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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 681 (Engine Controls - Pinpoint Tests - Diesel 6.0L (99P E-Series & 99P F450/550)) >> PINPOINT TEST P: Misfire/Injector Driver Circuit Operation >> Test Procedure

Test Procedure

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  1. P1 PRELIMINARY DIAGNOSIS 
    • Carry out a visual inspection.
    • Retrieve and record any continuous and on-demand DTCs.
    • Record the freeze frame data.
    • Clear the DTCs.
    • Carry out the injector electrical self-test. Refer to the DIAGNOSTIC METHODS article.
    • Carry out the KOER self-test.
    • Are any DTCs retrieved? 
    Yes No
    For DTCs P0261, P0264, P0267, P0270, P0273, P0276, P0279 or P0282, GO to  P2.
    For DTCs P0262, P0265, P0268, P0271, P0274, P0277, P0280 or P0283, GO to  P5.
    For DTCs P0301, P0302, P0303, P0304, P0305, P0306, P0307 or P0308, GO to  P8.
    For DTCs P0263, P0266, P0269, P0272, P0275, P0278, P0281 or P0284, GO to  P16.    		 Unable to duplicate the condition. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the concern. REPAIR as necessary. REFER to the SYMPTOM CHARTS article, Symptom Charts, if a driveability concern exists.
  2. P2 DIAGNOSTIC TROUBLE CODES (DTCS) P0261, P0264, P0267, P0270, P0273, P0276, P0279, OR P0282, 
    NOTE: Disconnect the suspect fuel injector harness connector. Only the suspect injector needs to be diagnosed.
    • Key in OFF position.
    • Fuel Injector connector disconnected.
    • Visually inspect the suspect injector pins.
    • Measure the resistance between:
      ( + ) Fuel Injector Connector, Component Side ( - ) Fuel Injector Connector, Component Side
      Fuel Injector, Open Coil, Power - Pin 1 Fuel Injector, Open Coil, Ground - Pin 2
      Fuel Injector, Close Coil, Power - Pin 3 Fuel Injector, Close Coil, Ground - Pin 4
    • Refer to the injector coil resistance table for resistance values.
      INJECTOR COIL RESISTANCE

