in-bed fuel tank solenoid valve wiring harness connector C4123 terminal No. 2 (Black wire). If resistance is less than 5 ohms, mark rear in-bed fuel tank solenoid valve as "Stuck Closed". A NEW solenoid valve will be installed after diagnostics are completed. Go to next step. If resistance is 5 ohms or more, repair open in Black wire between chassis ground and solenoid valve. See WIRING DIAGRAMS article. Retest system for normal operation and go to next step.

  6. Check Forward In-Bed Fuel Tank Solenoid Valve For An Open

    Turn ignition off. Reconnect rear in-bed fuel tank solenoid valve harness connector C4123. Close manual lock-down valve jackscrew on rear in-bed fuel tank solenoid valve. See Figure. Tighten jackscrew to 62-79 INCH lbs. (7-9 N.m). See Figure. Open manual lock-down jackscrew on forward in-bed fuel tank solenoid valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds, then close bleed valve. Observe and record system pressure on fuel filler neck venting kit pressure gauge. If pressure is zero psi (zero kPa), go to step  8. If pressure is more than zero psi (zero kPa), go to next step.

  7. Check Forward In-Bed Fuel Tank Solenoid Valve Power Circuit For Short To Voltage

    Ensure ignition is off. Disconnect forward in-bed fuel tank solenoid valve harness connector C4124. Using DVOM, measure voltage between chassis ground and forward in-bed fuel tank solenoid valve harness connector C4124 terminal No. 1 (Pink/Black wire). See Figure. Proceed as follows:
    • If voltage is 10 volts or more and vehicle is not equipped with a midship fuel tank, repair short to voltage in Pink/Black wire. See WIRING DIAGRAMS article. Replace solenoids marked "Stuck Open" or "Stuck Closed" and retest system for normal operation.
    • If voltage is 10 volts or more and vehicle is equipped with a midship fuel tank, repair short to voltage in Pink/Black wire and go to step  11. See WIRING DIAGRAMS article.
    • If voltage is less than 10 volts and vehicle is not equipped with a midship fuel tank, replace forward in-bed fuel tank solenoid valve and all other solenoids marked "Stuck Open" or "Stuck Closed". Retest system for normal operation.
    • If voltage is less than 10 volts and vehicle is equipped with a midship fuel tank, mark forward in-bed fuel tank solenoid valve as "Stuck Open" and go to step  11.
    8. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  8. Check Forward In-Bed Fuel Tank Solenoid Valve Operation
    Ensure ignition is off. Reconnect forward in-bed fuel tank solenoid valve harness connector C4124. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record pressure on fuel filler neck venting kit pressure gauge. Press "Stop" button on scan tool. If pressure is zero psi (zero kPa) when "Start" button is pressed, go to next step. If pressure is not zero psi (zero kPa) when "Start" button is pressed, mark forward in-bed fuel tank solenoid valve as "Functions Normally". If vehicle is equipped with a midship fuel tank, go to step  11. If vehicle is not equipped with a midship fuel tank, replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open". Retest system for normal operation.
    9. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  9. Check Forward In-Bed Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect forward in-bed fuel tank solenoid valve harness connector C4124. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Using DVOM, measure voltage between chassis ground and forward in-bed fuel tank solenoid valve harness connector C4124 terminal No. 1 (Pink/Black wire). See Figure. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire. See WIRING DIAGRAMS article. If vehicle is equipped with a midship fuel tank, go to step  11. If vehicle is not equipped with a midship fuel tank, replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open". Retest system for normal operation.

  10. Check Forward In-Bed Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and forward in-bed fuel tank solenoid valve harness connector C4124 terminal No. 2 (Black wire). Proceed as follows:
    • If resistance is 5 ohms or more and vehicle is not equipped with a midship fuel tank, repair open in Black wire and replace any solenoids marked "Stuck Open" or "Stuck Closed". See WIRING DIAGRAMS article. Retest system for normal operation.
    • If resistance is 5 ohms or more and vehicle is equipped with a midship fuel tank, repair open in Black wire and go to next step. See WIRING DIAGRAMS article.
    • If resistance is less than 5 ohms and vehicle is not equipped with a midship fuel tank, replace forward in-bed fuel tank solenoid valve and any other solenoid marked "Stuck Open" or "Stuck Closed". Retest system for normal operation.
    • If resistance is less than 5 ohms and vehicle is equipped with a midship fuel tank, mark forward in-bed fuel tank solenoid valve as "Stuck Closed" and go to next step.

  11. Check Midship Fuel Tank Solenoid Valve For An Open

    Ensure ignition is off. Reconnect forward in-bed fuel tank solenoid valve harness connector C4124. Close manual lock-down valve jackscrews on forward and rear in-bed fuel tank solenoid valves. See Figure. Tighten manual lock-down jackscrews 62-79 INCH lbs. (7-9 N.m). Open manual lock-down jackscrew on midship fuel tank solenoid valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds, then close bleed valve. Observe and record system pressure on fuel filler neck venting kit pressure gauge. If pressure is zero psi (zero kPa), go to step  13. If pressure is more than zero psi (zero kPa), go to next step.

  12. Check Midship Fuel Tank Solenoid Valve Power Circuit For Short To Voltage

    Ensure ignition is off. Disconnect midship fuel tank solenoid valve harness connector C4126. Using DVOM, measure voltage between chassis ground and midship fuel tank solenoid valve harness connector C4126 terminal No. 1 (Pink/Black wire). See Figure. If voltage is more than 10 volts, repair short to power in Pink/Black wire. Replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open" and retest system for normal operation. See WIRING DIAGRAMS article. If voltage is 10 volts or less, replace midship fuel tank solenoid valve and any solenoid valve that is marked "Stuck Closed" or "Stuck Open". Retest system for normal operation.
    13. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  13. Check Midship Fuel Tank Solenoid Valve Operation
    Ensure ignition is off. Reconnect midship fuel tank solenoid valve harness connector C4126. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record pressure on fuel filler neck venting kit pressure gauge. Press "Stop" button on scan tool. If pressure is zero psi (zero kPa) when "Start" button was pressed, go to next step. If pressure is more than zero psi (zero kPa) when "Start" button was pressed, mark midship fuel tank solenoid valve as "Functions Normally". Replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open" and retest system for normal operation.
    14. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  14. Check Midship Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect midship fuel tank solenoid valve harness connector C4126. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Using DVOM, measure voltage between chassis ground and midship fuel tank solenoid valve harness connector C4126 terminal No. 1 (Pink/Black wire). If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire. See WIRING DIAGRAMS article. Replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open" and retest system for normal operation.

  15. Check Midship Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and midship fuel tank harness connector C4126 terminal No. 2 (Black wire). If resistance is more than 5 ohms, repair open in Black wire. See WIRING DIAGRAMS article. Replace any solenoid valve that is marked "Stuck Closed" or "Stuck Open" and retest system for normal operation. If resistance is 5 ohms or less, replace midship fuel tank solenoid valve and any solenoid valve that is marked "Stuck Closed" or "Stuck Open". Retest system for normal operation.
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