Download Ford E-150/E-250/E-350/E-450 F-250/F-350

2011-2013
Ford E-150/E-250/E-350/E-450
F-250/F-350
Liquid Propane Autogas Fuel System (3rd Generation)
Includes:
E-150/E-250/E-350 Cargo Van/Wagon
E-150/E-250/E-350 Extended Range Cargo Van/Wagon
E-450 Custom Body
F-250/F-350
Revision History
-AA
Intital Release
2/2013
-AB
Revised
5/2013
DIAGNOSTIC MANUAL
P-01B101-AB
TABLE OF CONTENTS
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation, Garaging and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Purging and Venting (Tanks and Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System and Diagnostic Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Diagnostic Trouble Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Flow Control Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bleed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tank Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Rail Pressure Control Module Supply Solenoid and Wiring. . . . . . . . . . . . . . . . . . . . . . . 9
SRM, CAN Bus Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electronic Fuel Pump Relay (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Integrated Pressure Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSTIC TESTS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
No Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Slow Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Over Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Cranks, No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Stumble, Stall, Rough Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Excess Flow Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maximum Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Supply Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel System Fails to Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel Pressure Drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel Level Indication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tank Solenoid Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fuel Rail Pressure Control Module Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Integrated Pressure Temperature Sensor Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Fuel Pump Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Pump Control Module Electrical Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Smart Relay Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fuel Level Sender Electrical Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel Level Interface Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
E-150/150/350 Extended Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . 50
E-150/250/350 Extended Range Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . 51
E-450 Custom Body Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . 53
E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness . . . . . . . . . . . 54
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness. . . . . . . . . . . . . 55
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . . . . . . 56
E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness . . . . . . . . . . . . . . 57
Page iii
TABLE OF CONTENTS
E-Series Extended Range and E-450 Electrical Schematic — Solenoid Harness . . . . . . . . . . . . . . .58
F-250/350 Pickup, Underhood Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 60
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . . . . . . .61
F-250/350 Pickup, Tank Solenoid Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . 63
F-250/350 Pickup, FTPT Jumper Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Page iv
INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
SAFETY INFORMATION
The National Fire Protection Association (NFPA)
publishes a code book of rules that apply to the
storage, handling, transportation and use of
liquefied petroleum gas (LP-Gas or LPG). The
book is known as NFPA 58. It is revised as
necessary and published every other year. This
code is adopted as law in virtually every political
subdivision in the United States. Check with your
local authorities for regulations applicable to
liquid propane.
Alert Messages
The following alert messages may appear from
time to time in appropriate places in this manual.
Ensure that all personnel read and adhere to
these alert messages.
Although propane is nontoxic, nonpoisonous,
has the lowest flammability range of any
alternative fuel and dissipates quickly when
released into the atmosphere, propane vapor
is heavier than air and seeks the lowest point.
When the ratio of propane to air is between
2.2% and 9.6%, propane will burn in the
presence of an ignition source at 940°F
(504°C) or hotter. Keep away from heat,
sparks, flames, static electricity or other
sources of ignition. Failure to heed this
danger may result in severe personal injury or
death.
The fuel supply lines remain pressurized after
engine shutdown. Keep away from heat,
sparks, flames, static electricity or other
sources of ignition. Do NOT enter storage
areas or confined space unless they are
adequately ventilated. Failure to heed this
danger may result in severe personal injury or
death.
Page 2
Do NOT carry lighted smoking materials or
smoke while working on fuel system
components. Failure to heed this danger
could result in severe personal injury or
death.
Disconnect the battery ground at the battery
to ensure that the vehicle electrical system
has no current. Failure to heed this danger
could result in severe personal injury or
death.
Propane is heavier than air and seeks the
lowest available level when released to the
atmosphere. Keep heat, sparks, flames, static
electricity or other sources of ignition out of
the area when venting or purging the fuel
lines or tank. Failure to heed this danger can
result in severe personal injury or property
damage.
Technicians working with, or around, fuel
systems should be properly trained to utilize
extreme care and caution at all times. Failure
to exercise extreme caution and care may
lead to serious accidents which can result in
property damage, personal injury and/or
death.
Liquid propane is cold. The temperature of
propane in its liquid state at atmospheric
pressure is −44°F (−42°C). Wear eye and ear
protection during venting and repair
operations. Keep moisture away from the
valves. Failure to heed this warning can result
in personal injury.
INTRODUCTION
Installation, Garaging and Training
Chapter 11 of NFPA 58 applies to engine fuel
systems using LP-Gas in internal combustion
engines, including containers, container
appurtenances, carburetion equipment, piping,
hose and fittings and their installation.
Additionally, this chapter applies to garaging of
vehicles and to the training of personnel.
Purging and Venting (Tanks and
Lines)
Venting of LP-Gas to the atmosphere is covered
by paragraphs 7.3.1, General, and 7.3.2, Purging
of NFPA 58, 2008 edition. Refer to NFPA 58,
Local Codes and Proper Training for specific
information relating to safe venting of LPG.
Paragraph 11.2 specifies that each person
engaged in installing, repairing, filling or
otherwise servicing an LP-Gas engine fuel
system shall be trained. Contact the Propane
Education and Research Council to learn more
about their CETP E-Learning computer-based
training program:
[email protected], or
[email protected].
Page 3
TROUBLESHOOTING
TROUBLESHOOTING
Page 4
TROUBLESHOOTING
DIAGNOSTIC TROUBLE
CODES
About Diagnostic Trouble Codes
All diagnostic trouble codes (DTCs) known to be
affected by the liquid propane autogas (LPA)
system are covered in this manual. For all other
DTCs, refer to the Ford Powertrain
Control/Emissions Diagnosis Service Manual at
www.motorcraft.com.
System and Diagnostic Terminology
Acronym or
Abbreviation
Description
BS
Bleed Solenoid
CAN
Controller Area Network
DTC
Diagnostic Trouble Code
EFPR
Electronic Fuel Pump Relay
ERFS
Electronic Returnless Fuel System
EVAP
Evaporative
FCS
Flow Control Solenoid
FLIM
Fuel Level Interface Module
FLS
Fuel Level Sender
FP
Fuel Pump
FPCM
Fuel Pump Control Module
FRP
Fuel Rail Pressure
FRPCM
Fuel Rail Pressure Control Module
FTS
Fuel Temperature Sensor
GRD
Ground
HEGO
Heated Exhaust Gas Oxygen
IC
Instrument Cluster
IPTS
Integrated Pressure Temperature Sensor
KOEO
Key On Engine Off
KOER
Key On Engine Running
LPA
Liquid Propane Autogas
MAF
Mass Air Flow
OEM
Original Equipment Manufacturer
OPD
Overfill Protection Device
PCM
Powertrain Control Module
PID
Parameter Identification
PWR GND
Power Ground
SIG RTN
Signal Return
SRM
Smart Relay Module
Page 5
TROUBLESHOOTING
Acronym or
Abbreviation
Description
SS
Supply Solenoid
TS
Tank Solenoid
VMV
Vapor Management Valve
VPWR
Voltage Power
VREF
Voltage Reference
WOT
Wide Open Throttle
Diagnostic Trouble Code List
Code
Description
Flow Control Solenoid
P0090
Fuel Pressure Regulator Circuit Open
Bleed Solenoid
P009E
Fuel Pressure Relief Control Performance Stuck Off
P009F
Fuel Pressure Relief Control Stuck On
P009B
Fuel Pressure Relief Control Circuit Open
Tank Solenoid
P0005
Fuel Shutoff Valve A Control Circuit Open
Fuel Rail Pressure Control Module Supply Solenoid and Wiring
P26B5
Fuel Shutoff Valve B Function Check
P2632
Fuel Pump B Control Circuit Open
P2665
Supply Solenoid Circuit Fault
SRM, CAN Bus Circuit Wiring
U0108
Lost Communication with Alternative Fuel Control Module
Fuel System
P0148
Fuel Delivery Error
P116E
Maximum Pressure
P0171, P0174
System Too Lean (Bank 1 and Bank 2)
P03xx
Misfire
U0309
Alt Fuel Module-Wrong SRM
Heated Exhaust Gas Oxygen Sensor
P2195, P2197
Heated Exhaust Gas Oxygen Sensor Stuck
Electronic Fuel Pump Relay (B)
U016C
Lost Communication with Fuel Pump Control Module B
P027A
Fuel Pump Control Module Circuit Range/Performance
Integrated Pressure Temperature Sensor
P0182
Fuel Temperature Sensor (A) Circuit Low
P0183
Fuel Temperature Sensor (A) Circuit High
P0190
Fuel Pressure Sensor A Circuit
P0192
Fuel Pressure Sensor A Circuit Low
P0193
Fuel Pressure Sensor A Circuit High
Page 6
TROUBLESHOOTING
Fuel Level Sender
P0460
Fuel Level Sender A Circuit
P0461
Fuel Level Sender A Circuit Range/Performance
P0462
Fuel Level Sender A Circuit Low
Flow Control Solenoid
P0090 — Fuel Pressure Regulator Circuit Open
Description
FCS circuit fault. SRM monitors FCS circuit for open and short circuit faults.
Possible Causes
앫 Short to voltage
앫 Water in the harness connector
앫 Open power circuit
앫 GND circuit
앫 Low battery voltage
앫 Corrosion
앫 Incorrect connections
앫 Damaged FCS coil
앫 Blown fuse
Symptom
Fuel pressure in the rail does not change when commanded. Extended fuel rail flush time.
Diagnostic Aid
Check the FRPCM and SRM electrical connector for damage, corrosion and water intrusion.
Action
Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests
and Procedures.
Bleed Solenoid
P009E — Fuel Pressure Relief Control Performance Stuck Off
Description
Fuel rail failed to bleed. The PCM measures fuel rail pressure on key-up to determine if fuel rail
has been properly bled.
Possible Causes
앫 BS did not open
앫 FRPCM check valve leaked
앫 FRPCM supply solenoid leaked
앫 Bleed port (bleed rate restrictor in outlet to VMV) clogged
앫 EVAP line kinked
앫 Blown fuse
Symptom
Fuel pressure present in the fuel rail after bleed event should have occurred; this may result in
hard starts.
Diagnostic Aid
Check that FRPCM bleeds fuel from rail. Leaks to FRPCM can also trigger a fault.
Action
Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures.
Page 7
TROUBLESHOOTING
P009F — Fuel Pressure Relief Control Stuck On
Description
Bleed solenoid stuck open. While the engine is running, the PCM seals the EVAP system and
checks for a rise in pressure. If pressure in the EVAP system exceeds the threshold, a fault is set.
Possible Causes
앫 Short to GRD
앫 Armature stuck in post
앫 Solenoid seal compromised
Symptom
There is a potential for fuel odor.
Diagnostic Aid
—
Action
Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests
and Procedures.
P009B — Fuel Pressure Relief Control Circuit Open
Description
Bleed solenoid circuit fault. The SRM monitors bleed solenoid circuit for open and short circuit
faults.
Possible Causes
앫 Short to voltage
앫 Water in the harness connector
앫 Open power circuit
앫 Open GND circuit
앫 Low battery voltage
앫 Corrosion
앫 Incorrect connections
앫 Damaged BS coil
Symptom
Fuel rail bleed system does not operate correctly. There is a potential for fuel odor or hard start.
Diagnostic Aid
Check the FRPCM and SRM electrical for damage, corrosion and water intrusion.
Action
Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests
and Procedures.
Tank Solenoid
P0005 — Fuel Shutoff Valve A Control Circuit Open
Description
TS circuit fault. The SRM monitors tank solenoid circuit for open and short circuit faults.
