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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis (Single Page) >> Engine Performance >> Testing & Diagnosis >> Engine Controls - Self-Diagnostics - EEC-V - CNG, Flex-Fuel & Gasoline >> System Tests >> Test HX: Evaporative Emission Monitor & System >> Diagnostic Aids

Diagnostic Aids

NOTE: After each service or repair procedure has been completed, reconnect all components. Clear DTCs. If any EVAP components were replaced, perform VEHICLE PREPARATION FOR OBD-II OR MONITOR REPAIR VERIFICATION DRIVE CYCLE and EVAP RUNNING LOSS SYSTEM REPAIR VERIFICATION DRIVE CYCLE. See DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. After drive cycle is complete, repeat QUICK TEST  procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

Perform this test when instructed during QUICK TEST or if directed by other test procedures. This test is used to diagnose the following:

To identify EVAP system components, see appropriate illustration. See Fig 1-Fig 7 .

Fig 1: Identifying EVAP System Components (Continental, Mustang, Sable, Taurus & Contour, Cougar & Mystique - Late Production)
G99A02607Courtesy of FORD MOTOR CO.
Fig 2: Identifying EVAP System Components (Contour, Cougar & Mystique - Early Production, Escort & Focus)
G00013274Courtesy of FORD MOTOR CO.
Fig 3: Identifying EVAP System Components (Crown Victoria, Grand Marquis & Town Car)
G98C00226Courtesy of FORD MOTOR CO.
Fig 4: Identifying EVAP System Components (Econoline, Expedition, Navigator, Pickup & Ranger)
G00013276Courtesy of FORD MOTOR CO.
Fig 5: Identifying EVAP System Components (Explorer & Mountaineer)
G00013277Courtesy of FORD MOTOR CO.
Fig 6: Identifying EVAP System Components (LS)
G00013275Courtesy of FORD MOTOR CO.
Fig 7: Identifying EVAP System Components (Windstar)
G00013278Courtesy of FORD MOTOR CO.
NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION  table of fault code setting condition.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P0443  HX2  HX2  HX1
P0452  HX26  HX26  HX26
P0453  HX33  HX33  HX33
P0460  HX76  HX76  HX76
P1450      HX18
P1451  HX65  HX65  HX65

  1. 1) DTC P0443: Inspect EVAP Canister Purge Valve Circuit

    This DTC indicates an intermittent EVAP canister purge valve circuit fault. Repeat KOEO ON-DEMAND SELF-TEST  and KOER ON-DEMAND SELF-TEST  . If DTC P0443 is present in KOEO or KOER self-test, go to next step. If DTC P0443 is present in Continuous Memory only, check for intermittent fault. Go to TEST Z . If no fault is indicated after performing TEST Z, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  2. 2) DTC P0443: Check VPWR Circuit Voltage

    Turn ignition switch to OFF position. Disconnect EVAP canister purge valve connector. Turn ignition switch to ON position. Measure voltage between VPWR terminal at EVAP canister purge valve harness connector and negative battery terminal. See Fig 8. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit.
    Fig 8: Identifying EVAP Canister Purge Valve Circuits & Connector Terminals
    G00013279Courtesy of FORD MOTOR CO.
    3. NOTE: Engine must be cold to check EVAP canister purge valve resistance.

  3. 3) Check EVAP Canister Purge Valve Resistance
    Turn ignition switch to OFF position. Measure resistance between EVAP canister purge valve terminals. If resistance is 30-38 ohms, go to next step. If resistance is not 30-38 ohms, replace EVAP canister purge valve. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure OBD-II DRIVE CYCLE PROCEDURES are performed to verify repair. After drive cycle is complete, repeat QUICK TEST .

  4. 4) Check EVAP Canister Purge Valve Circuit For Open In Harness

    Ensure ignition switch is turned to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Using a DVOM, measure resistance of EVAP CANISTER PURGE VALVE circuit between PCM harness connector and EVAP canister purge valve harness connector. See Figure or Figure, and Fig 8 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in EVAP CANISTER PURGE VALVE circuit.

