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Home >> Ford >> 2000 >> Contour SVT >> Repair and Diagnosis >> External Pages >> Different car >> Section 130 (ENGINE CONTROLS - SELF-DIAGNOSTICS - 7.3L (995, 996 F650/750, 99F E Series & 99F F450/550) DIESEL) >> System Tests >> Test Kc: Glow Plug System (Federal Emissions) >> Testing

Test Kc: Glow Plug System (Federal Emissions): Testing

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2003 Ford RV Cutaway, 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P0380
All except F650-750 (1) Test KC  , Step  1)   Test KC  , Step  1)
F650-750 Test KC  , Step  1)   Test KC  , Step  1)
(1) MIL illuminates when fault is detected in second drive cycle (California, OBD-II calibration).
WARNING: Red-striped wires carry 115 volts DC. Severe electrical shock may be received. DO NOT pierce engine electrical wires or damage to harness may occur.
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) KOEO & Continuous Memory DTC P0380: Repeat KOEO Self-Test
    Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. Retrieve DTCs. If KOEO DTC P0380 is present, go to next step. If KOEO DTC P0380 is not present, go to step  7).

  2. 2) DTC P0380: Check PWR Circuit To Glow Plug Relay

    DTC P0380 indicates that PCM detects a glow plug relay control circuit malfunction. Possible causes are:
    • Short To Voltage
    • Blown Fuse
    • Faulty Glow Plug Relay
    • PWR Circuit To Glow Plug Relay Open, Or Shorted To Ground Or Power
    • Faulty PCM

    Turn ignition on. Using DVOM, measure voltage between chassis ground and Red wire at glow plug relay. Glow plug relay is located on top of engine. See Figure or Figure . If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in PWR circuit to glow plug relay. On Excursion and F250-550, check PWR circuit fuse No. 22 (20-amp) from PCM relay to glow plug relay. If fuse is blown, check PWR circuit for short to ground. On all models, repair as necessary. See WIRING DIAGRAMS . Clear DTCs and retest.

  3. 3) Check Glow Plug Relay Resistance

    Turn ignition off. Disconnect Violet/Orange wire at glow plug relay. Using DVOM, measure resistance between terminal for Violet/Orange wire and terminal for Red wire at glow plug relay. On all models, if resistance is 1-8 ohms, go to next step. If resistance is not 1-8 ohms, replace glow plug relay. Clear DTCs and retest.

  4. 4) Check For Short To Power

    Turn ignition off. Ensure Violet/Orange wire is disconnected from glow plug relay. 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), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 101 at breakout box. If voltage is 10.5 volts or less, go to next step. If voltage is more than 10.5 volts, repair short to voltage in Violet/Orange wire between PCM and glow plug relay. Clear DTCs and retest.

  5. 5) Check For Short To Ground

    Turn ignition off. Using DVOM, measure resistance between chassis ground and disconnected Violet/Orange wire. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, locate and repair short to ground in Violet/Orange wire between PCM and glow plug relay. Clear DTCs and retest.

  6. 6) Check For Open Circuit

    Using DVOM, measure resistance between disconnected Purple/Orange wire and test pin No. 101 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Purple/Orange wire. Clear DTCs and retest.
    7. NOTE: Glow plug "on" time is dependent on oil temperature and altitude. Glow plug relay comes on between 1-120 seconds and does not come on at all if oil temperature is above 86°F (30°C) for Econoline, or 131°F (55°C) for Excursion and F250-750. GPCTM PID value can be used to verify glow plug "on" time.

  7. 7) Check Glow Plug Relay "On" Time
    Turn ignition on. Using scan tool, access EOT and GPCTM PIDs from PID/DATA MONITOR & RECORD menu. Verify EOT PID value is less than 86°F (30°C) on Econoline, or less than 131°F (55°C) on Excursion and F250-750. On all models, measure voltage between chassis ground and glow plug relay terminal No. 87 (Brown wire on Econoline and F650-750, or White wire on F250-550). See WIRING DIAGRAMS . If voltage is present for the time indicated on GPCTM PID, go to next step. If voltage is not present for the time indicated on GPCTM PID, replace glow plug relay. Clear DTCs and retest.

  8. 8) Check For Intermittent Fault

    Clear DTCs. Wiggle and bend small sections of wiring harness starting at glow plug relay and working toward PCM. PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous DTC P0380 is present, locate and repair intermittent circuit fault in wiring harness. If Continuous DTC P0380 is not present, fault cannot be duplicated at this time and testing is complete.
    9. NOTE: Perform test steps 9)  and 10)  when directed here from NO-START/NORMAL CRANK, ERRATIC START OR CRANK, HARD START OR LONG CRANK OR STALLS AFTER START symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - 7.3L DIESEL article.

  9. 9) Check Glow Plugs
    Turn ignition off. Disconnect glow plug/injector connectors at both valve cover gaskets. Using DVOM and Glow Plug Adapter (134-00132), measure resistance between chassis ground and each glow plug connector. See WIRING DIAGRAMS . If resistance is .1-2.0 ohms, go to next step. If resistance is not .1-2.0 ohms, remove valve cover and inspect harness for opens and shorts. If harness is okay, replace appropriate glow plug.

  10. 10) Check Glow Plug Connectors

    Using DVOM, measure resistance between each glow plug contact in engine harness and the 2 brown wires on glow plug relay. If resistance is 0-2.0 ohms, inspect inside of air filter-to-turbocharger air duct. If dirt or abrasives are present, engine may be damaged or worn. See 7.3L V8 TURBO DIESEL article in ENGINES for engine testing and repair procedures. If resistance is not 0-2.0 ohms, replace engine wiring harness.
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