Possible Causes
앫 Short to voltage
앫 Water in the harness connector
앫 Open power circuit
앫 Open GND circuit
앫 Low battery voltage
앫 Corrosion
앫 Incorrect connections
앫 Damaged TS coil
앫 Blown fuse
Symptom
Vehicle does not start. The pumps run but no pressure builds in the fuel rail.
Diagnostic Aid
Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action
Refer to the Tank Solenoid Electrical Check procedure in Diagnostic Tests and Procedures.
Page 8
TROUBLESHOOTING
Fuel Rail Pressure Control Module Supply Solenoid and Wiring
P26B5 — Fuel Shutoff Valve B Function Check
Description
Fuel supply solenoid stuck. The SRM monitors fuel rail pressure before and after the solenoid was
commanded open. If the pressure rise is below a threshold, the fault is set.
Possible Causes
앫 Electrical fault
앫 Damaged SS coil
앫 Damaged SS armature
앫 Excess flow valve tripped
앫 Tank solenoid stuck closed
앫 Tank manual valve closed
앫 Fuel pumps not powering on
앫 Blown fuse
Symptom
Vehicle does not start. The pumps run (or may not) but no pressure builds in the fuel rail.
Diagnostic Aid
Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action
Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.
P2665 — Supply Solenoid Circuit Fault
Description
FRPCM supply solenoid circuit fault. SRM monitors supply solenoid circuit for open and short
circuit faults.
Possible Causes
앫
Short to voltage
앫
Water in the harness connector
앫
Open power circuit
앫
Open GND circuit
앫
Low battery voltage
앫
Corrosion
앫
Incorrect connections
앫
Damaged SS coil
앫
Blown fuse
Symptom
Vehicle does not start. The pumps run but no pressure builds in the fuel rail.
Diagnostic Aid
Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action
Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests
and Procedures.
Page 9
TROUBLESHOOTING
SRM, CAN Bus Circuit Wiring
U0108 — Lost Communication with Alternative Fuel Control Module
Description
Lost communication with SRM. The PCM monitors CAN bus communication for missing
messages from the SRM. If the messages are continuously missing, a fault is set.
Possible Causes
앫 Wiring between the SRM and PCM
앫 SRM lacks power
앫 Blown fuse
Symptom
Rough idle.
Diagnostic Aid
Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Check for power at the SRM.
Action
Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures.
Fuel System
P0148 — Fuel Delivery Error
Description
LPA system is operating in vapor space. At least one bank is lean at WOT.
Possible Causes
앫 Severely restricted fuel filter
앫 Severely restricted fuel supply line
앫 Damaged or worn fuel pump
앫 Damaged or contaminated MAF sensor
앫 Excess flow valve tripped
앫 TS or SS closed
앫 Tank manual shutoff valve not completely open
Symptom
Vehicle hesitation or stall condition.
Diagnostic Aid
—
Action
Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.
P116E — Maximum Pressure
Description
Maximum injection pressure reached. The PCM monitors fuel rail pressure and battery voltage.
Based on these measurements, the PCM adjusts fuel pump speed to stay below the maximum
operating pressure of the injectors.
Possible Causes
앫 Operating the vehicle in high ambient conditions
Symptom
Vehicle hesitation, stall, rough idle, misfire or no start.
Diagnostic Aid
The P116E code is meant as an indication that the fuel system was operated at the limits of the
system. The customer may have experienced drive issues although the system is performing as
expected.
Action
Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures.
앫 Vehicle operated in a low voltage condition
Page 10
TROUBLESHOOTING
P0171, P0174 — System Too Lean (Bank 1 and Bank 2)
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
앫 The LPA system was operated in the vapor region
앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other
causes.
Symptom
—
Diagnostic Aid
Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action
Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
P03xx — Misfire
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
앫 The LPA system was operated in the vapor region
앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other
causes.
Symptom
—
Diagnostic Aid
Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action
Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
Heated Exhaust Gas Oxygen Sensor
P2195, P2197 — Heated Exhaust Gas Oxygen Sensor Stuck
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
앫 The LPA system was operated in the vapor region
앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other
causes.
Symptom
—
Diagnostic Aid
Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action
Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
Page 11
TROUBLESHOOTING
Electronic Fuel Pump Relay (B)
U016C — Lost Communication with Fuel Pump Control Module B
Description
The SRM repeats the signal from the second EFPR to the PCM over the CAN bus. The PCM
monitors this communication. If there is a lack of communication for a long enough period of time,
a fault is set.
Possible Causes
앫 Wire fault between the EFPR and SRM
앫 Wire fault between SRM and PCM
앫 No power to the EFPR
앫 SRM fault
앫 CAN bus fault
앫 Blown fuse
앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other
causes.
Symptom
—
Diagnostic Aid
—
Action
Refer to the Fuel Pump Control Module Electrical Continuity Test procedure and also the Smart
Relay Module Electrical Test procedure in Diagnostic Tests and Procedures.
P027A — Fuel Pump Control Module Circuit Range/Performance
Description
The SRM receives the output of the second fuel pump monitor line and repeats the output over the
CAN bus to the PCM. The PCM monitors the commanded output versus the monitor’s feedback. If
the monitor is out-of-range, a fault is set.
Possible Causes
앫 Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other
causes.
Symptom
Poor starts, rough idle, hesitation/surge.
Diagnostic Aid
—
Action
Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests
and Procedures.
Page 12
TROUBLESHOOTING
Integrated Pressure Temperature Sensor
P0182 — Fuel Temperature Sensor (A) Circuit Low
Description
The SRM reads the IPTS and passes the voltage reading over the CAN to the PCM monitors the
voltage as if the sensor were plugged into the vehicle.
Possible Causes
앫 CAN bus fault between the SRM and PCM
앫 Wiring fault between IPTS and SRM
앫 Short in harness
앫 VREF open or short
앫 Low ambient temperature operation
앫 Incorrect harness connection
앫 Damaged IPTS (or FTS)
앫 IPTS failure
앫 SRM failure
Symptom
—
Diagnostic Aid
Verify the fuel rail temperature PID value to determine open or short.
Action
Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic
Tests and Procedures.
P0183 — Fuel Temperature Sensor (A) Circuit High
Description
The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM
monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes
앫 CAN bus fault between the SRM and PCM
앫 Wiring fault between IPTS and SRM
앫 Open circuit
앫 Open or short to voltage in harness
앫 Incorrect harness connection
앫 Damaged IPTS (FTS)
앫 IPTS failure
앫 SRM failure
Symptom
—
Diagnostic Aid
Verify the fuel rail temperature PID value to determine open or short.
Action
Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic
Tests and Procedures.
Page 13
TROUBLESHOOTING
P0190 — Fuel Pressure Sensor A Circuit
Description
The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM
monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes
앫 CAN bus fault between the SRM and PCM
앫 Wiring fault between IPTS and SRM
앫 VREF open in harness
앫 VREF open in sensor
앫 Vacuum leaks
앫 IPTS failure
앫 SRM failure
Symptom
—
Diagnostic Aid
VREF should be between 4–6 volts.
Action
Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic
Tests and Procedures.
P0192 — Fuel Pressure Sensor A Circuit Low
Description
The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM
monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes
앫 CAN bus fault between the SRM and PCM
앫 Wiring fault between IPTS and SRM
앫 IPTS FRP signal short to SIG RTN or PWR GND
앫 Damaged IPTS (or FRP)
앫 IPTS failure
앫 SRM failure
Symptom
—
Diagnostic Aid
A FRP PID value during ignition ON, engine OFF, or ignition ON, engine running is less than 0.3
volt. This indicates a concern is present.
Action
Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic
Tests and Procedures.
P0193 — Fuel Pressure Sensor A Circuit High
Description
The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM
monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes
앫 CAN bus fault between the SRM and PCM
앫 Wiring fault between IPTS and SRM
앫 IPTS FRP signal short to VREF or VPWR
앫 IPTS (or FRP) open signal
앫 Damaged IPTS (or FRP)
앫 IPTS failure
앫 SRM failure
Symptom
—
Diagnostic Aid
Verify the FRP PID value to determine open or short.
Action
Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic
Tests and Procedures.
Page 14
TROUBLESHOOTING
Fuel Level Sender
P0460 — Fuel Level Sender A Circuit
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
Refer to the Ford service manual. Causes are the same except that communication is between the
FLS and the SRM and not the IC.
Symptom
—
Diagnostic Aid
The SRM reads fuel level sender input and broadcasts it to the IC and PCM.
Action
Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.
P0461 — Fuel Level Sender A Circuit Range/Performance
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
Refer to the Ford service manual. Causes are the same except that communication is between the
sender and the SRM and not the IC.
Symptom
—
Diagnostic Aid
The SRM reads fuel level sender input and broadcasts it to the IC and PCM.
Action
Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.
P0462 — Fuel Level Sender A Circuit Low
Description
Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive
information.
Possible Causes
Refer to the Ford service manual. Causes are the same except that communication is between the
sender and the SRM and not the IC.
Symptom
—
Diagnostic Aid
The SRM reads fuel level sender input and broadcasts it to the IC and PCM.
Action
Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.
Page 15
TROUBLESHOOTING
DIAGNOSTIC TESTS AND
PROCEDURES
Expected Fuel Tank Pressure — On a tank at
ambient temperature conditions, the following
pressures can be expected:
General Information
Pressure (psi)
Measuring Fuel Rail and Fuel Tank Pressure
Measuring Fuel Tank Pressure — Fuel tank
pressure can be measured two ways: Refer to
Tools and Equipment, Special Tools in the 2012
Ford E-150/250/350/450 or 2013 F-250/350
Liquid Propane Autogas Fuel System Service
Manual Supplement for more information
regarding the tools required.
Method 1 — Install a 0–500 psi (0–3447 kPa)
fuel pressure gauge on the bleeder valve at
the tank, or to the remote bleeder valve
location. Open the valve to monitor the fuel
tank pressure. Record the value.
Method 2 — If a 0–500 psi (0–3447 kPa) fuel
pressure gauge is not available, fuel rail
pressure can be used to infer fuel tank
pressure. Refer to Method 1 of Measuring
Fuel Rail Pressure. Monitor fuel rail pressure
with the engine running. Turn the engine off
and continue to monitor fuel rail pressure.
When the pressure has stabilized, record the
value as fuel tank pressure.
Temperature (°F)
Min.
Nominal
Max.
0
15
25
35
5
19
29
39
10
23
33
43
15
28
38
48
20
33
43
53
25
38
48
58
30
43
53
63
35
49
59
69
40
55
65
75
45
62
72
82
50
69
79
89
55
77
87
97
60
84
94
104
65
93
103
113
70
102
112
122
75
111
121
131
80
121
131
141
Measuring Fuel Rail Pressure — Fuel rail
pressure can be measured two ways: Refer to
Tools and Equipment, Special Tools in the 2012
Ford E-150/250/350/450 or 2013 F-250/350
Liquid Propane Autogas Fuel System Service
Manual for more information regarding the tools
required.
Method 1 — Using the OBD-II scan tool, read the
fuel rail pressure PID. If using the Ford IDS
tool, it will be necessary to select the tool
box tab, then select Powertrain near bottom
of selection, OBD Test Modes, Mode 1
Powertrain Data. Then locate and select
FRP (pressure) from PID selection table.
Method 2 — Empty the fuel rails and fuel lines.
