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Home >> Ford >> 2001 >> Focus ZTS, Standard >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> Engine Controls Self-Diagnostics - EEC-V - CNG & Gasoline - System Tests Ff - Kc >> 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 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)
G99A02607Courtesy of FORD MOTOR CO.
Fig 2: Identifying EVAP System Components (Crown Victoria, Grand Marquis & Town Car)
G98C00226Courtesy of FORD MOTOR CO.
Fig 3: Identifying EVAP System Components (Econoline, Expedition, Navigator, Pickup & Ranger)
G00013276Courtesy of FORD MOTOR CO.
Fig 4: Identifying EVAP System Components (Cougar, Escape, Escort & Focus)
G00035604Courtesy 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
P0457      HX43
P0460  HX76  HX76  HX76
P1450      HX18
P1460  HX65  HX65  HX65

  1. 1) Continuous Memory DTC P0443: Inspect EVAP Canister Purge Valve Circuit For Intermittent Failure

    This DTC is set when PCM detects EVAP canister purge valve circuit signal reads outside minimum or maximum allowable calibrated parameters for a specified duty cycle. Possible causes are:
    • VPWR Circuit Open
    • EVAP Canister Purge Valve Circuit Open, Or Shorted To Ground Or VPWR
    • Faulty EVAP Canister Purge Valve
    • Faulty PCM

    Repeat KOEO ON-DEMAND SELF-TEST and KOER ON-DEMAND SELF-TEST . If DTC P0443 is present in Continuous Memory only, check for intermittent fault. Go to TEST Z, step 1) . If no fault is indicated after performing TEST Z, replace PCM. If DTC P0443 is present in KOEO or KOER ON-DEMAND self-test, go to next step.

  2. 2) KOEO & KOER DTC P0443: Check VPWR Voltage To EVAP Canister Purge Valve

    Turn ignition switch to OFF position. Disconnect EVAP canister purge valve connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and EVAP canister purge valve harness connector VPWR 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. Ensure EVAP canister purge valve is disconnected. Using a DVOM, 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.

  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 voltage 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.
    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) Continuous Memory DTC P1450: Check For Visual Causes Of Excessive Fuel Tank Vacuum

    This DTC is set when PCM EVAP running loss monitor detects excessive fuel tank vacuum with engine running (not at idle). Possible causes are:
    • Blocked Or Kinked EVAP Canister Tube Or EVAP Canister Purge Outlet Tube
    • Fuel Filler Cap Stuck Closed (No Vacuum Relief)
    • Contaminated Fuel Vapor Elbow On EVAP Canister
    • Restricted EVAP Canister
    • Canister Vent (CV) Solenoid Stuck Open
    • Plugged CV Solenoid Filter
    • EVAP Canister Purge Valve Stuck Open
    • Open In VREF Circuit
    • Faulty Fuel Tank Pressure (FTP) Sensor
    NOTE: Some components may need to be removed to gain access and diagnose EVAP components. For removal and installation procedures, see appropriate REMOVAL, OVERHAUL & INSTALLATION article.

    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 FTP V PID Voltage (Fuel Filler Cap Installed)

    Turn ignition switch to OFF position. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access FTP V V PID from PID/DATA MONITOR & RECORD menu. 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, step 1) . 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, check for blocked or plugged EVAP system. Perform appropriate testing for DTC P1450. See EVAPORATIVE EMISSIONS DIAGNOSTIC TROUBLE CODE REFERENCE table 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. Perform KOEO ON-DEMAND SELF-TEST , KOER ON-DEMAND SELF-TEST and CONTINUOUS MEMORY SELF-TEST . If any other DTCs are present along with DTC P1450, perform appropriate system test, see DIAGNOSTIC TROUBLE CODE DEFINITIONS table, and repair as necessary. If no other DTCs are present, turn ignition switch to OFF position and go to next step.

  11. 22) Check VREF Voltage From PCM To FTP Sensor

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between FTP sensor harness connector VREF and SIG RTN terminals. See Fig 9 and Fig 10 . If voltage is not 4-6 volts, go to next step. If voltage is 4-6 volts, turn ignition switch to OFF position and replace FTP sensor. Clear DTCs and 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 P1450 is still present, perform appropriate testing for DTC P1450 in SYSTEM TESTS (EVAPORATIVE EMISSIONS) . Repair as necessary.
    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 Between PCM & FTP Sensor

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Using a DVOM, measure resistance of VREF and SIG RTN circuits between PCM harness connector and FTP sensor harness connector. See Fig 9 and Fig 10 . If both resistance measurements are less than 5 ohms, replace PCM. If either resistance measurement is 5 ohms or more, repair open in VREF or SIG RTN 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 should be 2.37-2.97 volts.