  5. 5) Check EVAP Canister Purge Valve Circuit For Short To PWR GND In Harness

    Disconnect scan tool from DLC. Using a DVOM, measure resistance between negative battery terminal and PCM harness connector EVAP CANISTER PURGE VALVE terminal. If resistance is 10 k/ohms or less, repair short to PWR GND in EVAP CANISTER PURGE VALVE circuit. If resistance is more than 10 k/ohms, go to next step.

  6. 6) Check EVAP Canister Purge Valve Circuit For Short To VPWR In Harness

    Turn ignition switch to ON position. Using a DVOM, measure resistance between negative battery terminal and PCM harness connector EVAP CANISTER PURGE VALVE circuit terminal. If voltage is more than 10.5 volts, repair short to VPWR in EVAP CANISTER PURGE VALVE circuit. If voltage is 10.5 volts or less, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 6) to step 18). No test procedures have been omitted.

  7. 18) DTC P1450: Visual Inspection For Cause Of Excessive Fuel Tank Vacuum

    This DTC indicates that PCM has detected EVAP control system has excessive fuel tank vacuum. Possible causes are:
    • EVAP Canister Purge Tube Blocked Or Kinked.
    • Fuel Vapor Elbow On EVAP Canister Is Contaminated.
    • Restricted EVAP Canister
    • Canister Vent (CV) Solenoid Stuck Open
    • Plugged Or Contaminated CV Solenoid Filter
    • EVAP Canister Purge Valve Stuck Open
    • Fuel Filler Cap Stuck Closed (No Vacuum Relief)
    • Open In VREF Circuit
    • Faulty Fuel Tank Pressure (FTP) Sensor

    Check for kinks in fuel vapor hoses/tubes. Visually inspect EVAP canister inlet port, CV solenoid filter and canister vent hose for contamination or debris. Check CV solenoid filter for blockage or contamination. Repair as necessary and go to next step. If no faults are found, go to next step.

  8. 19) Check Fuel Tank Pressure Sensor PID Voltage

    Turn ignition switch to ON position. Using scan tool, select FTP V PID. If FTP V PID voltage is not 2.4-2.8 volts with fuel filler cap installed, turn ignition switch to OFF position and go to next step. If FTP V PID voltage is 2.4-2.8 volts with fuel filler cap installed, a possible intermittent condition may be causing DTC P1450. Go to TEST Z . If circuit is okay, check for blocked or plugged EVAP system. Perform appropriate testing for DTC P1450, or blocked or plugged EVAP system problem in SYSTEM TESTS (EVAPORATIVE EMISSIONS) . Repair as necessary.

  9. 20) Check Fuel Tank Pressure Sensor FTP V PID (Fuel Filler Cap Removed)

    Remove fuel filler cap. Turn ignition switch to ON position. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID voltage is not 2.4-2.8 volts, turn ignition switch to OFF position and go to next step. If FTP V PID voltage is 2.4-2.8 volts with fuel filler cap removed, perform appropriate testing for a blocked or plugged EVAP system problem in SYSTEM TESTS (EVAPORATIVE EMISSIONS) . Repair as necessary.

  10. 21) Check For Other DTCs

    Check for other 3-wire sensor DTCs that are present with DTC P1450. If any other DTCs are present, perform appropriate system test and repair as necessary. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no other DTCs are present, go to next step.

  11. 22) Check Voltage Between VREF & SIG RTN Circuits

    Turn ignition switch to OFF position. Disconnect FTP sensor connector, located on top of fuel tank. Turn ignition switch to ON position. Measure voltage between VREF and SIG RTN terminals at FTP sensor harness connector. See Fig 9 and Fig 10 . If voltage is 4-6 volts, replace FTP sensor. If voltage is not 4-6 volts, go to next step.
    Fig 9: Identifying FTP Sensor Circuits & Connector Terminals (Escort)
    G00013280Courtesy of FORD MOTOR CO.
    Fig 10: Identifying FTP Sensor Circuits & Connector Terminals (All Others)
    G00013281Courtesy of FORD MOTOR CO.