Refer to the Fuel Line Purging Procedure in
the 2012 Ford E-150/250/350/450 or 2013
F-250/350 Liquid Propane Autogas Fuel
System Service Manual Supplement for
more information. Using the Jiffy-Tite
disconnect tool, disconnect the fuel supply
line at the rear of the RH fuel rail. Install the
ROUSH service port adapter between the
fuel line and the fuel rail. Attach 0–500 psi
(0–3447 kPa) fuel pressure gauge to the
service port on the adapter. Record the
value.
85
131
141
151
90
142
152
162
95
153
163
173
100
165
175
185
105
178
188
198
110
191
201
211
115
205
215
225
120
219
229
239
Page 16
On vehicles that have been operated for
extended periods of time, the tank (fuel) can be
much warmer and so higher pressures are to be
expected.
Expected Fuel Rail Pressure — Under normal
operating conditions, the fuel pump has two
operating speeds. The pump operates in low
speed mode at idle and during moderate fuel
flow/part throttle driving. Once a fuel demand
threshold is met, typically during wide open
throttle (WOT) operation, the pump is switched to
high speed. The pump is also operated at high
speed during the pre-start flush sequence.
TROUBLESHOOTING
The fuel pressure controls are designed to keep
the rails at a certain pressure over tank pressure,
therefore, it is important to measure tank
pressure prior to collecting fuel rail pressure data.
For example, if the fuel tank is at 150 psi
(1034 kPa) and pressure in the rail is measured
at 200 psi (1379 kPa), the rail is running at 50 psi
(345 kPa) over tank.
Condition
Pump Speed
Pressure
Over Tank
Engine Off
Off
<10
Idle
Low
>30
Part Throttle
Low
<25
Part Throttle
High
>25
WOT
High
>25
Under extreme operating conditions, there is a
third pump mode. In the event that the fuel
system has degraded and the sensor detects
vapor, or if the fuel rail pressure is approaching
the limit of the fuel system, the pump runs in a
variable speed mode, controlling to a target
pressure. In this mode there is no predicted rise
over tank pressure. The fuel pump will adjust the
pressure to maintain a required operating
pressure. This condition will likely result in a
P116E or P0148 code.
No Fill
Step
Procedure
Action
1
Inspect vehicle to check for kinked fill lines.
Are fill lines kinked?
Yes — Replaced kinked fill lines.
No — Go to Step 2.
2
Determine the location of the overflow protection device (OPD).
Is the OPD located in the end cap of the fuel tank?
Yes — Go to Step 3.
No — Go to Step 6.
3
Check the fuel gauge in the instrument cluster.
Is the gauge indicating less than 1/4 full?
Yes — Go to Step 4.
No — Go to Step 6.
4
Check to see if the OPD is being activated.
Yes — Go to Step 5.
No — Go to Step 6.
Fuel splashing off the sides of the empty tank could be activating the
OPD float and shutting off the fuel fill line.
a.
b.
Loosen the fuel fill line at the fill valve or at the inlet to the fuel filter
to relieve any pressure in the fill line and release the OPD valve.
Retighten the fill line.
Install a fuel fill pressure tester on the fill valve and close the ball
valve.
c.
Connect the fuel dispensing nozzle to the pressure tester and turn
on the pump. Slightly open the ball valve to slowly add
approximately 10 gal (38 L) of fuel.
d.
Did the tank fill?
5
Remove the fuel fill pressure tester and attempt to fill the vehicle
fuel tank to full 80% capacity.
Does the vehicle fuel tank fill to capacity?
Yes — Diagnostic is complete.
No — Go to Step 6.
6
Check the fuel gauge in the instrument cluster.
Is the gauge indicating more than 1/2 full?
Yes — Go to Step 7.
No — Go to Step 11.
7
Reverse direction of vehicle at the pump and try to fill the vehicle.
Does the vehicle fuel tank fill?
Yes — Vehicle not on level ground.
Diagnostic is complete.
No — Drive vehicle until fuel gauge
indicates less than 1/2 full and go to Step
8.
Page 17
TROUBLESHOOTING
Step
Procedure
Action
8
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill?
Yes — Go to Step 9.
No — Go to Step 11.
9
Open bleeder valve.
Does liquid fuel vent?
Yes — Go to Step 10.
No — Go to Step 12.
10
Check fuel gauge.
Does fuel gauge read full?
Yes — Diagnostic complete.
No — Refer to Fuel Level Indicator Check.
11
Check for sufficient fill station pressure.
Yes — Go to Step 12.
No — Fill station may not be providing
enough pressure to fill. Go to Step 19.
a.
b.
12
Connect pressure gauge service tool to the fuel tank bleeder valve
and record pressure.
Using a fuel fill pressure tester installed on the fill valve, attempt to
fill the vehicle.
c.
With the dispensing pump on and dispensing nozzle open,
measure and record fill station pump pressure.
d.
Is fill station pump pressure at least 20 psi (138 kPa) greater than
tank pressure?
Check body side fuel fill valve; it may be stuck closed.
a.
b.
c.
Loosen the fuel fill line connection at the fill valve or at the inlet to
the fuel filter to relieve any pressure in the fill line.
Attempt to push open the piston in the fill valve to determine if it is
stuck closed.
Yes — Replace body-side fill valve and go
to Step 13.
No — Replace filter in the fuel fill line and
go to Step 15.
Is the fill valve piston stuck closed?
13
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill?
Yes — Diagnostic is complete.
No — Go to Step 14.
14
Replace the filter in the fuel fill line and then attempt to fill the
vehicle fuel tank.
Does the vehicle fuel tank fill?
Yes — Diagnostic is complete.
No — Go to Step 16.
15
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill?
Yes — Diagnostic is complete.
No — Go to Step 16.
16
Replace the OPD valve in the vehicle fuel tank.
Is the OPD valve located in the end cap of the fuel tank?
Yes — Go to Step 17.
No — Go to Step 18.
17
Attempt to fill the vehicle fuel tank as follows:
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer
Service at 800-597-6874.
When filling a new tank that has the OPD valve mounted in the end
cap of the fuel tank, fuel splashing off the sides of the empty tank could
be activating the OPD float and shutting off the fuel fill line.
a.
18
Page 18
b.
Install a fuel fill pressure tester on the fill valve and close the ball
valve.
Connect the fuel dispensing nozzle to the pressure tester and turn
on the pump. Slightly open the ball valve to slowly add
approximately 10 gal (38 L) of fuel.
c.
Remove the fuel fill pressure tester.
d.
Attempt to fill the remaining tank volume (to 80% full capacity) at
full flow from the dispensing nozzle.
e.
Did the tank fill?
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill?
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer
Service at 800-597-6874.
TROUBLESHOOTING
Step
19
Procedure
Fill station is not providing enough pressure to fill.
a.
b.
20
Vehicle fuel tank is at a higher pressure.
a.
b.
21
Higher pressure is likely caused by heavy vehicle usage heating
the fuel.
Allow the vehicle (fuel tank) to cool and then recheck pressure in
the fuel tank.
Measure and compare vehicle fuel tank and fill station pressures.
a.
b.
22
Using the tables provided at the front of this section, determine
expected propane tank pressure based on ambient temperature.
Is the vehicle fuel tank pressure greater than 20 psi
(138 kPa) over the nominal expected pressure?
Connect a pressure gauge service tool to the fuel tank bleeder
valve and record fuel tank pressure.
Using a fuel fill pressure tester installed on the fill valve, attempt to
fill the vehicle.
c.
With the dispensing pump on and dispensing nozzle open,
measure and record fill station pump pressure.
d.
Is fill station pump pressure at least 20 psi (138 kPa) greater than
fuel tank pressure?
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill?
Action
Yes — Go to Step 20.
No — Locate a dispensing facility with
pump output capacity in excess of 100 psi
(689 kPa) (preferably an Auto Gas-type
facility). Then, go to Step 12.
When tank pressure is within 10 psi (69
kPa) of expected tank pressure, go to Step
21.
Yes — Go to Step 22.
No — Fill station is not providing enough
pressure to fill vehicle tank. Go to Step 22.
Locate a dispensing facility with pump
output capacity in excess of 100 psi
(689 kPa) (preferably an Auto Gas-type
facility).
Yes — Diagnostic is complete.
No — Go to Step 12.
Slow Fill
Step
Procedure
Action
1
Inspect vehicle to check for kinked fill lines.
Are fill lines kinked?
Yes — Replaced kinked fill lines.
No — Go to Step 2.
2
Determine flow rate at which the vehicle fuel system fills.
Yes — System fill rate is OK; diagnostic is
complete.
No — Fill station is not providing enough
pressure to fill vehicle tank. Go to Step 3.
a.
b.
c.
3
b.
Connect a pressure gauge service tool to the fuel tank bleeder
valve and record fuel tank pressure.
Using a fuel fill pressure tester installed on the fill valve, attempt to
fill the vehicle.
c.
With the dispensing pump on and dispensing nozzle open,
measure and record fill station pump pressure.
d.
Is fill station pump pressure at least 50 psi (345 kPa) greater than
fuel tank pressure?
Check fuel fill valve; it may not be opening completely.
a.
b.
c.
5
Is the fill station pump flow rate at least 6 gal (23 L) per minute?
Measure and compare vehicle fuel tank and fill station pressures.
a.
4
Time the fill station pump for 10 seconds and record the number
of gallons dispensed.
Multiply the gallons dispensed by six to determine the flow rate in
gallons per minute.
Loosen the fuel fill line connection at the fill valve or at the inlet to
the fuel filter to relieve any pressure in the fill line.
Attempt to push open the piston in the fill valve to determine if it is
opening completely. Piston should travel 1/4 inch.
Yes — Go to Step 4.
No — Fill station is not providing enough
pressure to fill vehicle tank. Go to Step 11.
Yes — Replace the filter in the fuel fill line
and then go to Step 7.
No — Replace the fuel fill valve and then
go to Step 5.
Is the fill valve piston opening completely?
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Go to Step 6.
Page 19
TROUBLESHOOTING
Step
Procedure
Action
6
Replace the filter in the fuel fill line.
Does the vehicle fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Go to Step 7.
7
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Go to Step 8.
8
Replace the overfill protection device (OPD) valve in the vehicle
fuel tank.
Is the OPD valve located in the end cap of the fuel tank?
Yes — Go to Step 9.
No — Go to Step 10.
9
Attempt to fill the vehicle fuel tank as follows:
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer
Service at 800-597-6874.
When filling a new tank that has the OPD valve mounted in the end
cap, fuel splashing off the sides of the empty tank could be activating
the OPD float and shutting off the fuel fill line.
a.
b.
Install a fuel fill pressure tester on the fill valve and close the ball
valve.
Connect the fuel dispensing nozzle to the pressure tester and turn
on the pump. Slightly open the ball valve to slowly add
approximately 10 gal (38 L) of fuel.
c.
Remove the fuel fill pressure tester.
d.
Attempt to fill the remaining tank volume (to 80% full capacity) at
full flow from the dispensing nozzle.
a.
Did the tank fill?
10
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer
Service at 800-597-6874.
11
Fill station is not providing enough pressure to fill.
Yes — Go to Step 12.
No — Locate a dispensing facility with
pump output capacity in excess of 100 psi
(689 kPa) (preferably an Auto Gas-type
facility). Then, go to Step 2.
a.
b.
12
Vehicle fuel tank is at a higher pressure.
a.
b.
13
b.
Page 20
Higher pressure is likely caused by heavy vehicle usage heating
the fuel.
Allow the vehicle (fuel tank) to cool and then recheck pressure in
the fuel tank.
