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Test Procedure

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  1. KF1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) 

    Is DTC P0480, P0481, P0691, P0692, P1474 or P1479 present? 

    Yes No
    For DTCs P0480, P0691, P0692 or P1474, GO to KF2  .
    For all others, GO to  KF7.    		 For symptoms without DTCs, GO to  KF12.
    For all others, RETURN to NO DIAGNOSTIC TROUBLE CODES (DTCS) PRESENT SYMPTOM CHART INDEX for further direction.
  2. KF2 CHECK THE VPWR VOLTAGE TO THE LFC RELAY 
    • LFC Relay connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) LFC Relay Connector, Harness Side (-)
      VPWR Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    GO to KF3  . REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  3. KF3 CHECK FOR LFC CIRCUIT CYCLING 
    • Connect a non-powered test lamp between:
      Point A LFC Relay Connector, Harness Side Point B LFC Relay Connector, Harness Side
      VPWR LFC
    • Carry out the PCM KOEO self-test.

    Does the test lamp illuminate on and off during the KOEO on demand self-test? 

    Yes No
    INSTALL a new LFC relay. Clear the PCM DTCs. REPEAT the self-test. GO to KF4  .
  4. KF4 CHECK THE LFC CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition OFF.
    • Remove the test lamp.
    • PCM connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) LFC Relay Connector, Harness Side (-)
      LFC Ground

    Is any voltage present? 

    Yes No
    GO to KF5  . REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  5. KF5 CHECK THE LFC CIRCUIT FOR A SHORT TO GROUND 
    • Measure the resistance between:
      (+) LFC Relay Connector, Harness Side (-)
      LFC Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to KF6  . REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  6. KF6 CHECK THE LFC CIRCUIT FOR AN OPEN 
    • Measure the resistance between:
      (+) LFC Relay Connector, Harness Side (-) PCM Connector, Harness Side
      LFC LFC

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KF21. REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  7. KF7 CHECK THE VPWR VOLTAGE TO THE HFC RELAY 
    • HFC Relay connector disconnected.
    • FC Relay connector disconnected.
    • Ignition ON, engine OFF.
    • For Fiesta and Mustang,
    • Measure the voltage between:
      (+) HFC Relay Connector, Harness Side (-)
      VPWR Ground
    • For all others,
    • Measure the voltage between:
      (+) FC Relay Connector, Harness Side (-)
      VPWR Ground
    • Measure the voltage between:
      (+) HFC Relay Connector, Harness Side (-)
      VPWR Ground

    Are the voltages greater than 10.5 V? 

    Yes No
    GO to KF8  . REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  8. KF8 CHECK FOR HFC CIRCUIT CYCLING 
    • PCM connector connected.
    • For Mustang,
    • Connect a non-powered test lamp between:
      Point A HFC Relay Connector, Harness Side Point B HFC Relay Connector, Harness Side
      VPWR HFC
    • For all others,
    • Connect a non-powered test lamp between:
      Point A HFC Relay Connector, Harness Side Point B HFC Relay Connector, Harness Side
      VPWR HFC
    • Connect a non-powered test lamp between:
      Point A FC Relay Connector, Harness Side Point B FC Relay Connector, Harness Side
      VPWR HFC
    • Carry out the PCM KOEO self-test.

    Does the test lamp illuminate ON and OFF during the KOEO on demand self-test? 

    Yes No
    INSTALL a new Relay in question.
    Clear the PCM DTCs. REPEAT the self-test.    		 GO to KF9  .
  9. KF9 CHECK THE HFC CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition ON, engine OFF.
    • Remove the test lamp.
    • PCM connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) HFC Relay Connector, Harness Side (-)
      HFC Ground

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test. GO to KF10  .
  10. KF10 CHECK THE HFC CIRCUIT FOR A SHORT TO GROUND 
    • Ignition OFF.
    • Measure the resistance between:
      (+) HFC Relay Connector, Harness Side (-)
      HFC Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to KF11  . REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.
  11. KF11 CHECK THE HFC CIRCUIT FOR AN OPEN 
    • Measure the resistance between:
      (+) HFC Relay Connector, Harness Side (-) PCM Connector, Harness Side
      HFC HFC

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KF21. REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  12. KF12 COOLING FAN ALWAYS RUNS 

    Is the symptom: cooling fan always runs? 

    Yes No
    GO to KF13  . GO to  KF15.
  13. KF13 THE COOLING FAN ALWAYS RUNS 
    • Verify the A/C system is OFF.
    • Ignition ON, engine running.
    • Access the PCM and monitor the AC_REQ (MODE) PID.

    Is A/C being requested? 

