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Home >> Ford >> 2003 >> Excursion 6.0 P, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (ENGINE CONTROLS - SELF-DIAGNOSTICS - 7.3L (995, 996 F650/750, 99F E Series & 99F F450/550) DIESEL) >> System Tests >> Test A: Vehicle Battery >> Testing

Test A: Vehicle Battery: Testing

WARNING: This page is about a different variant/trim than selected.
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) KOEO, KOER & Continuous Memory DTC P0560, P0562 Or P0563: Check Battery Voltage
    DTC P0562 may be a temporary condition at crank with a low battery condition. DTC P0563 may be a temporary condition with a 24-volt jump start. Turn ignition on. Using DVOM, measure voltage between battery terminals. If voltage is 10.5 volts or less, repair charging system as necessary. If voltage is more than 10.5 volts, go to next step (Excursion and F250-550), or step  8) (Econoline and F650-750).

  2. 2) Check PCM VPWR Fuse No. 22 (Excursion & F250-550)

    Ensure ignition is off. Remove and inspect PCM VPWR fuse No. 22 (20-amp) from Central Junction Box (CJB). Central junction box is located behind lower left side of instrument panel. If fuse is blown, check VPWR circuit for short to ground. Repair wiring, replace fuse and retest. If fuse is okay, turn ignition on. Measure voltage between input side of PCM VPWR fuse No. 22 and negative battery terminal. If voltage is more than 10.5 volts, go to step  6). If voltage is less than 10.5 volts, go to next step.

  3. 3) Check Supply Voltage To PCM Relay

    Remove PCM relay and fuse No. 22. Turn ignition on, engine off. Measure voltage between PCM relay power supply terminal No. 30 in CJB and battery negative post. If the voltage is 10.5 volts or more, go to next step. If the voltage is less than 10.5 volts, repair open in PCM power supply circuit or fuse links. Restore vehicle and retest.

  4. 4) Check PCM Relay Coil Ground Circuit

    Turn ignition off. Measure resistance between PCM relay coil ground terminal No. 86 in CJB and battery negative post. If the resistance is less than 5 ohms, go to next step. If the resistance is 5 ohms or more, repair open in relay ground circuitry. Note that PCM diode is internal to CJB. Restore vehicle and retest.

  5. 5) Check PCM Relay Ignition Voltage Supply

    Turn ignition on, engine off. Measure voltage between PCM relay coil ignition voltage supply terminal No. 85 in CJB and battery negative post. If the voltage is 10.5 volts or more, go to next step. If the voltage is less than 10.5 volts, repair open in ignition power circuit to PCM relay, fuse No. 116 or CJB. Restore vehicle and retest.

  6. 6) Check Supply Voltage From PCM Fuse To PCM

    Turn ignition off. Install 104-pin breakout box to PCM connector, leaving PCM disconnected. Using DVOM, measure resistance of Red wire between non-powered side of PCM fuse No. 22 and test pins No. 71 and 97. See Fig 3 and Fig 2 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red wire between PCM and PCM fuse No. 22.
    Fig 1: Identifying Central Junction Box & Circuits (Excursion & F250-550)
    G00191048Courtesy of FORD MOTOR CO.
    Fig 2: Identifying IDM & PCM Power Circuits (Excursion & F250-550)
    G00191039Courtesy of FORD MOTOR CO.

  7. 7) Check Power Ground (PWR GND) Continuity

    Ensure ignition is off. Using DVOM, measure resistance between negative battery terminal and test pins No. 25, 51, 77 and 103. If each resistance is less than 5 ohms, check PCM relay for proper operation. If PCM relay is good and DTC still exists, replace PCM and retest. If any resistance is 5 ohms or more, repair open in appropriate PWR GND circuit. See WIRING DIAGRAMS .