Measure and compare vehicle fuel tank and fill station pressures.
a.
14
Using the tables provided at the front of this section, determine
expected propane tank pressure based on ambient temperature.
Is the vehicle fuel tank pressure greater than 20 psi (38 kPa) over
the nominal expected pressure?
Connect a pressure gauge service tool to the fuel tank bleeder
valve and record fuel tank pressure.
Using a fuel fill pressure tester installed on the fuel fill valve,
attempt to fill the vehicle.
c.
With the dispensing pump on and dispensing nozzle open,
measure and record fill station pump pressure.
d.
Is fill station pump pressure at least 50 psi (345 kPa) greater than
fuel tank pressure?
Attempt to fill the vehicle fuel tank.
Does the fuel tank fill at greater than six gal (23 L) per minute?
When tank pressure is within 10 psi
(69 kPa) of expected tank pressure, go to
Step 13.
Yes — Go to Step 14.
No — Fill station is not providing enough
pressure to fill vehicle tank. Go to Step 14.
Locate a dispensing facility with pump
output capacity in excess of 100 psi (689
kPa) (preferably an Auto Gas-type facility).
Yes — Diagnostic is complete.
No — Go to Step 4.
TROUBLESHOOTING
Over Fill
Step
1
Procedure
Suspect overfill because fuel fill volumes achieved during
refueling exceed the rated fuel capacity or excessive vehicle
range between refueling.
a.
b.
2
3
b.
4
Check to determine if the vehicle is level using the vehicle frame
as reference.
Does the vehicle sit level?
Locate the American Society of Mechanical Engineers (ASME)
inspection plate on the fuel tank.
a.
b.
5
Listen at valve to verify propane vapor is venting.
Is propane vapor venting?
Park the vehicle at the refueling station.
a.
Yes — Go to Step 2.
No — Drive vehicle until gauge reads
below 1/4 tank.
Check the fuel gauge.
Is the gauge reading below 1/2 tank?
Open bleeder valve located on the tank or remotely mounted on
the vehicle.
a.
b.
Action
Yes — Go to Step 3.
No — Bleeder valve is not functioning
properly. Replace the valve.
Yes — Go to Step 4.
No — Using a jack, raise the vehicle to
obtain a level condition. Then, go to Step 4.
With the value recorded, go to Step 5.
Note the tank water capacity listed on the plate.
Multiply the listed capacity by 0.05 (5%) and record the value.
Refuel the vehicle as follows:
Yes — Record the volume of fuel
dispensed and then go to Step 6.
No — Go to Step 7.
If the key is on during refueling, it will take the fuel level gauge in the
instrument cluster longer to register full.
6
a.
b.
Verify that the ignition is in the off position.
Install the fuel fill pressure tester on the fill valve and close the ball
valve.
c.
Connect the fuel dispensing nozzle to the pressure tester. Verify
that the bleeder valve is open.
d.
With the bleeder valve open, turn on the pump. Open the ball
valve slightly to very slowly refuel the vehicle.
e.
While refueling, observe the bleeder valve for fuel discharge.
f.
Stop filling when a solid stream of liquid fuel flows from the
bleeder valve or the dispensing pump stops automatically.
g.
Did a solid stream of liquid flow from the bleeder valve?
Resume filling until the dispensing pump stops automatically.
a.
b.
7
Record the total volume of fuel dispensed and subtract the
amount from the volume recorded in Step 5.
Is the additional amount of fuel dispensed less than 5% of the
tank water capacity determined in Step 4?
The dispensing pump stopped automatically and a liquid fuel
stream was not observed flowing from bleeder valve.
Yes — Tank does not overfill. Diagnostic is
complete.
No — Tank is overfilling. Replace the OPD
fill valve in the fuel tank; then, go to Step 8.
Tank does not overfill. Diagnostic is
complete.
Page 21
TROUBLESHOOTING
Step
8
Procedure
Refuel the vehicle as follows:
Action
Yes — Record the volume of fuel
dispensed and then go to Step 9.
No — Go to Step 7.
If the key is on during refueling, it will take the fuel level gauge in the
instrument cluster longer to register full.
9
a.
b.
Verify that the ignition is in the off position.
Install the fuel fill pressure tester on the fill valve and close the ball
valve.
c.
Connect the fuel dispensing nozzle to the pressure tester. Verify
that the bleeder valve is open.
d.
With the bleeder valve open, turn on the pump. Open the ball
valve slightly to very slowly to refuel the vehicle.
e.
While refueling, observe the bleeder valve for fuel discharge.
f.
Stop filling when a solid stream of liquid fuel flows from the
bleeder valve or the dispensing pump stops automatically.
g.
Did a solid stream of liquid flow from the bleeder valve?
Resume filling until the dispensing pump stops automatically.
a.
b.
Record the volume of fuel dispensed and subtract the amount
from the volume recorded in Step 8.
Is the additional amount of fuel dispensed less than 5% of the
tank water capacity determined in Step 4?
Yes — Tank does not overfill. Diagnostic is
complete.
No — Tank is overfilling. Replace the fuel
tank assembly.
Engine Does Not Crank
Step
Procedure
Action
1
Is battery voltage above 10 volts?
Yes — Go to Step 2.
No — Determine cause of low battery
voltage.
2
Verify that the smart relay module (SRM) has communication.
Yes — Go to Step 3.
No — Go to the Smart Relay Module
Electrical Test procedure.
Can fuel rail pressure and temperature be read with a scan tool?
3
Page 22
Refer to the Ford Powertrain Control/Emission Diagnosis Service
Manual.
Is the problem corrected?
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer
Service at 800-597-6874.
TROUBLESHOOTING
Engine Cranks, No Start
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
Step
1
Procedure
Verify the following:
a.
b.
Is there fuel in the tank of at least 1/8 tank or more? (add fuel if
necessary).
Is the tank supply manual shutoff valve fully open?
c.
Is battery voltage above 10 volts?
Action
Yes — Go to Step 2.
No — Correct fault and retry.
2
Check for diagnostic trouble codes (DTC).
Are any codes present?
Yes — Go to Step 3.
No — Go to Step 4.
3
Is the DTC identified on the ROUSH LPA DTC list?
Yes— Refer to Diagnostic Trouble Codes.
No — Refer to Ford service manual DTC
chart.
4
Check fuel pressure.
Yes — Go to Step 11.
No — Go to Step 5.
a.
b.
5
c.
Record the highest pressure observed.
d.
Does fuel pressure rise 25 psi (172 kPa) before engine crank?
Check fuel pump operation.
a.
6
Measure and record fuel rail and fuel tank pressure, key on,
engine off (KOEO).
While monitoring fuel pressure, attempt to start engine.
b.
Using a current clamp, check current draw on both fuel pump
power wires at the fuel tank. Refer to In-Tank Harness for correct
circuits.
Turn ignition switch to start position and release. Vehicle will start
the flush cycle and pumps should be running. Check current draw.
A minimum of 2 amps should be recorded on both fuel pump
circuits.
c.
Do fuel pumps draw current?
Check excess flow valve (XFV).
a.
b.
Turn ignition key to the OFF position.
Close the manual shutoff valve on tank.
c.
Wait 1 minute and then slowly open manual shutoff valve.
d.
Measure and record fuel pressure, using a scan tool, at integrated
pressure temperature sensor (IPTS).
e.
Is problem resolved?
Yes — Go to Step 6.
No — If both circuits are showing no
current, check the OEM fuel pump (FP)
fuse. If only one fuel pump circuit shows
current, check the ROUSH CleanTech fuel
pump fuse. (See ROUSH CleanTech fuse
box for location.)
If both fuel pump fuses (OEM and ROUSH
CleanTech) are good, go to Step 10.
Yes — Go to Step 11.
No — Go to Step 7.
7
Check ROUSH fuel pump (FP) fuse.
Is fuse intact and OK?
Yes — Go to Step 8.
No — Determine the cause of the short
and repair; replace the fuse. Diagnostic is
complete.
8
Check the tank solenoid (TS) and supply solenoid (SS) fuses.
Yes — Determine the cause of the short
and repair; replace the fuse.
No — Go to Step 9.
a.
b.
Locate the TS fuse (E3-E4) and check its condition.
Locate the SS fuse (F1-F2) and check its condition.
c.
Are the fuses blown?
Page 23
TROUBLESHOOTING
Step
9
Procedure
Verify that there is power and proper grounding at the tank
solenoid (TS) and supply solenoid (SS) wiring circuits.
a.
10
b.
Check for +12 volts at the TS and SS connectors. Refer to the
Tank Solenoid Electrical Check procedure.
Is +12 volts present at the TS connector?
c.
Is +12 volts present at the SS connector?
Verify that there is power and proper grounding in the wiring
circuit to the tank.
a.
b.
Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2
(FP2) connectors. Refer to the Fuel Pump Electrical Check
procedure.
Is +12 volts present at the FP1 connector?
c.
Is +12 volts present at the FP2 connector?
Action
Yes — Voltage present at SS, replace
FRPCM. Voltage present at TS, replace
fuel supply valve assembly.
No — Check for an open(s) in the wiring
circuits and repair. Diagnostic is complete.
Yes — Go to Step 12.
No — Check for an open(s) in the wiring
circuits and repair.
11
Integrated Pressure Temperature Sensor Rationality
Does temperature and pressure make sense to verification procedure?
Yes — Refer to the Integrated Pressure
Temperature Sensor Electrical Check.
No — Verify that wiring in circuit is OK.
Refer to the Integrated Pressure
Temperature Sensor Electrical Check
procedure. If not, repair wiring. If OK,
replace sensor.
12
Check wiring.
Yes — Replace harness.
No — Go to Step 13.
a.
b.
13
Drain the propane from the fuel tank. Refer to the Fuel Tank
Draining Procedure in the appropriate ROUSH CleanTech Service
Manual for more information.
Remove tank service cover.
c.
Check for open or short circuits on tank pass-through harness.
d.
Is a wiring problem present?
Check fuel hoses and quick-connect fittings.
앫 Are in-tank fuel hoses and quick-connect fittings connected and in
good condition?
Page 24
Yes — Replace fuel pump assembly.
No — Replace hose assemblies as
needed.
TROUBLESHOOTING
Engine Stumble, Stall, Rough Idle
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
Step
1
Procedure
Verify the following:
a.
b.
Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if
necessary.)
Is the tank supply manual shutoff valve fully open?
c.
Is battery voltage above 11 volts with engine running?
Action
Yes — Go to Step 2.
No — Correct the fault and retry.
2
Check for diagnostic trouble codes (DTCs).
Are any codes present?
Yes — Go to Step 3.
No — Go to Step 4.
3
Identify the DTC.
Yes — Refer to ROUSH CleanTech
Diagnostic Trouble Codes.
No — Refer to the appropriate Ford
Powertrain Control/Emissions Diagnosis
Service Manual at www.motorcraft.com.
a.
b.
Is the DTC covered in the ROUSH CleanTech DTC listing for
LPA-fueled vehicles?
Correct all DTCs before continuing.
4
Does the problem occur only after cold start?
Yes — Go to Step 6.
No — Go to Step 5.
5
Determine fuel pressure.
Yes — Go to Step 7.
No — Go to Step 6.
6
7
a.
b.
Measure tank pressure with key on and engine off (KOEO).
Measure fuel rail pressure with key on and engine running
(KOER).
c.
Subtract the KOEO pressure from the KOER pressure to obtain
the difference. Compare to the chart in Expected Fuel Rail
Pressure.
d.