      Temperature Minimum Resistance (Ohms) Maximum Resistance (Ohms)
      Ambient 0.4 0.6
      Normal Operating 0.4 1.5
    • Is the resistance within specification? 
    Yes No
    GO to  P3. INSTALL a new Fuel Injector. CLEAR the DTCs. REPEAT the self-test.
  3. P3 CHECK FOR SHORTS IN THE INJECTOR 
    • Measure the resistance between:
      ( + ) Fuel Injector Connector, Component Side ( - ) Fuel Injector Connector, Component Side
      Fuel Injector, Open Coil, Power - Pin 1 Fuel Injector, Close Coil, Power - Pin 3
      Fuel Injector, Open Coil, Power - Pin 1 Fuel Injector, Close Coil, Ground - Pin 4
      Fuel Injector, Open Coil, Ground - Pin 2 Fuel Injector, Close Coil, Power - Pin 3
      Fuel Injector, Open Coil, Ground - Pin 2 Fuel Injector, Close Coil, Ground - Pin 4
    • Are the resistances greater than 10K ohms? 
    Yes No
    GO to  P4. INSTALL a new Fuel Injector. CLEAR the DTCs. REPEAT the self-test.
  4. P4 CHECK THE FUEL INJECTOR CIRCUITS FOR AN OPEN 
    • Suspect FICM connector disconnected.
    • Measure the resistance between:
      ( + ) Fuel Injector Connector, Harness Side ( - ) Suspect FICM Connector, Harness Side
      Fuel Injector, Open Coil, Power - Pin 1 Fuel Injector, Open Coil, Power
      Fuel Injector, Close Coil, Power - Pin 3 Fuel Injector, Close Coil, Power
      Fuel Injector, Open Coil, Ground - Pin 2 Fuel Injector, Open Coil, Ground
      Fuel Injector, Open Coil, Power - Pin 1 Fuel Injector, Open Coil, Power
    • Are the resistances less than 5 ohms? 
    Yes No
    INSTALL a new FICM. CLEAR the DTCs. REPEAT the self-test. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  5. P5 DIAGNOSTIC TROUBLE CODES (DTCS) P0262, P0265, P0268, P0271, P0274, P0277, P0280, OR P0283 
    NOTE: Disconnect the suspect fuel injector harness connector. Only the suspect injector needs to be diagnosed.
    • Key in OFF position.
    • Fuel Injector connector disconnected.
    • Suspect FICM connector disconnected.
    • Measure the resistance between:
      ( + ) Fuel Injector Connector, Harness Side ( - ) Fuel Injector Connector, Harness Side
      Fuel Injector, Close Coil, Ground - Pin 4 Fuel Injector, Close Coil, Power - Pin 3
      Fuel Injector, Close Coil, Ground - Pin 4 Fuel Injector, Open Coil, Ground - Pin 2
      Fuel Injector, Close Coil, Ground - Pin 4 Fuel Injector, Open Coil, Power - Pin 1
      Fuel Injector, Close Coil, Power - Pin 3 Fuel Injector, Open Coil, Ground - Pin 2
      Fuel Injector, Close Coil, Power - Pin 3 Fuel Injector, Open Coil, Power - Pin 1
      Fuel Injector, Open Coil, Ground - Pin 2 Fuel Injector, Open Coil, Power - Pin 1
    • Are the resistances greater than 10K ohms? 
    Yes No
    GO to  P6. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  6. P6 CHECK THE FUEL INJECTOR CIRCUITS FOR A SHORT TO GROUND 
    • Measure the resistance between:
      ( + ) Fuel Injector Connector, Harness Side ( - )
      Fuel Injector, Close Coil, Ground - Pin 4 Ground
      Fuel Injector, Close Coil, Power - Pin 3 Ground
      Fuel Injector, Open Coil, Ground - Pin 2 Ground
      Fuel Injector, Open Coil, Power - Pin 1 Ground
    • Are the resistances greater than 10K ohms? 
    Yes No
    GO to  P7. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  7. P7 CHECK THE FUEL INJECTOR CIRCUITS FOR A SHORT TO VOLTAGE 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) Fuel Injector Connector, Harness Side ( - )
      Fuel Injector, Open Coil, Power - Pin 1 Ground
      Fuel Injector, Open Coil, Ground - Pin 2 Ground
      Fuel Injector, Close Coil, Power - Pin 3 Ground
      Fuel Injector, Close Coil, Ground - Pin 4 Ground
    • Check for continuous memory DTCs.
    • Is any voltage present? 
    Yes No
    REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test. GO to  P2.
  8. P8 CHECK FOR CONTINUOUS MEMORY DTCS 
    • Check for continuous memory DTCs.
    • Are DTCs P0301, P0302, P0303, P0304, P0305, P0306, P0307, or P0308 present? 
    Yes No
    INSPECT the valve train, pistons, and for other base engine concerns. REPAIR as necessary. REFER to appropriate ENGINE article.
    If OK, REFER toPERFORMANCE DIAGNOSTIC PROCEDURES to continue diagnosis.    		 GO to  P9.
  9. P9 CARRY OUT THE KOEO SELF-TEST AND THE INJECTOR ELECTRICAL SELF-TEST 
    • Carry out the KOEO self-test and the injector electrical self-test.
    • Are any DTCs present? 
    Yes No
    REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS . GO to  P10.
  10. P10 CHECK FOR KOER DTCS 
    • Carry out the KOER self-test.
    • Are any DTCs present? 
    Yes No
    REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS . GO to  P11.
  11. P11 CHECK THE FUEL SUPPLY PRESSURE 
    Yes No
    GO to  P12. REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.
  12. P12 CHECK FOR FUEL AERATION 
    Yes No
    REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  P13.
  13. P13 CHECK FOR OIL AERATION 
    Yes No
    CHANGE the engine oil. REPEAT the Oil Aeration Test. If oil aeration is present again, REFER to appropriate ENGINE article. GO to  P14.
  14. P14 CARRY OUT THE INJECTOR ENHANCED DIAGNOSTICS 
    Yes No
    If all 4 cylinders on one bank are identified, CHECK the oil rail check valve for restriction, the fuel inlet check valve, the FICM, compression/head gaskets, or fuel contamination. If multiple or individual cylinders are identified, CHECK the dual mass flywheel. If individual cylinders are identified, CHECK the wiring to the injector, injector hold down bolt, injector copper gasket presence, or for a faulty injector. INSTALL a new fuel injector copper gasket, then REMOVE the injector to inspect the copper gasket for an even circular crush pattern. If the crush pattern is visible install a new copper gasket. Refer to appropriate FUEL CHARGING AND CONTROLS article. If the 2 rear cylinders are identified on either bank as weak, CHECK the AWA fitting in the oil rail, and the compression/head gasket. Any individual cylinder concern can be seen in the conditions listed above. If any two adjacent cylinders are identified as weak, CHECK the compression/head gasket. GO to  P15.
  15. P15 CHECK THE CRANKCASE PRESSURE 
    Yes No
    REPAIR as necessary. REFER to appropriate ENGINE article. GO to  P20.
  16. P16 DTCS P0263, P0266, P0269, P0272, P0275, P0278, P0281 OR P0284: CHECK THE FUEL SYSTEM PRESSURE 
    Yes No
    GO to  P17. REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.
  17. P17 CYLINDER POWER BALANCE CHECK 
    Yes No
    GO to  P19. GO to  P18.
  18. P18 CRANKCASE AND COMPRESSION TESTS 
    • Carry out the Crankcase Pressure Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
    • Carry out a cylinder compression test on the suspect cylinder.
    • Are any concerns present? 
    Yes No
    REPAIR as necessary. REFER to appropriate ENGINE article. GO to  P19.
  19. P19 CARRY OUT A VISUAL INSPECTION 
    • Carry out a visual inspection for the following mechanical concerns:
      • push rods
      • rocker arms
      • valves
      • valve springs
    • Are any concerns present? 
    Yes No
    REPAIR as necessary. REFER to appropriate ENGINE article. INSPECT the fuel injector copper compression washer and O-rings. REPAIR as necessary. If the fuel injector copper compression washer and O-rings are OK, INSTALL a new fuel injector and copper compression washer.
    CLEAR the DTCs. REPEAT the self-test.
  20. P20 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect all the PCM connectors.
    • Visually inspect for:
      • pushed out pins
      • corrosion
    • Connect all the PCM connectors and make sure they seat correctly.
    • Carry out the PCM self-test and verify the concern is still present.
    • Is the concern still present? 
    Yes No
    INSTALL a new PCM. REFER toFLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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