    Yes No
    REFER to the applicable service information article, Climate Control System, to diagnose the A/C system. GO to KF14  .
  14. KF14 CHECK FOR RELAY CONTACTS ALWAYS CLOSED 
    • FC Relay connector disconnected.
    • HFC Relay connector disconnected.
    • LFC Relay connector disconnected.
    • Ignition ON, engine OFF.

    Does the fan run with the ignition in the ON position? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test. INSTALL a new Relay in question.
    Clear the PCM DTCs. REPEAT the self-test.
  15. KF15 ELECTRIC COOLING FAN FUNCTIONAL CHECK 
    • Ignition ON, engine OFF.
    • Carry out the PCM KOEO self-test.

    Does the fan operate sometime during the KOEO self-test? 

    Yes No
    The cooling fan primary circuits are OK.
    GO to KF16  .    		 GO to KF16  .
  16. KF16 COMMAND THE FANS ON AND CHECK FOR VOLTAGE TO THE COOLING FAN MOTORS 
    NOTE: Diagnose the suspect cooling fan motor connector indicated by the concern.
    • Ignition OFF.
    • Low Speed Cooling Fan Motor connector disconnected.
    • High Speed Cooling Fan Motor connector disconnected.
    • Ignition ON, engine OFF.
    • For Fiesta,
    • Access the PCM and control the LFC (MODE) PID.
    • For all others,
    • Access the PCM and control the LFC (MODE) PID.
    • Access the PCM and control the HFC (MODE) PID.
    • Measure the voltage between:
      (+) Cooling Fan Motor Connector, Harness Side (-)
      FANPWR Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    For Fiesta and Mustang, GO to  KF19.
    For all others, GO to  KF20.    		 GO to KF17  .
  17. KF17 CHECK THE B+ VOLTAGE TO THE FC RELAY 
    • Ignition OFF.
    • LFC Relay connector disconnected.
    • For Fiesta,
    • Measure the voltage between:
      (+) LFC Relay Connector, Harness Side (-)
      B+ Ground
    • For all others,
    • LFC Relay connector disconnected.
    • HFC Relay connector disconnected.
    • Measure the voltage between:
      (+) LFC Relay Connector, Harness Side (-)
      B+ Ground
    • Measure the voltage between:
      (+) HFC Relay Connector, Harness Side (-)
      B+ Ground

    Are the voltages greater than 10.5 V? 

    Yes No
    GO to KF18  . REPAIR the open circuit. CHECK the condition of the related fuses. If OK, REPAIR the open circuit. If a fuse is damaged, CHECK the circuit for a short to ground before replacing the fuse.
    Clear the PCM DTCs. REPEAT the self-test.
  18. KF18 CHECK THE FAN PWR CIRCUIT FOR AN OPEN 
    NOTE: Diagnose the suspect cooling fan motor connector indicated by the concern.
    • For Fiesta,
    • Measure the resistance between:
      (+) LFC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR
    • For Mustang,
    • Measure the resistance between:
      (+) HFC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR
    • Measure the resistance between:
      (+) LFC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR
    • For all others,
    • Measure the resistance between:
      (+) FC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR
    • Measure the resistance between:
      (+) HFC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR
    • Measure the resistance between:
      (+) LFC Relay Connector, Harness Side (-) Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR

    Are the resistances less than 5 ohms? 

    Yes No
    INSTALL a new Relay in question.
    Clear the PCM DTCs. REPEAT the self-test.    		 REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  19. KF19 CHECK THE GROUND CIRCUIT TO THE COOLING FAN MOTOR 
    NOTE: Diagnose the suspect cooling fan motor connector indicated by the concern.
    • Ignition OFF.
    • Measure the resistance between:
      (+) Cooling Fan Motor Connector, Harness Side (-)
      GND Ground

    Is the resistance less than 5 ohms? 

    Yes No
    INSTALL a new Cooling Fan motor. Clear the PCM DTCs. REPEAT the self-test. REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  20. KF20 CHECK GROUND CIRCUITS 
    • Ignition OFF.
    • FC Relay connector disconnected.
    • Measure the resistance between:
      (+) High Speed Cooling Fan Motor Connector, Harness Side (-)
      GND - Pin 2 Ground
    • Measure the resistance between:
      (+) Low Speed Cooling Fan Motor Connector, Harness Side (-) FC Relay Connector, Harness Side
      GND - Pin 2 FC
    • Measure the resistance between:
      (+) FC Relay Connector, Harness Side (-) High Speed Cooling Fan Motor Connector, Harness Side
      FANPWR FANPWR - Pin 1
    • Measure the resistance between:
      (+) FC Relay Connector, Harness Side (-)
      GND Ground

    Are the resistances less than 5 ohms? 

    Yes No
    INSTALL a new Cooling Fan motor. Clear the PCM DTCs. REPEAT the self-test. REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.
  21. KF21 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.
    • Verify the concern is still present.

    Is the concern still present? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) , Programming the VID Block for a Replacement PCM. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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