Is the resulting fuel pressure reading within the expected range?
Determine if the excess flow valve (XFV) is tripped.
a.
b.
Turn off the engine.
Wait one minute and then restart the engine.
c.
Is the fault condition resolved?
Check fuel pump operation.
a.
8
b.
Using a current clamp, check current draw on both fuel pump
power wires at the fuel tank. Refer to In-Tank Harness for correct
circuits.
Turn ignition switch to start position and release. Vehicle will start
the flush cycle and pumps should be running. Check current draw.
A minimum of 2 amps should be recorded on both fuel pump
circuits.
c.
Do fuel pumps draw current?
Verify that there is power and proper grounding in the wiring
circuit to the tank.
a.
b.
Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2
(FP2) connectors. Refer to the Fuel Rail Pressure Control Module
Electrical Check procedure.
Is +12 volts present at the FP1 connector?
c.
Is +12 volts present at the FP2 connector?
Yes — Refer to the Excess Flow Valve
Check procedure.
No — Go to Step 7.
Yes — Go to Step 11.
No — If both circuits are showing no
current, check the OEM fuel pump (FP)
fuse. If only one fuel pump circuit shows
current, check the ROUSH CleanTech fuel
pump fuse. (See ROUSH CleanTech fuse
box for location.)
If both fuel pump fuses (OEM and ROUSH
CleanTech) are good, go to Step 8.
Yes — Go to Step 9.
No — Check for an open/short in the wiring
circuit and repair.
Page 25
TROUBLESHOOTING
Step
9
Procedure
Check wiring.
a.
10
Action
b.
Drain the propane from the fuel tank. Refer to the Fuel Tank
Draining Procedure in the appropriate ROUSH CleanTech Service
Manual for more information.
Remove tank service cover.
c.
Check for open or short circuits on tank pass-through harness.
d.
Is a wiring problem present?
Check fuel hoses and quick-connect fittings.
앫 Are in-tank fuel hoses and quick-connect fittings connected and in
good condition?
Yes — Replace harness.
No — Go to Step 10.
Yes — Replace fuel pump assembly.
No — Replace hose assemblies as
needed.
11
Integrated Pressure Temperature Sensor Rationality
Does temperature and pressure make sense to verification? Refer to
the Integrated Pressure Temperature Sensor Electrical Check
procedure.
Yes — Go to Step 12.
No — Verify that wiring in circuit is OK. If
not, repair wiring. If OK, replace sensor.
12
Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis
Service Manual at www.motorcraft.com.
—
Excess Flow Valve Check
The excess flow valve (XFV) is designed to
restrict fuel exiting the tank if the pump is
energized while the fuel lines are not connected
to the fuel tank. Under normal circumstances, the
XFV should not trip. The XFV will reset itself after
the fuel pumps have been off for about one
minute.
If the fuel lines have not been serviced recently
and the problem persists, there may be a leak in
the supply side fuel line. If the problem is only
present after the vehicle has been sitting for a
length of time, but not present during a short
soak, or there is a propane odor when the vehicle
is running, refer to the Fuel Line Leak Detection
procedure.
It is common to trip the XFV after the fuel lines
have been serviced and contain no pressure. If
the XFV trips, turn the vehicle off, wait one
minute, and restart. This may take more than one
attempt.
Step
1
Page 26
Procedure
Verify fuel supply line pressure prior to cranking engine.
a.
b.
Read fuel rail pressure and tank pressure.
Energize bleed solenoid until rail pressure is at least 50 psi
(345 kPa) below tank pressure. If rail is bled, skip to Step D.
c.
Let pressure stabilize for 1 minute.
d.
Open the supply solenoid.
e.
Read fuel rail pressure and tank pressure.
f.
Does fuel rail pressure jump to tank pressure?
Action
Yes — Check is OK.
No — Repair the leak in the fuel supply
line.
TROUBLESHOOTING
Maximum Pressure Check
The LPA system operates over a wide range of
pressures depending on ambient temperature,
driving mode, etc. When the vehicle is subjected
to a severe drive cycle in high ambient
temperatures, the fuel rail pressure can rise to the
limit of the injectors capabilities. This limit is a
function of injector voltage and fuel rail pressure.
The PCM protects for this condition by reducing
the fuel pump speed when the condition is
sensed, however, there still may be drive
concerns. When the PCM starts controlling the
fuel pump a P116E code is set. While this
Step
1
condition can occur in a normally functioning
vehicle, it can also be exacerbated by several
factors. If the fuel tank was not properly bled
during the first fill, trapped air in the vapor space
can increase tank pressure. In this condition
there is often only a faint smell of propane when
the bleeder valve is opened. The tank should be
vented until there is a strong propane odor
coming from the bleeder valve. The tank pressure
should be confirmed against the expected
pressure.
Allow the fuel tank to cool to ambient temperature
before performing the following procedure.
Procedure
Measure tank pressure and tank surface temperature.
Is tank pressure more than 15 psi (103 kPa) over expected tank
pressure?
Action
Yes — Vent the tank until pressure is within
the expected range.
No — Vehicle is working properly; inform
and explain operating characteristics to
customer.
Supply Solenoid Check
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
Step
1
Procedure
Verify the following:
a.
b.
Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if
necessary.)
Is the tank supply manual shutoff valve fully open?
c.
Is battery voltage above 10 volts?
Action
Yes — Go to Step 2.
No — Correct fault and retry.
2
Check for diagnostic trouble codes (DTC).
Are any codes present?
Yes — Go to Step 3.
No — Go to Step 4.
3
Is the DTC identified on the ROUSH liquid propane autogas DTC
list?
Yes — Refer to Diagnostic Trouble Codes.
No — Refer to the Ford service manual
DTC chart.
4
Check fuel pressure.
Yes — Go to Step 11.
No — Go to Step 5.
a.
b.
Measure and record fuel rail pressure and fuel tank pressure at
key on, engine off (KOEO).
While monitoring fuel pressure, attempt to start engine.
c.
Record the highest pressure observed.
d.
Does fuel pressure rise 20 psi (138 kPa) before engine crank?
Page 27
TROUBLESHOOTING
Step
5
Procedure
Check fuel pump operation.
a.
6
b.
Using a current clamp, check current draw on both fuel pump
power wires at the fuel tank. Refer to In-Tank Harness for correct
circuits.
Turn ignition switch to start position and release. Vehicle will start
the flush cycle and pumps should be running. Check current draw.
A minimum of 2 amps should be recorded on both fuel pump
circuits.
a.
Do fuel pumps draw current?
Check XFV.
a.
b.
Turn off engine.
Wait 1 minute and then restart engine.
c.
Measure and record fuel rail pressure and fuel tank pressure.
d.
Is problem resolved?
Action
Yes — Go to Step 6.
No — If both circuits are showing no
current, check the OEM fuel pump (FP)
fuse. If only one fuel pump circuit shows
current, check the ROUSH CleanTech fuel
pump fuse. (See ROUSH CleanTech fuse
box for location.)
If both fuel pump fuses (OEM and ROUSH
CleanTech) are good, go to Step 10.
Yes — Go to Step 11.
No — Go to Step 7.
7
Check ROUSH FP fuse.
Is fuse intact and OK?
Yes — Go to Step 8.
No — Determine the cause of the short
and repair; replace the fuse.
8
Check the TS and SS fuses.
Yes — Determine the cause of the short
and repair; replace the fuse.
No — Go to Step 9.
9
a.
b.
Locate the TS fuse (E3-E4) and check its condition.
Locate the SS fuse (F1-F2) and check its condition.
c.
Are the fuses blown?
Verify that there is power and grounding in the TS and SS wiring
circuits.
a.
10
b.
Check for +12 volts at the TS and SS connectors. Refer to the
Tank Solenoid Electrical Check procedure.
Is +12 volts present at the TS connector?
c.
Is +12 volts present at the SS connector?
Verify that there is power and grounding in the wiring circuit to
the tank.
a.
b.
Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2
(FP2) connectors. Refer to the Fuel Rail Pressure Control Module
Electrical Check procedure.
Is +12 volts present at the FP1 connector?
c.
Is +12 volts present at the FP2 connector?
Yes — Voltage present at SS, replace
FRPCM. Voltage present at TS, replace
fuel supply valve assembly.
No — Check for an open/short in the wiring
circuit and repair.
Yes — Refer to Engine Stumble, Stall,
Rough Idle Step 12.
No — Check for an open/short in the wiring
circuit and repair.
11
Integrated Pressure Temperature Sensor Rationality
Does temperature and pressure make sense to verification?
Yes — Go to Step 12.
No — Verify that wiring in circuit is OK.
Refer to the Integrated Pressure
Temperature Sensor Electrical Check
procedure. If not, repair wiring. If OK,
replace sensor.
12
Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis
Service Manual at www.motorcraft.com.
—
Page 28
TROUBLESHOOTING
Fuel System Fails to Bleed
Step
1
2
3
Procedure
Determine if fault condition repeats.
a.
b.
Start the engine and allow it to run for a few minutes.
Turn off the engine and wait one minute.
c.
Measure and record the fuel rail pressure, fuel rail temperature
and fuel tank pressure with the engine off (KOEO).
d.
Energize the bleed solenoid. Refer to the Manual Solenoid
Activation Procedure.
e.
With the engine off, monitor fuel rail pressure for 15 minutes.
f.
Does fuel rail pressure drop more than 20 psi (138 kPa)?
Verify solenoid/restrictor function.
a.
b.
Start the engine and allow it to run for a few minutes.
Turn off the engine.
c.
Disconnect the EVAP line from the FRPCM port.
d.
Energize the bleed solenoid. Refer to the Manual Solenoid
Activation Procedure.
e.
Is there propane flowing from the port?
Verify that wiring is in good condition and functioning.
a.
b.
4
Check for a kinked EVAP line.
a.
b.
5
Perform wiring checks of the FRPCM harness.
Is the wiring OK?
Inspect the EVAP line between the FRPCM and EVAP canister.
Are there kinks in the line?
Check for leaks to the FRPCM.
a.
b.
Start the engine and allow it to run for a few minutes.
Turn off the engine and unplug the FRPCM.
c.
Measure and record fuel rail pressure.
d.
Bleed pressure from fuel rail until fuel pressure drops more than
50 psi (345 kPa).
e.
De-energize bleed solenoid.
f.
Let vehicle sit for 30 minutes.
g.
Measure fuel rail pressure and fuel tank pressure.
h.
Does fuel rail pressure rise more than 10 psi (69 kPa)?
Action
Yes — Go to Step 5.
No — Go to Step 2.
Yes — Go to Step 4.
No — Go to Step 3.
Yes — Bleed solenoid stuck closed or port
restrictor is plugged. Replace the FRPCM.
No — Repair wiring and repeat Step 1.
Yes — Replace the kinked EVAP line and
then repeat Step 1.
No — Go to Step 5.
Yes — FRPCM leaks at either supply
solenoid or return check valve. Replace
FRPCM.
No — Potential intermittent fault. Return
vehicle to customer and see if problem
persists.
Page 29
TROUBLESHOOTING
Fuel Pressure Drop
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
Step
1
2
Procedure
Verify the following:
a.
b.
Is there fuel in the tank of at least 1/8 tank?
Is the tank supply manual shutoff valve fully open?
c.
Is battery voltage above 10 volts?
Determine fuel pressure.
a.
b.
3
4
c.
Subtract the tank measurement from the KOER measurement.
d.
Is the resulting fuel pressure in the expected range?
Determine if the excess flow valve is tripped.
a.
b.