  12. 23) Check For Open VREF & SIG RTN Circuits

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Measure resistance of VREF circuit between PCM connector terminal and terminal at FTP sensor harness connector. See Fig 9 and Fig 10 . If all resistance readings are less than 5 ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If any resistance reading is 5 ohms or more, repair open circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 23) to step 26). No test procedures have been omitted.

  13. 26) DTC P0452: Check For FTP Sensor Connector Contamination

    This DTC is set when PCM detects Fuel Tank Pressure (FTP) sensor input signal drops below minimum allowable parameter. Possible causes are:
    • Contaminated FTP Sensor
    • Faulty Powertrain Control Module (PCM)
    • FTP Circuit Shorted To GND Or SIG RTN
    • Faulty FTP Sensor

    Turn ignition switch to OFF position. Visually inspect FTP sensor connector for liquid fuel contamination. Check for submerged FTP sensor in liquid fuel (tank mounted type only). Repair as necessary and adjust fuel tank overfill. If FTP sensor connector is okay, go to next step.

    14. NOTE: FTP sensor input with no pressure or vacuum on fuel tank (fuel filler cap open or not open to atmosphere) should be 2.37-2.97 volts.

  14. 27) Check FTP Sensor Voltage
    Turn ignition switch to ON position. Using scan tool, select FTP V PID. If FTP V PID is not available on scan tool, measure voltage between PCM connector terminals for FTP and SIG RTN circuits. See Fig 9 and Fig 10 . If measured voltage or PID voltage is less than .22 volt, go to next step. If voltage is .22 volt or more, fault is intermittent. Go to TEST Z .

  15. 28) Check Opposite Induced High FTP Signal

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Connect a jumper wire between FTP sensor harness connector VREF and FTP terminals. Turn ignition switch to ON position. If scan tool communication link error is displayed, remove jumper wire and go to next step. Using scan tool, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage by backprobing between PCM harness connector FTP and SIG RTN circuit terminals. If voltage measurement on DVOM or FTP V PID value is 4-6 volts, replace FTP sensor. If voltage measurement on DVOM or FTP V PID value is not 4-6 volts, remove jumper wire and go to next step.

  16. 29) Check Voltage At FTP Sensor Connector

    Measure voltage between VREF and SIG RTN terminals at FTP sensor harness connector. See Fig 9 and Fig 10 . If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, VREF voltage is out of range. Go to TEST C .

  17. 30) Check FTP Circuit For Short To SIG RTN Or PWR GND In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Disconnect scan tool from DLC. Using a DVOM, measure resistance between PCM harness connector FTP and SIG RTN circuit terminals, and between battery negative cable and PCM harness connector FTP circuit terminal. If any resistance reading is 10 k/ohms or less, repair FTP circuit short to SIG RTN or PWR GND circuit. If both resistance measurements are more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 30) to step 33). No test procedures have been omitted.
    18. NOTE: FTP sensor input with no pressure or vacuum on fuel tank (fuel filler cap open or not open to atmosphere) should be 2.37-2.97 volts.

  18. 33) DTC P0453: Check FTP Sensor Voltage
    Turn ignition switch to ON position. Using scan tool, select FTP V PID. If FTP V PID is not available on scan tool, measure voltage between PCM connector terminals for FTP and SIG RTN circuits. See Fig 9 and Fig 10 . If measured voltage or PID voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, fault is intermittent. Go to TEST Z .

  19. 34) Check For Short To Power

    Turn ignition switch to OFF position. Disconnect FTP sensor connector, located on top of fuel tank. Turn ignition switch to ON position. Measure voltage between FTP terminal at FTP sensor harness connector and negative battery terminal. If voltage is 10.5 volts or less, go to step  36). If voltage is more than 10.5 volts, a short to VPWR exists. Go to next step.