  8. 8) Check Battery Voltage At PCM Fuse (Econoline & F650-750)

    Turn ignition off. On Econoline, measure voltage between negative battery terminal and input side of PCM fuse No. 9 (30-amp), located in battery junction box. On F650-750, measure voltage between negative battery terminal and input side of PCM fuse No. 117 (20-amp), located in battery junction box. See Fig 1-Fig 6 . Battery junction box is located on left front of engine compartment. If voltage is more than 10.5 volts, go to next step. If voltage is less than 10.5 volts, repair open in B+ circuit between battery and PCM fuse in battery junction box. See POWER DISTRIBUTION in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
    Fig 3: Identifying Battery Junction Box & Circuits (Econoline)
    G00096661Courtesy of FORD MOTOR CO.
    Fig 4: Identifying IDM & PCM Power Circuits (Econoline)
    G00096663Courtesy of FORD MOTOR CO.
    Fig 5: Identifying Battery Junction Box & Circuits (F650-750)
    G00096662Courtesy of FORD MOTOR CO.
    Fig 6: Identifying IDM & PCM Power Circuits (F650-750)
    G00096665Courtesy of FORD MOTOR CO.

  9. 9) Check PCM Fuse

    Remove and inspect PCM fuse No. 9 (Econoline) or fuse No. 117 (F650-750) from battery junction box. If PCM fuse is okay, go to next step. If fuse is blown, locate and repair short to ground and replace PCM fuse.

  10. 10) Check VPWR Circuit To PCM Relay

    Remove PCM relay and fuse. Using DVOM, measure resistance of Yellow wire (Econoline) or Yellow/Black wire (F650-750) between output side of PCM fuse and PCM power relay cavity No. 30 in battery junction box. See Fig 4 or Fig 6 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow or Yellow/Black wire.

  11. 11) Check Ignition Feed To PCM Relay Diode

    Ensure ignition is off. Remove PCM diode from battery junction box. Turn ignition on. Using DVOM, measure voltage between negative battery terminal and input side of PCM diode connector in battery junction box. If voltage is more than 10.5 volts, go to next step. If voltage is 10 volts or less, repair open in Red/Light Green wire between PCM relay diode and fuse No. 8 (Econoline) or fuse No. 30 (F650-750) in battery junction box.

  12. 12) Check PCM Diode

    Turn ignition off. Remove PCM diode from battery junction box. Using an ohmmeter, check PCM diode continuity. Ensure continuity exists in one direction only. Replace PCM diode as necessary and retest. If PCM diode is okay, go to next step.

  13. 13) Check PCM Relay Coil Circuit

    Measure resistance of coil circuit between the non-power side of diode connector and the PCM relay connector terminal No. 85 in power distribution box. If the resistance is less than 5 ohms, go to next step. If the resistance is 5 ohms or more, repair open in PCM relay coil power circuit. Restore vehicle.

  14. 14) Check PCM Relay Coil Ground

    Using DVOM, measure resistance of ground circuit between PCM power relay cavity No. 86 in battery junction box and negative battery terminal. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, REPAIR open in Black wire between PCM relay and ground. Restore vehicle.

  15. 15) Check Circuit No. 361 (Red Wire) From PCM Relay To PCM

    Ensure ignition is off. 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 104-pin breakout box to PCM connector, leaving PCM disconnected. Using DVOM, measure resistance of Red wire between PCM power relay cavity No. 87 in battery junction box and test pins No. 71 and 97. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red wire between PCM power relay and PCM harness connector.

  16. 16) Check Power Ground (PWR GND) Circuit Continuity

    Ensure ignition is off. Using DVOM, measure resistance between negative battery terminal and test pins No. 25, 51, 77 and 103. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open in PWR GND circuit. See WIRING DIAGRAMS .

  17. 17) Check PCM Relay

    Install PCM relay. Leave PCM disconnected. Install PCM relay diode. Remove PCM relay power fuse. Turn ignition on, engine off. Measure resistance between PCM test pins 71 and 97 and the non-power side of PCM power fuse. If the resistance is less than 5 ohms, and a fault code is still present, install a new PCM. Restore vehicle. If resistance is 5 ohms or more, install a new PCM relay. Restore vehicle.
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