Turn off the engine.
Wait one minute and then restart the engine.
c.
Is the problem resolved?
Check fuel pump operation.
a.
5
b.
Using a current clamp, check current draw on both fuel pump
power wires at the fuel tank. Refer to In-Tank Harness for correct
circuits.
Turn ignition switch to start position and release. Vehicle will start
the flush cycle and pumps should be running. Check current draw.
A minimum of 2 amps should be recorded on both fuel pump
circuits.
c.
Do fuel pumps draw current?
Check tank solenoid (TS) and supply solenoid (SS) fuses.
a.
b.
6
Measure and record fuel tank pressure.
Measure and record fuel rail pressure with key on, engine running
(KOER).
Locate the TS (E3-E4) and SS (F1-F2) fuses.
Are the fuses blown?
Verify that there is power and ground in the wiring circuit to the
tank.
a.
b.
Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2
(FP2) connectors. Refer to the Fuel Rail Pressure Control Module
Electrical Check procedure.
Is +12 volts present at the FP1 connector?
c.
Is +12 volts present at the FP2 connector?
Action
Yes — Go to Step 2.
No — Correct the fault condition and retry.
Yes — Go to Step 4.
No — Go to Step 3.
Yes — Refer to the Excess Flow Valve
Check procedure.
No — Go to Step 4.
Yes — Go to Step 5.
No — If both circuits are showing no
current, check the OEM fuel pump (FP)
fuse. If only one fuel pump circuit shows
current, check the ROUSH CleanTech fuel
pump fuse. (See ROUSH CleanTech fuse
box for location.)
If both fuel pump fuses (OEM and ROUSH
CleanTech) are good, go to Step 6.
Yes — Find and repair the short; replace
the fuse.
No — Go to Step 8.
Yes — Refer to Engine Stumble, Stall,
Rough Idle Step 9.
No — Check for an open/short in the wiring
circuit and repair.
7
Integrated Pressure Temperature Sensor Rationality
Does temperature and pressure make sense to verification? See the
Integrated Pressure Temperature Sensor Electrical Check procedure.
Yes — Go to Step 8.
No — Verify that wiring in circuit is OK. If
not, repair wiring. If OK, replace sensor.
8
Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis
Service Manual at www.motorcraft.com.
—
Page 30
TROUBLESHOOTING
Fuel Level Indication Check
The ROUSH CleanTech fuel level indication
system differs from the gasoline system as the
fuel level sender is not wired directly to the
instrument cluster. Instead, the fuel level sender
is wired to the SRM, which reads the fuel level
and transmits the signal to the PCM via the CAN
bus, and to the FLIM, which in turn simulates the
resistance the instrument cluster expects to see
for a given fuel level.
The gauge on the sending unit must not be used
for any diagnostics. The gauge is not accurate.
Only resistance or voltage outputs should be
used for diagnostic purposes.
Symptom
Cause/Action to be taken
Fuel gauge does not move on a partial fill
This behavior is not uncommon. The fuel level sender may not move far enough
to trigger movement on the gauge if only a small amount of fuel is added to the
tank. Once driven, the gauge may move to reflect the fill.
Malfunction Indicator Lamp (MIL)
There is a circuit fault that has been identified by the PCM. Initially follow the
Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a
circuit check is called for, refer to the Fuel Level Interface Module Electrical Test
procedure.
Gauge points below E
This is an indication of an error state. Initially follow the Ford Powertrain
Control/Emissions Diagnosis Service Manual, whenever a circuit check is called
for, refer to the Fuel Level Interface Module Electrical Test procedure.
Doesn’t read full after a fill
This could be the result of either a fuel level sender fault or an OPD valve
triggering prematurely. Refer to fill issues and the Fuel Level Sender Electrical
Check procedure for more information.
Page 31
TROUBLESHOOTING
Tank Solenoid Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
5
3
5
1
2 4
3
5
1
B
2 4
6
4
3
2
3
3
E
1
5
A
2 4
1
FUSE BOX
5
2 4
1
F
1
44
1
15
30
31
32
44
18
29
3
15
45
1
2
46
A1
PBT/ASA-GF20
16
17
F
E
D
C
B
A
100070a
Figure 1 — Underhood Harness Connectors
2
21
30
A
B
C
A
B
D
C
D
E
F
100071a
Figure 2 — Rear Frame Harness Connectors
3
1
9
D
C
B
A
A
B
100072a
Figure 3 — Solenoid Harness Connectors
Page 32
TROUBLESHOOTING
PROCEDURE
Step
Procedure
Action
1
Unplug the solenoid harness connector 9 from the tank solenoid.
Go to Step 2.
2
Using a multimeter, measure resistance of the solenoid.
Is the measured resistance within 6–35 ohms?
Yes — Go to Step 3.
No — Replace the tank solenoid.
3
Using a multimeter, measure voltage at the tank solenoid as
follows:
Yes — Supply circuit OK.
No — Go to Step 4.
a.
b.
With the ignition key on, check for voltage present at pin-A,
connector 9 (solenoid harness). Use the body as the reference
ground.
Is battery (B+) voltage present?
4
Check fuse (E3-E4, 20A) in auxiliary fuse box.
Is fuse blown?
Yes — Replace fuse.
No — Fuse OK; go to Step 5.
5
Check relay.
Is relay functioning properly?
Yes — Go to Step 6.
No — Replace relay.
6
Check supply circuit continuity from solenoid harness to fuse
box.
Yes — Go to Step 7.
No — Repair supply circuit wiring.
a.
b.
7
Check continuity between:
앫 Pin-A, connector 9 and pin-A, connector 1 (solenoid harness)
앫 Pin-A, connector 21 and pin-A, connector 30 (rear wiring
harness)
앫 Pin-A, connector 15 and cavity A5, fuse box (underhood
harness)
Is there good continuity in the circuit?
Check ground circuit continuity from solenoid harness to smart
relay module (SRM) connector.
a.
b.
Check continuity between:
앫 Pin-B, connector 9 and pin-B, connector 1 (solenoid harness)
앫 Pin-B, connector 21 and pin-E, connector 30 (rear wiring
harness)
앫 Pin-E, connector 15 and pin-44, connector 1 (underhood
harness)
Is there good continuity in the circuit?
Yes — Refer to the Smart Relay Module
Electrical Test procedure.
No — Repair ground circuit wiring.
Page 33
TROUBLESHOOTING
Fuel Rail Pressure Control Module
Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
4
30
31
2
32
44
18
29
3
15
6
4
3
5
2 4
1
5
3
3
5
1
46
45
11
46
A1
PBT/ASA-GF20
1
2 4
B
33
1
2
3
3
E
1
5
A
2 4
1
FUSE BOX
5
2 4
1
F
F1-F2
16
17
17
F
E
D
C
B
A
100073a
Figure 4 — Underhood Harness Connectors
PROCEDURE
Step
Procedure
Action
1
Unplug the fuel rail pressure control module (FRPCM) connector
from connector 11 of underhood harness.
Go to Step 2.
2
Using a multimeter, check the resistance of each solenoid.
Yes — Go to Step 3.
No — Replace the FRPCM if resistance for
any one of the solenoids is not within the
specified range.
a.
b.
3
Page 34
Check resistance across the terminals of the FRPCM connector in
sequence as follows:
앫 Supply Solenoid — Pin-A and pin-F
앫 Flow Control Solenoid — Pin-B and pin-E
앫 Bleed Solenoid — Pin-C and pin-D
Is the measured resistance for each solenoid within 6–35 ohms?
Check supply voltage to FRPCM solenoids.
Using a multimeter, measure voltage between the terminal for each
solenoid at the harness side connector 11 and ground as follows:
Go to Steps 4–6.
TROUBLESHOOTING
4
Supply Solenoid — Pin-A and body ground
B+ Voltage — Go to Step 5.
No Voltage — Go to Step 5.
5
Flow Control Solenoid — Pin-B and body ground
B+ Voltage — Go to Step 6.
No Voltage — Go to Step 6 if Step 4 has
voltage; if Step 4 has no voltage, go to
Step 7.
6
Bleed Solenoid — Pin-C and body ground
B+ Voltage — Continue with Step 9.
No Voltage — Go to Step 8 if Step 4 has
voltage; if Step 4 has no voltage, go to
Step 7.
7
Check fuses (F1-F2, 10A) in auxiliary fuse box.
Is a fuse blown?
Yes — Replace fuse.
No — Go to Step 8.
8
Check solenoid supply circuit continuity.
Yes — Go to Step 9.
No — Repair wiring circuit.
a.
b.
9
Check continuity between:
앫 Supply Solenoid — Pin-A, connector 11 (underhood harness)
and cavity F2 (auxiliary fuse box)
앫 Flow Control Solenoid — Pin-B, connector 11 (underhood
harness) and cavity F2 (auxiliary fuse box)
앫 Bleed Solenoid — Pin-C, connector 11 (underhood harness)
and cavity F2 (auxiliary fuse box)
Is there good continuity in all three circuits?
Check solenoid ground circuit continuity.
a.
b.
Check continuity in the underhood harness between:
앫 Supply Solenoid — Pin-F, connector 11 and pin-46, connector
1 at SRM
앫 Flow Control Solenoid — Pin-E, connector 11 and pin-33,
connector 1 at SRM
앫 Bleed Solenoid — Pin-D, connector 11 and pin-17, connector 1
at SRM
Is there good continuity in all three circuits?
Yes — Refer to the Smart Relay Module
Electrical Test procedure.
No — Repair wiring circuit.
Page 35
TROUBLESHOOTING
Integrated Pressure Temperature
Sensor Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
Figure 5 — Underhood Harness Connectors
PROCEDURE
Step
Procedure
Action
1
Unplug the connector 8 (underhood harness) to the IPTS.
Go to Step 2.
2
Check resistance of the integrated pressure temperature sensor
(IPTS).
Yes — Go to Step 3.
No — Replace the IPTS.
a.
b.
Page 36
With vehicle at ambient room temperature (20–30°C, 68–86°F)
and using a multimeter, measure resistance across the IPTS
terminals (between pin-1 and pin-3).
Is the resistance value between 8K–12K ohms?
TROUBLESHOOTING
Step
3
Procedure
Check circuit continuity between the IPTS and the smart relay
module (SRM).
a.
b.
Using a multimeter, check continuity in the underhood harness
between:
앫 Pin-1, connector 8 and pin-40, connector 1
앫 Pin-2, connector 8 and pin-7, connector 1
앫 Pin-3, connector 8 and pin-5, connector 1
앫 Pin-4, connector 8 and pin-25, connector 1
Is there good continuity in the circuits?
Action
Yes — Refer to the Smart Relay Module
Electrical Test procedure.
No — Repair circuit wiring.
Page 37
TROUBLESHOOTING
Fuel Pump Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
5
12 13
24
4
1
8
5
27
B
A
B
A
100075a
Figure 6 — Rear Frame Harness Connectors
6
1
2
4A 4B
A
B
A
B
100076a
Figure 7 — In-Tank Harness Connectors
PROCEDURE
Step
1
Procedure
Check fuel pump circuit continuity.
a.
2
3
b.
Unplug the FPCM connector 12 for fuel pump 1. Check fuel pump
circuit continuity.
Using a multimeter, measure resistance between pin-5 and pin-8.
c.
Is resistance between 0.4–1.0 ohm?
Check fuel pump circuit continuity.
a.
b.
Unplug the FPCM connector 13 for fuel pump 2.
Using a multimeter, measure resistance between pin-5 and pin-8.
c.