  20. 35) Check FTP Circuit For Short To VPWR Circuit

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Turn ignition switch to ON position. Measure voltage between PCM connector FTP circuit terminal and negative battery terminal. If voltage is more than 10.5 volts, repair short circuit. If voltage is 10.5 volts or less, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  21. 36) Check Opposite Induced Low FTP Signal

    Turn ignition switch to OFF position. Connect a jumper wire between SIG RTN and FTP terminals at FTP sensor harness connector. Turn ignition switch to ON position. If scan tool communication link error is displayed, remove jumper wire and go to step  41). Using scan tool, select FTP V PID. If FTP V PID is not available on scan tool, measure voltage between PCM connector terminals for FTP and SIG RTN circuits. See Fig 9 and Fig 10 . If PID voltage is less than .1 volt, remove jumper wire and go to next step. If PID voltage is .1 volt or more, unable to induce opposite signal. Go to step  39).

  22. 37) Check Voltage At FTP Sensor Connector

    Ensure ignition switch is in ON position. Measure voltage between VREF and SIG RTN terminals at FTP sensor harness connector. If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, VREF voltage is out of range. Go to TEST C .

  23. 38) Check FTP Circuit For Short To VREF In Sensor Or Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Using a DVOM, measure voltage between PCM harness connector FTP and VREF circuit terminals (both VREF terminals on 150-pin PCM). See WIRING DIAGRAMS article. If resistance is more than 10 k/ohms, replace FTP sensor. If resistance is 10 k/ohms or less, repair short to VREF in FTP circuit.

  24. 39) Check For Open FTP Circuit

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance of FTP circuit between PCM connector terminal and FTP terminal at FTP sensor harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in FTP circuit.

  25. 40) Check For Open SIG RTN Circuit

    Measure resistance SIG RTN circuit between PCM connector terminal and SIG RTN terminal at FTP sensor harness connector. See Fig 9 and Fig 10 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in SIG RTN circuit.

  26. 41) Check FTP Circuit For Short To VREF Circuit

    Measure resistance between PCM connector terminals FTP and VREF circuits. If resistance is more than 10 k/ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If resistance is 10 k/ohms or less, repair FTP circuit short to VREF circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 41) to step 43). No test procedures have been omitted.

  27. 43) DTC P0457: Check For Missing Or Leaking Fuel Filler Cap

    This DTC is set when PCM detects a fuel tank pressure decreases more than 7 in. H2 O within 30 seconds after refueling, or excessive purge (fuel vapor) flow more than .06 lbs. per minute. Possible causes are:
    • Fuel Filler Cap Not Installed After Refueling (CHECK FUEL CAP Indicator May Be Illuminated)
    • Fuel Filler Cap Loose Or Cross-Threaded

    Check for missing, cross-threaded or leaking fuel filler cap. Repair or replace as necessary. Clear DTCs. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure OBD-II DRIVE CYCLE PROCEDURES are performed to verify repair. After drive cycle is complete, repeat QUICK TEST . If DTC P0455 or P0457 is present, see EVAPORATIVE EMISSIONS SYMPTOMS  table under SYSTEM TESTS (EVAPORATIVE EMISSIONS). If a missing, cross-threaded or leaking fuel filler cap condition was not found, clear DTCs. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure OBD-II DRIVE CYCLE PROCEDURES are performed to verify repair. After drive cycle is complete, repeat QUICK TEST . If DTC P0455 is present, see EVAPORATIVE EMISSIONS SYMPTOMS  table under SYSTEM TESTS (EVAPORATIVE EMISSIONS).

    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 43) to step 65). No test procedures have been omitted.

  28. 65) DTC P1451: Check VPWR Voltage To CV Solenoid

    This DTC is set when PCM detects Canister Vent (CV) solenoid circuit signal falls below minimum or exceeds maximum allowable parameters for a specified CV duty cycle. Possible causes are:
    • VPWR Circuit Open
    • CV Solenoid Circuit Open, Or Shorted To Chassis GND, PWR GND Or VPWR
    • Faulty CV Solenoid
    • Faulty PCM

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Disconnect CV solenoid connector. Connect a test light between CV solenoid harness connector CV and VPWR circuit terminals. See Fig 11. Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. See OUTPUT TEST MODE  under ADDITIONAL SYSTEM FUNCTIONS. Attempt to open and close CV solenoid driver. Select ALL OFF mode. Observe test light while cycling START button ON and OFF. If test light cycles on and off, go to next step. If test light stays off, go to step  67). If test light stays on (illuminated), go to step  70).