  14. 27) Check For Low FTP Sensor Voltage
    Turn ignition switch to OFF position. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition switch to ON position. 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 terminals for FTP and SIG RTN circuits. See Fig 9 and Fig 10 . If voltage measurement on DVOM or FTP V PID value is less than .22 volt, go to next step. If voltage is .22 volt or more, fault is unable to be duplicated at this time. Go to TEST Z, step 1) .

  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 meaurement 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 Between VREF & SIG RTN Circuits At FTP Sensor

    Ensure ignition switch is turned to ON position. Using a DVOM, measure voltage between FTP sensor harness connector VREF and SIG RTN terminals. 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, step 1) .

  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 both resistance measurements are more than 10 k/ohms, replace PCM. If either resistance measurement is 10 k/ohms or less, repair FTP circuit short to SIG RTN or PWR GND circuit.
    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. 33) DTC P0453: Check For High FTP Sensor Voltage

    This DTC is set when PCM detects Fuel Tank Pressure (FTP) sensor input signal exceeds maximum allowable parameter. Possible causes are:
    • FTP Circuit Open
    • VREF Shorted To VPWR
    • Faulty Powertrain Control Module (PCM)
    • FTP Circuit Shorted To VREF Or VPWR
    • SIG RTN Circuit Open
    • Faulty FTP Sensor
    NOTE: FTP sensor input with no pressure or vacuum on fuel tank should be 2.37-2.97 volts.

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. 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. See Fig 9 and Fig 10 . If voltage measurement on DVOM or PID voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volts or less, fault is unable to be duplicated at this time. Go to TEST Z, step 1) .

  19. 34) Check FTP Circuit For Short To VPWR

    Turn ignition switch to OFF position. Disconnect FTP sensor connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and FTP sensor harness connector FTP circuit 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 In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals. Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and PCM harness connector FTP circuit terminal. If voltage is more than 10.5 volts, repair short to VPWR in FTP circuit. If voltage is 10.5 volts or less, replace PCM.

  21. 36) Check Opposite Induced Low FTP Signal

    Turn ignition switch to OFF position. Connect a jumper wire between FTP sensor harness connector SIG RTN and FTP terminals. 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, access FTP V PID from PID/DATA MONITOR & RECORD menu. If FTP V PID is not available on scan tool, measure voltage between PCM harness connector FTP and SIG RTN circuit terminals. See Fig 9 and Fig 10 . If voltage measurement on DVOM or FTP V PID value is less than .1 volt, remove jumper wire and go to next step. If voltage measurement on DVOM or FTP V PID value is .1 volt or more, unable to induce opposite signal. Go to step  39).

  22. 37) Check For In Range Voltage Between VREF & SIG RTN Circuits At FTP Sensor

    Ensure ignition switch is turned to ON position. Using a DVOM, measure voltage between FTP sensor harness connector VREF and SIG RTN terminals. 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, step 1) .

  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 PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. 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 FTP Circuit For Open In 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 resistance of FTP circuit between PCM harness connector and 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 FTP circuit.

  25. 40) Check For Open SIG RTN Circuit Between PCM & FTP Sensor

    Ensure ignition switch is turned to OFF position. Using a DVOM, measure resistance SIG RTN circuit between PCM harness connector and 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 SIG RTN circuit.

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

    Ensure ignition switch is turned to OFF position and PCM is disconnected. Using a DVOM, measure resistance between PCM harness connector FTP and VREF circuit terminals (both VREF terminals on 150-pin PCM). See PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. If resistance is more than 10 k/ohms, replace PCM. If resistance is 10 k/ohms or less, repair short to VREF in FTP 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) Continuous Memory 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, loose or cross-threaded fuel filler cap. Repair or replace as necessary. Clear DTCs and 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 DIAGNOSTIC TROUBLE CODE REFERENCE under SYSTEM TESTS (EVAPORATIVE EMISSIONS) table. If problem was not found, clear DTCs and 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 DIAGNOSTIC TROUBLE CODE REFERENCE under SYSTEM TESTS (EVAPORATIVE EMISSIONS) table.

    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 CV Solenoid Circuits & Connector Terminals
    G00035605Courtesy of FORD MOTOR CO.

  29. 66) Check CV Solenoid Resistance

    Turn ignition switch to OFF position. Using a DVOM, measure resistance between CV solenoid terminals. If resistance is 48-65 ohms, fault is unable to be duplicated at this time. Go to TEST Z, step 1) . If resistance is not 48-65 ohms, replace CV solenoid.