Is resistance between 0.4–1.0 ohm?
Check resistance of each fuel pump.
a.
b.
c.
Page 38
Unplug the fuel pump connectors (in-tank harness) at the fuel
pump assembly.
Using a multimeter, measure resistance for fuel pump 1 across
the terminals of the fuel pump.
Is resistance between 0.4–1.0 ohm?
Action
Yes — Go to Step 2.
No — Go to Step 3.
Yes — Refer to the Fuel Pump Control
Module Electrical Continuity Test
procedure.
No — Go to Step 3.
Yes — Go to Step 4.
No — Replace fuel pump assembly.
TROUBLESHOOTING
Step
4
Procedure
Check resistance continued.
a.
b.
5
Using a multimeter, measure resistance for fuel pump 2 across
the terminals of the fuel pump.
Is resistance between 0.4–1.0 ohm?
Check harness circuit continuity from fuel pumps to FPCM.
a.
b.
Check continuity for pump 1, wire FPPWR, V+ across:
앫 Pin-A, connector 4A (in-tank harness) to pin-A, connector 1
(in-tank harness)
앫 Pin-A, connector 24 (rear frame harness) and pin-5, connector
12 (rear frame harness)
Check continuity for pump 1, wire FPRTN, V– across:
c.
앫 Pin-B, connector 4A (in-tank harness) to pin-B, connector 1
(in-tank harness)
앫 Pin-B, connector 24 (rear frame harness) and pin-8, connector
12 (rear frame harness)
Check continuity for pump 2, wire FPPWR, V+ across:
d.
앫 Pin-A, connector 4B (in-tank harness) to pin-A, connector 2
(in-tank harness)
앫 Pin-A, connector 27 (rear harness) and pin-5, connector 13
(rear harness)
Check continuity for pump 2, wire FPRTN, V– across:
e.
앫 Pin-B, connector 4B (in-tank harness) to pin-B, connector 2
(in-tank harness)
앫 Pin-B, connector 27 (rear frame harness) and pin-8, connector
13 (rear frame harness)
Is there good continuity in all circuits?
Action
Yes — Go to Step 5.
No — Replace fuel pump assembly.
Yes — Refer to the Fuel Pump Control
Module Electrical Continuity Test
procedure.
No — Repair circuit wiring.
Page 39
TROUBLESHOOTING
Fuel Pump Control Module
Electrical Continuity Test
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
7
A3
E4
FUSE BOX
6
4
5
3
5
1
2 4
3
5
1
2 4
B
A
2 4
1
3
2
3
3
15
E
1
5
5
2 4
1
F
A5
F
E
D
C
B
A
100077a
Figure 8 — Underhood Harness Connectors
8
1
12 13
27
1
4
4
1
5
8
8
5
30
A
B
C
D
E
F
A
B
41
A
B
100078a
Figure 9 — Rear Frame Harness Connectors
Page 40
TROUBLESHOOTING
PROCEDURE
Step
Procedure
Action
For fuel pump control module (FPCM) functional testing and diagnostic trouble codes, refer to the Ford Powertrain
Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
1
2
Check Ford FPCM circuit continuity to Ford harness.
a.
b.
Disconnect rear frame harness connectors 1 and 12.
Check for continuity in the rear frame harness across:
c.
앫 Pin-1, connector 1 and pin-1, connector 12
앫 Pin-3, connector 1 and pin-3, connector 12
앫 Pin-4, connector 1 and pin-4, connector 12
앫 Pin-5, connector 1 and pin-5, connector 12
앫 Pin-6, connector 1 and pin-6, connector 12
앫 Pin-7, connector 1 and pin-7, connector 12
Is there good continuity in each circuit?
Check FPCM circuit continuity to Ford harness.
a.
b.
Disconnect rear frame harness connector 13.
Check wire VPWR (V+) for continuity across:
c.
앫 Pin-1, connector 13 (rear frame harness) and pin-A, connector
30 (rear frame harness)
앫 Pin-A, connector 15 (underhood harness) and cavity-A5, fuse
box (underhood harness)
앫 Cavity-A3, fuse box (underhood harness) and cavity-E4, fuse
box (underhood harness)
Is there good continuity in each circuit?
Yes — Go to Step 2.
No — Repair circuit wiring.
Yes — Go to Step 3.
No — Repair circuit wiring.
3
Check fuse condition (E3-E4).
Is the fuse blown?
Yes — Replace the fuse.
No — Go to Step 4.
4
Check Roush CleanTech FPCM circuit continuity to Ford harness. Yes — Refer to the Ford Powertrain
Control/Emissions Diagnosis Service
a. Check for continuity in the rear frame harness across:
Manual for functional testing of the FPCM.
앫 Pin-A, connector 30 and pin-1, connector 13
No — Repair circuit wiring.
앫 Pin-4, connector 1 and pin-4, connector 13
앫 Pin-A, connector 27 and pin-5, connector 13
앫 Pin-6, connector 1 and pin-6, connector 13
앫 Pin-B, connector 27 and pin-8, connector 13
앫 Pin-A, connector 41 and pin-7, connector 13
b. Is there good continuity in each circuit?
Page 41
TROUBLESHOOTING
Smart Relay Module Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
9
E1-E2
4
5
3
2
E
1
6
1
3
5
1
2 4
31
F
FUSE BOX
1
32
44
18
29
3
15
45
3
5
1
2
46
A1
PBT/ASA-GF20
2 4
3
5
1
31
16
17
B
2 4
3
5
A
2 4
1
30
100079a
2
Figure 10 — Underhood Harness Connectors
10
5
9
7
1
A
C
D
14
8
F
100080a
Figure 11 — CAN Harness Connectors
PROCEDURE
Step
Procedure
Action
1
Disconnect the smart relay module (SRM) connector 1
(underhood harness).
Go to Step 2.
2
Check for battery voltage (B+) to the SRM.
Yes — Go to Step 5.
No — Go to Step 3.
a.
b.
3
Check for battery voltage (B+) to the SRM.
a.
b.
Page 42
Using a multimeter, check for B+ voltage at cavity 2,
connector 1. Use a body ground for reference.
Is there voltage (B+)?
Check circuit continuity between cavity 2, connector 1 and cavity
E2, auxiliary fuse box.
Is there good continuity in the circuit?
Yes — Go to Step 4.
No — Repair circuit wiring.
TROUBLESHOOTING
Step
4
Procedure
Check for battery voltage (B+) to the SRM.
a.
b.
5
Check the SRM ground circuit for continuity.
a.
b.
6
b.
Check condition of fuse (F5-F6, 5A) in auxiliary fuse box.
Is fuse blown?
E-Series Only: Check CAN harness for SRM circuit continuity.
a.
b.
9
Using a multimeter, check the underhood harness for continuity in
the E-Series system between pin-26, connector 1 and pin-A,
connector 23 and in F-Series system between pin-26, connector 1
and pin-1, connector 51/55.
Is there good continuity in the circuit?
Check fuse.
a.
b.
8
Using a multimeter, check ground at cavity 31, connector 1
(underhood harness). Use a body ground for reference.
Is there good continuity?
Check for active signal to SRM.
a.
7
Check condition of SRM power fuse (E1-E2, 25A) in the auxiliary
fuse box.
Is fuse blown?
Check continuity between pin-A, connector 9 and pin-12,
connector 5.
Is there good continuity in the circuit?
Check CAN and underhood harness continuity.
a.
Check CAN-H(+) continuity across:
앫 Pin-28, SRM connector 1 (underhood harness) and pin-C,
connector 23 (underhood harness)
Action
Yes — Replace fuse.
No — Go to Step 5.
Yes — Go to Step 6.
No — Repair circuit wiring.
Yes — E-Series: Go to Step 8,
F-Series: Go to Step 9.
No — Go to Step 7.
Yes — Replace fuse.
No — Repair circuit wiring
Yes — Go to Step 9.
No — Repair circuit wiring.
Yes — Go to Step 10.
No — Repair circuit wiring.
앫 Pin-C, connector 9 (CAN harness) and pin-2, connector 5
(CAN harness)
b.
10
Is there good continuity in the circuits?
Check CAN and underhood harness continuity.
a.
Check CAN-H(−) continuity across:
앫 Pin-43, SRM connector 1 (underhood harness) and pin-B,
connector 23 (underhood harness)
앫 Pin-B, connector 9 (CAN harness) and pin-3, connector 5
(CAN harness)
b.
Yes — Refer to the Ford Powertrain
Control/Emissions Diagnosis Service
Manual for functional testing of the CAN
bus.
No — Repair circuit wiring.
Is there good continuity in the circuits?
Page 43
TROUBLESHOOTING
Fuel Level Sender Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
11
1
15
30
31
32
44
18
29
3
15
45
1
2
46
A1
PBT/ASA-GF20
16
17
3
F
E
Figure 12 — Underhood Harness Connectors
12
21
30
A
A
B
C
B
C
D
D
E
100082a
Figure 13 — Rear Frame Harness Connectors
13
1
6
A
D
C
B
A
B
100083a
Figure 14 — Solenoid Harness Connectors
Page 44
F
D
C
B
A
100081a
TROUBLESHOOTING
PROCEDURE
Step
Procedure
Action
For fuel level sender (FLS) functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and
Diagnostic Trouble Codes.
1
2
3
4
5
Check resistance in FLS circuit wiring.
a.
b.
Disconnect the SRM connector 1 (underhood harness).
Using a multimeter, measure the resistance between pin-3 and
pin-40 of the harness connector.
c.
Is resistance between 24–260 ohms?
Check resistance of the FLS.
a.
b.
Disconnect the FLS connector 6 (solenoid harness).
Using a multimeter, measure the resistance across the FLS
connector pins.
c.
Is resistance between 24–260 ohms?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
b.
Disconnect connector 1 of the solenoid harness.
Check continuity between pin-B, connector 6 (solenoid harness)
and pin-C, connector 1 (solenoid harness).
c.
Is there good continuity in the circuit?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
b.
Disconnect connector 30 of the rear frame harness.
Check continuity between pin-C, connector 21 (rear frame
harness) and pin-D, connector 30 (rear frame harness).
c.
Is there good continuity in the circuit?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
b.
6
b.
7
b.
8
b.
Yes — Go to Step 5.
No — Repair circuit wiring.
Yes — Go to Step 6.
No — Repair circuit wiring.
Yes — Go to 7.
No — Repair circuit wiring.
Yes — Go to Step 8.
No — Repair circuit wiring.
Check continuity between pin-D, connector 21 (rear frame
harness) and pin-C, connector 30 (rear frame harness).
Is there good continuity in the circuit?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
Yes — Go to Step 4.
No — Repair circuit wiring.
Check continuity between pin-A, connector 6 (solenoid harness)
and pin-D, connector 1 (solenoid harness).
Is there good continuity in the circuit?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
Yes — Go to Step 3.
No — Replace the FLS.
With SRM connector 1 and connector 15 of the underhood
harness disconnected, check continuity between pin-C, connector
15 and pin-3, SRM connector 1.
Is there good continuity in the circuit?
Check circuit wiring continuity between FLS connector and SRM
connector.
a.
Yes — Refer to the Smart Relay Module
Electrical Test procedure or the Fuel Level
Interface Module Electrical Test procedure.
No — Go to Step 2.
Check continuity between pin-D, connector 15 (rear frame
harness) and pin-40, SRM connector (underhood harness).
Is there good continuity in the circuit?
Yes — Refer to the Smart Relay Module
Electrical Test procedure or the Fuel Level
Interface Module Electrical Test procedure.