    Fig 11: Identifying Canister Vent Solenoid Circuits & Connector Terminals
    G00013285Courtesy of FORD MOTOR CO.

  29. 66) Check CV Solenoid Resistance

    Turn ignition switch to OFF position. Measure resistance between CV solenoid terminals. If resistance is 48-65 ohms, go to TEST Z . If resistance is not 48-65 ohms, replace CV solenoid and perform EVAP system leak test. See EVAPORATIVE EMISSIONS SYSTEM LEAK TEST  under SYSTEM TESTS (EVAPORATIVE EMISSIONS). Repair as necessary. Perform DRIVE CYCLE PROCEDURES  under ADDITIONAL SYSTEM FUNCTIONS. Ensure OBD-II DRIVE CYCLE PROCEDURES are performed to verify repair.

  30. 67) Check For Open VPWR Circuit Between CV Solenoid & Power Relay Resistance

    Using a DVOM, measure voltage between negative battery cable and CV solenoid harness connector VPWR terminal. See Fig 11. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 ohms or less, repair open in VPWR circuit.

  31. 68) Check VPWR Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance of VPWR circuit between CV solenoid harness connector and VPWR fuse to power relay (vehicles with 150-pin PCM) or PCM harness connector (all other vehicles). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in VPWR circuit.

  32. 69) Check CV Circuit Resistance

    Measure resistance of CV circuit between PCM connector terminal and CV terminal at CV solenoid harness connector. See Fig 11. If resistance is 5 ohms or more, repair open in CV circuit. See WIRING DIAGRAMS article. If resistance is less than 5 ohms, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  33. 70) Check CV Circuit For Short To Ground

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Disconnect scan tool from DLC. Measure resistance between CV terminal at CV solenoid harness connector and negative battery terminal. If resistance is more than 10 k/ohms, reconnect scan tool to DLC and go to next step. If resistance is 10 k/ohms or less, repair short to ground in CV circuit.

  34. 71) Check CV Circuit Short To PWR Or Chassis Ground

    Turn ignition switch to ON position. Measure voltage between chassis ground and PCM connector CV circuit terminal. If voltage is less than one volt, turn ignition switch to OFF position. Replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If voltage is one volt or more, turn ignition switch to OFF and repair short to VREF, VPWR or chassis ground in CV circuit.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 71) to step 76). No test procedures have been omitted.

  35. 76) DTC P0460: Check Fuel Tank Level

    This DTC is set when PCM detects Fuel Level Input (FLI) circuit signal falls below minimum or exceeds maximum allowable calibrated parameters for a specified fuel fill percentage in fuel tank. Possible causes are:
    • Empty Fuel Tank
    • Fuel Pump Module (FPM) Stuck Open
    • Incorrectly Installed Fuel Gauge
    • Faulty Fuel Gauge Or Instrument Cluster
    • CASE GND Circuit Open Or Shorted To VPWR
    • FLI Circuit Open, Or Shorted To CASE GND, PWR GND Or VPWR
    • Faulty PCM
    • Overfilled Fuel Tank
    • Fuel Pump Module (FPM) Stuck Closed
    • Faulty Fuel Pump

    On Expedition, Focus, Mustang, Navigator, F150 Pickup (including Lightning 5.4L SC), Town Car, Windstar and vehicles with 150-pin PCM, diagnose fuel level indicator or Rear Electronic Module (REM). See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. On all other models, connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Note fuel gauge reading. Using scan tool, access FLI PID from PID/DATA MONITOR & RECORD menu. If both fuel gauge and FLI PID readings are between 1/3 (33 percent for FLI PID) and 3/4 (75 percent for FLI PID), go to step  78). If readings are not as specified, check fuel tank for leaks. Repair as necessary. If fuel tank is okay, check for faulty fuse for fuel pump-to-fuel gauge circuit. Proceed as follows:

    • If fuse is okay and DTC P0460 is present, go to next step.
    • If fuse is blown and DTC P0460 is not present, check for CASE GND short to VPWR circuit. On Escort and Mustang, go to TEST X step  1). On all other models, go to TEST B, step  1).
    • If fuel gauge is inoperative and DTC P0460 is not present, go to appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT and diagnose fuel gauge problem.