  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 For Open In Harness

    Using a DVOM, measure resistance of CV circuit between PCM harness connector and CV solenoid harness connector. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open in CV circuit.

  33. 70) Check CV Circuit For Short To PWR GND In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Disconnect scan tool from DLC. Using a DVOM, measure resistance between negative battery terminal and CV solenoid harness connector CV circuit terminal. See Fig 11. 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 PWR GND in CV circuit.

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

    Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and PCM harness connector CV circuit terminal. If voltage is less than one volt, turn ignition switch to OFF position and replace PCM. If voltage is one volt or more, turn ignition switch to OFF position 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 Escape, 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) problem. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. On all other models, turn ignition switch to OFF position. 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 measurements 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 Cougar 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 Cougar 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 within specification, go to step  87) (Continental) or go to step  86) (all other models). If voltage measurement on DVOM or FLI V PID value is not within specification, go to next step (all models).

  38. 79) Check Fuel Pump Module Resistance

    Turn ignition switch to OFF position. Disconnect fuel pump module connector. Using a DVOM, measure resistance between fuel pump module harness connector FLI and CASE GND terminals. See Fig 12-Fig 17 . 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 (Cougar)
    G00035606Courtesy 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)
    G00013286Courtesy of FORD MOTOR CO.
    Fig 15: Identifying Fuel Pump Module Circuits & Connector Terminals (Continental, Crown Victoria, Explorer, Explorer Sport, Explorer Sport Trac, Grand Marquis & Mountaineer)
    G00035607Courtesy of FORD MOTOR CO.
    Fig 16: Identifying Fuel Pump Module Circuits & Connector Terminals (Ranger)
    G00013287Courtesy of FORD MOTOR CO.
    Fig 17: 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. For instrument cluster removal and installation, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Turn ignition switch to ON position. Using a DVOM, measure voltage by backprobing between negative battery terminal and fuel pump module harness connector FLI 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 In Harness

    Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure voltage between negative battery terminal and fuel pump module harness connector FLI circuit terminal. If voltage is more than 10.5 volts, repair short to VPWR in FLI circuit. If voltage is 10.5 volts or less, replace PCM.

  41. 82) Check FLI Circuit For Short To PWR GND In Harness

    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. If resistance is more than 10 k/ohms, go to step  84) (Continental), or go to next step (all other models). If resistance is 10 k/ohms or less, repair short to PWR GND in FLI circuit.

  42. 83) Check FLI Circuit For Short To CASE GND In Harness

    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 In Harness (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 18 . 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 18: Identifying Virtual Image Instrument Cluster Harness Connector Terminals (Continental)
    G97C28607Courtesy of FORD MOTOR CO.

  44. 85) Check FLI Circuit For Open In Harness

    Using a DVOM, measure resistance of FLI circuit between PCM harness connector and fuel pump module harness connector. See Fig 12-Fig 17 . 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 either resistance measurement is 10 ohms or more, repair open in FLI circuit.

  45. 86) Check CASE GND Circuit For Open In Harness

    Turn ignition switch to OFF position. Ensure PCM is disconnected. Using a DVOM, measure resistance of CASE GND circuit between PCM harness connector and fuel pump module harness connector. See Fig 12-Fig 17 . Also, measure resistance between PCM harness connector CASE GND circuit terminal and instrument cluster harness connector fuel gauge ground terminal. If either resistance measurement is more than 10 ohms, repair open in CASE GND circuit. If both resistance measurements are 10 ohms or less, check fuel gauge. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. Clear DTCs and repeat QUICK TEST . If DTC P0460 is still present, replace PCM.

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

    Turn ignition switch to OFF position. Disconnect PCM connector. Using a DVOM, measure resistance of CASE GND circuit between PCM harness connector terminal No. 25 (CASE GND) and virtual image instrument cluster harness connector terminal No. 27 (fuel logic ground). See Fig 15 and Fig 18 . Also, measure resistance between fuel pump module harness connector CASE GND circuit terminal and virtual image instrument cluster harness connector terminal No. 28 (fuel level return). If both resistance measurements are more than 10 k/ohms, repair open circuit. If either resistance measurement is 10 k/ohms or less, check fuel gauge and circuits. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. Clear DTCs and repeat QUICK TEST . If DTC P0460 is still present, replace PCM.
    47. NOTE: Perform test step  88) when directed from WARNING INDICATOR LIGHTS symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - CNG & GASOLINE article.
    NOTE: Perform test step  89) when directed from WARNING INDICATOR LIGHTS symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - CNG & 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. 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.
    PCM FUEL CAP OFF INDICATOR CIRCUIT TERMINALS

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