  36. 77) Check For Inadequate Fuel Level

    Turn ignition switch to ON position. Observe both fuel gauge and FLI PIDs. If fuel level is less than 1/3 (33 percent on FLI PID), add 2-3 gallons of fuel to fuel tank. If fuel level is more than 3/4 (75 percent on FLI PID), drain 2-3 gallons of fuel from fuel tank. If fuel gauge or FLI PID value does not increase or decrease as fuel is added or drained, go to step  79). If either fuel gauge or FLI PID value increases or decreases as fuel is added or drained, clear DTCs. Road test vehicle and repeat QUICK TEST . If DTC P0460 is still present, go to next step.
    37. NOTE: DO NOT use scan tool to access FLI V PID for diagnosis on Contour, Cougar and Mystique 2.5L during the following procedure. Only use FLI V PID on vehicles without returnless fuel systems.

  37. 78) Check FLI Circuit Voltage
    Start engine and allow to idle. On Contour, Cougar and Mystique 2.5L, use a DVOM and measure voltage by backprobing between PCM harness connector FLI and SIG RTN circuit terminals. On all other models, using scan tool, access FLI V PID from PID/DATA MONITOR & RECORD menu. Voltage measurement on DVOM or FLI V PID value should be 4.39-6.14 volts (2.0L and 2.5L Cougar), or 1.23-2.25 volts (all others). If voltage measurement on DVOM or FLI V PID value is not within specification, go to next step. If voltage measurement on DVOM or FLI V PID value is within specification, go to step  87) (Continental), or go to step  86) (all other models).

  38. 79) Check Fuel Pump Module Resistance

    Turn ignition switch to OFF position. Disconnect fuel pump module connector. Measure resistance between FLI and CASE GND terminals at fuel pump module harness connector. See Fig 12-Fig 18 . If resistance is 15-160 ohms, go to next step. If resistance is not 15-160 ohms, check for stuck fuel level float on fuel pump. Repair as necessary. If float moves freely, replace fuel pump module.
    Fig 12: Identifying Fuel Pump Module Circuits & Connector Terminals (Contour, Cougar & Mystique)
    G99C02613Courtesy of FORD MOTOR CO.
    Fig 13: Identifying Fuel Pump Module Circuits & Connector Terminals (Escort)
    G99B02622Courtesy of FORD MOTOR CO.
    Fig 14: Identifying Fuel Pump Module Circuits & Connector Terminals (Econoline, Expedition, Navigator & Pickup)
    G00013286Courtesy of FORD MOTOR CO.
    Fig 15: Identifying Fuel Pump Module Circuits & Connector Terminals (Continental, Crown Victoria, Explorer, Grand Marquis, Mountaineer, Town Car & Windstar)
    G00013288Courtesy of FORD MOTOR CO.
    Fig 16: Identifying Fuel Pump Module Circuits & Connector Terminals (Ranger Flex Fuel)
    G99H02615Courtesy of FORD MOTOR CO.
    Fig 17: Identifying Fuel Pump Module Circuits & Connector Terminals (Ranger Gasoline)
    G00013287Courtesy of FORD MOTOR CO.
    Fig 18: Identifying Fuel Pump Module Circuits & Connector Terminals (Sable & Taurus)
    G00013289Courtesy of FORD MOTOR CO.

  39. 80) Check FLI Circuit Voltage At Fuel Pump Module

    Reconnect all connectors. Disconnect instrument cluster connector to fuel gauge. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Turn ignition switch to ON position. Measure voltage between FLI terminal at fuel pump module harness connector and negative battery terminal. If voltage is more than 5 volts, go to next step. If voltage is 5 volts or less, go to step  82).

  40. 81) Check FLI Circuit For Short To VPWR

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Measure voltage between FLI terminal at fuel pump module harness connector and negative battery terminal. If voltage is more than 10.5 volts, repair short in FLI circuit. If voltage is 10.5 volts or less, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  41. 82) Check FLI Circuit For Short To Ground

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance between negative battery terminal and PCM harness connector FLI circuit terminal. See Figure or Figure . See WIRING DIAGRAMS article. If resistance is 10 k/ohms or less, repair short to ground. If resistance is more than 10 k/ohms, go to step  84) for Continental, or go to next step for all other models.

  42. 83) Check FLI & CASE GND Circuits

    Using a DVOM, measure resistance between PCM harness connector CASE GND and FLI circuit terminals. If resistance is more than 10 k/ohms, go to step  85). If resistance is 10 k/ohms or less, repair short between FLI and CASE GND circuits.

  43. 84) Check FLI Circuit For Short To CASE GND (Continental)

    Using a DVOM, measure resistance between Virtual Image Instrument Cluster (VIC) harness connector terminal No. 4 (FLI) and terminals No. 27 (fuel logic ground) and No. 28 (fuel level return). See Fig 15 and Fig 19 . If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short between FLI and fuel level return or fuel logic ground circuits.
    Fig 19: Identifying Virtual Image Instrument Cluster Wiring Harness Connector Terminals (Continental)
    G97C28607Courtesy of FORD MOTOR CO.

  44. 85) Check For Open In FLI Circuit

    Using a DVOM, measure resistance of FLI circuit between PCM harness connector and fuel pump module harness connector. See Fig 12-Fig 18 . Also, measure resistance of FLI circuit between PCM harness connector and instrument cluster connector. For instrument cluster connector identification, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If both resistance measurements are less than 10 ohms, go to step  87) (Continental), or go to next step (all other models). If any resistance reading is 10 ohms or more, repair open in FLI circuit

  45. 86) Check For Open In CASE GND Circuit

    Measure resistance between PCM connector terminal No. 25 (CASE GND) and CASE GND terminal at fuel pump module harness connector. Measure resistance between PCM connector terminal No. 25 (CASE GND) and fuel gauge ground terminal at instrument cluster harness connector. If any resistance reading is 10 k/ohms or more, repair open in CASE GND circuit. If both resistance readings are less than 10 k/ohms, check fuel gauge. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. Clear DTCs. Repeat QUICK TEST . If DTC P0460 is still present, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .

  46. 87) Check For Open In CASE GND Circuit (Continental)

    Measure resistance between PCM connector terminal No. 25 (CASE GND) and terminal No. 27 at virtual image instrument cluster C255 harness connector. See Fig 19. If resistance is less than 10 k/ohms, check fuel gauge and circuits. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. Repeat QUICK TEST . If DTC P0460 is still present, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If resistance is 10 k/ohms or more, repair open circuit.
    47. NOTE: Perform test step  88) when directed from WARNING INDICATOR LIGHTS symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V (GASOLINE) article.

  47. 88) Check Fuel Cap Light Always On (No DTCs)
    Turn ignition switch to OFF position. Disconnect PCM connector(s). Turn ignition switch to ON position. If fuel cap indicator light is off, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE . If fuel cap indicator light is still on, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary.

  48. 89) Check Fuel Cap Light Always Off (No DTCs)

    Turn ignition switch to OFF position. Disconnect fuel cap indicator light connector at instrument cluster. Disconnect PCM connector(s). Using a DVOM, measure resistance of FUEL CAP OFF INDICATOR circuit between fuel cap indicator light harness connector and PCM harness connector. See PCM FUEL CAP OFF INDICATOR CIRCUIT TERMINALS  table. See Figure and Figure . If resistance is 5 ohms or more, repair open circuit. If resistance is less than 5 ohms, check fuel cap indicator bulb. If bulb is okay, replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Program PCM. See FLASH VEHICLE IDENTIFICATION BLOCK PROCEDURE .
    PCM FUEL CAP OFF INDICATOR CIRCUIT TERMINALS

    Application PCM Terminal No.
    Crown Victoria & Grand Marquis 20
    Escort 79
    Explorer & Mountaineer 4.0L, & Focus 46
    Sable, Taurus & Ranger 82
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