No — Repair circuit wiring.
Page 45
TROUBLESHOOTING
Fuel Level Interface Module
Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to System
Wiring Diagrams and to System Electrical
Schematics.
CONNECTORS
14
15
1
35
37
30
31
32
44
18
29
3
15
45
1
2
16
30
A
B
C
D
E
17
2
B
A
C
D
100084a
Figure 15 — Underhood Harness Connectors
100085a
Figure 16 — Rear Frame Harness Connectors
PROCEDURE
Step
Procedure
Action
For FLIM functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic
Trouble Codes.
1
2
Check FLIM circuit wiring for continuity to SRM.
a.
b.
Disconnect underhood harness connector 1 to SRM.
Check underhood harness continuity between pin-A, connector 35
and pin-2, connector 1.
c.
Is there good continuity in the circuit?
Check FLIM circuit wiring for continuity to SRM.
a.
b.
3
b.
4
Check underhood harness continuity between pin-C, connector
35 and body ground.
Is there good continuity in the circuit?
Check FLIM circuit wiring for continuity to SRM.
a.
b.
c.
Page 46
Check underhood harness continuity between pin-B, connector 35
and pin-37, connector 1.
Is there good continuity in the circuit?
Check FLIM circuit wiring for continuity to SRM.
a.
F
46
A1
PBT/ASA-GF20
9
Disconnect underhood harness connector 15 to rear frame
harness.
Check underhood harness continuity between pin-D, connector 35
and pin-F, connector 15.
Is there good continuity in the circuit?
Yes — Go to Step 2.
No — Repair circuit wiring.
Yes — Go to Step 3.
No — Repair circuit wiring.
Yes — Go to Step 4.
No — Repair circuit wiring.
Yes — Go to Step 5.
No — Repair circuit wiring.
TROUBLESHOOTING
Step
5
Procedure
Check FLIM circuit wiring for continuity to SRM.
a.
b.
Disconnect rear frame harness connector 9 to Ford harness.
Check rear frame harness continuity between pin-F, connector 30
and pin-2, connector 9.
c.
Is there good continuity in the circuit?
Action
Yes — Refer to the Smart Relay Module
Electrical Test procedure.
No — Repair circuit wiring.
Page 47
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
Page 48
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-150/150/350 Extended Wiring Harnesses and Connector Layout
E-150/250/350 WIRING HARNESSES AND
CONNECTOR LAYOUT
APPROXIMATE LOCATION OF
LPA SYSTEM HARNESSES AND CONNECTORS
8
5
1
11
27
GND
R1
GND
R2
23 9
35
1
PASS
THRU
15 30
47 41
9
UNDER BODY LPA
FUEL TANK
6
4A
7 9
4B
GND
4 1 1
27 24 21
13 12 1
UNDERHOOD HARNESS
CAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESS
SOLENOID HARNESS
Page 50
100129a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-150/250/350 Extended Range Wiring Harnesses and Connector Layout
IN-VEHICLE LPA
FUEL TANK
6
4A
7 9
4B
8
5
1
11
27
GND
R1
GND
R2
23 9
PASS
THRU
35
1
15 30
9
GND
4 1 1
13 16 9
E-150/250/350 EXTENDED RANGE WIRING
HARNESSES AND CONNECTOR LAYOUT
APPROXIMATE LOCATION OF
LPA SYSTEM HARNESSES AND CONNECTORS
13 12 1
47 41
1B 1A 4
27 24 21
GND
UNDERHOOD HARNESS
CAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESS
SOLENOID HARNESS
IN-BED FUEL TANK JUMPER
100152a
Page 51
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Custom Body Wiring Harnesses and Connector Layout
E-450 WIRING HARNESSES AND
CONNECTOR LAYOUT
APPROXIMATE LOCATION OF
LPA SYSTEM HARNESSES AND CONNECTORS
8
5
1
11
27
GND
R1
GND
R2
23 9
PASS
THRU
35
1
15 30
47 41
1
12 13 GND
AFT-AXLE LPA
FUEL TANK
6
4A
7 9
4B
4 1 1
27 24 21
UNDERHOOD HARNESS
CAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESS
SOLENOID HARNESS
IN-BED FUEL TANK JUMPER
Page 52
100153a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout
F-250/350 PICKUP, IN-BED TANK WIRING
HARNESSES AND CONNECTOR LAYOUT
APPROXIMATE LOCATION OF
LPA SYSTEM HARNESSES AND CONNECTORS
GND
R2
1
8
4A
4B
1 13 12
*
GND
1B 1A 4
27 24 21
GND
6
15 30
9
4
11
1 4 1
16 13 9
5
1
51 55
35
PASS
THRU
9
23 9
7
+
–
GND
R1
6
BATTERY
IN-BED LPA
FUEL TANK
27 1
47 41
UNDERHOOD HARNESS
CAN HARNESS
*FTPT Harness depends
upon the Ford Fuel Tanks
REAR FRAME HARNESS
IN-TANK HARNESS
SOLENOID HARNESS
IN-BED FUEL TANK JUMPER
FTPT JUMPER HARNESS
100187a
Page 53
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical
E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness
1
A
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
UNDERHOOD HARNESS
PWR_W
PWR
10
Delphi Terminal
02984789
Connector
B
1
To Battery Positive
TO SRM
C
2
D
3
5
31
43
37
40
28
25
44
26
29
1
D
C
D
D
F
A
SUPPLY_SOL
FLOW_CNTL_ SOL
B
BLEED_SOL
E
A
F
C
S5
B
E
SUPPLY_SOL_RTN
E
FLOW_CNTL_SOL_RTN
F6
F
BLEED_SOL_RTN
E6
KEY_PWR_2
H
11
4
IPTS_PWR
PWR_W_6
F4
5A
3
IPTS_TEMP_OUT
E4
F3
G
KEY_PWR_3
20A
F5
2
IPTS_PRES_OUT
E2
E5
C
TO IPTS
46
F2
E3
S4
F
20
36
10A
F1
PWR_W_3
17
35
3
SRM_PWR
25A
E1
PWR_W_2
15
34
8
Connector
IPTS_GND
PWR_W_1
E
7
33
1
B
TO SOLENOID
MODULE
Connector
4
2
G
H
I
I
CIT RELAY
A11CSQ 20A@14VDC
J
J
A2
A5
A3
A4
A1
A1 = 85
A2 = 86
A3 = 30
A4 = 87A
A5 = 87
K
K
Connector
L
ELECTRICAL
CENTER
M
S1
SOLENOID_PWR
27
L
M
A
KEY_PWR_4
Connector
B
35
N
D
A
TO FUEL
LEVEL
INTERFACE
MODULE
O
D
O
C
C
FG_RTN
B
FG_RTN_SRM
N
P
P
FG_SND
Q
Connector
F
FRAME GROUND (GND_R2)
DELPHI TERMINAL 02984626
S3
FL_RTN_1
R
D
FL_RTN_2
15
Q
TO REAR
FRAME
HARNESS
R
E
TANK_SOL_RTN
C
FL_SND
B
VPWR_RI
S
S
A
VPWR_RO
T
T
Connector
U
B
PLUG
GND3
FPM_2
A
GND1
V
E
C
Y
PLUG
CAN-H_1(+)
CAN-H_1(-)
B
FRAME GROUND (GND_R1)
DELPHI TERMINAL 02984172
PLUG
D
C
X
U
V
F
W
LAMP_RTN_1
47
TO REAR
FRAME
HARNESS
B
A
S2
GND2
A
KEY_PWR_1
W
D
X
Connector
23
A
F
TO CAN
HARNESS
Z
100130b
1
Page 54
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Y
Z
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness
1
A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
7
CAN BUS HARNESS
30
31
32
33
34
35
36
37
38
39
1
A
B
B
Connector
5
C
C
CONNECT TO FORD HARNESS
CONNECTOR C2142
8
2
8
3
E
10
5
11
7
6
12
13
14
FUSE_33_2
9
4
E
D
1
14
D
F
C
F
E
D
C
B
A
KEY_PWR_1
10
CAN-H(-)_2
BRK_PED_POS
I
4
CAN-H(+)_2
H
3
PLUG
PLUG
9
PLUG
CAN-H(-)_1
11
GND
J
5
J
G
2
CAN-H(+)_1
I
F
8
FUSE_18
H
8
1
D
G
1
12
FUSE_33_1
6
S1
K
13
K
7
TOW_BRK
A
14
F
L
L
Connector
9
7
CONNECT TO ROUSH UNDERHOOD
HARNESS
M
CONNECT TO TRAILER
BRAKE MODULE
14
M
Connector
1
N
N
100131b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Page 55
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
REAR FRAME HARNESS
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
TO ROUSH FPCM
MODULE (FUEL
PUMP CONTROL
MODULE)_2
B
Connector
Connector
13
12
TO FORD FPCM
MODULE (FUEL
PUMP CONTROL
MODULE)_1
B
Connector
1
2
3
4
8
5
7
6
C
ENS_2
7
SHILED_3
6
GND_2
5
PLUG
8
FPC_2
4
VPWR_2
3
SHILED_4
VPWR_P2
B
PLUG
ENS_1
Connector
Connector
S4
30
PLUG
S3
VPWR_RI
2
PLUG
B
VPWR_1
S1
C
VPWR_RI
H
D
H
F
G
1
A
CONNECT
TO FORD
HARNESS
FPCM
S2
VPWR_RO
S5
G
FPC_1
3
F
4
GND_1
E
1
5
TO ROUSH UNDERHOOD
HARNESS
7
FPM_1
A
E
D
8
PLUG
FPM_2
6
D
2
ENS_3
1
TO ROUSH UNDERHOOD
HARNESS
GND_3
C
PLUG
41
FPC_3
A
2
S6
SHILED_5
E
I
D
C
B
FG_SND
PLUG
3
2
SHILED_1
A_FPPWR_1
A_FPRTN_1
K
A
B
A
Connector
21
PLUG
PLUG
4
M
J
A
B
L
SHILED_2
A_FPRTN_2
SHILED FRAME
GROUND (GND)
DELPHI TERMINAL
02984626
A_FPPWR_2
K
A_SOL_1
J
A_SOLRTN_1
A_FLS_1
A_FLSRTN_1
F
I
TO FUEL
TANK_SENDER_SOLONOID
1
Connector
Connector
27
24
L
M
TO
FUEL_TANK_1_PWR
TO
FUEL_TANK_2_PWR
Connector
N
N
9
O
O
CONNECT TO
FORD HARNESS
FUEL PUMP
MODULE
P
100132b
1
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
P
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness
E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness
1
A
2
WIRE NO.
5
6
7
8
9
10
11
12
B
C
D
3
4
5
6
DESCRIPTION
PINK/BLACK 12 AWG
BROWN/WHITE 12 AWG
DARK BLUE 12 AWG
BLACK 12 AWG
PINK/BLACK 12 AWG
BROWN/WHITE 12 AWG
DARK BLUE 12 AWG
BLACK 12 AWG
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
IN-TANK HARNESS
CIRCUIT
INLINE FUEL PUMP-1 (V+)
INLINE FUEL PUMP-1 (V-)
INLINE FUEL PUMP-2 (V+)
INLINE FUEL PUMP-2 (V-)
FUEL PUMP-1 (V+)
FUEL PUMP-1 (V-)
FUEL PUMP-2 (V+)
FUEL PUMP-2 (V-)
A
B
C
IN-TANK
HARNESS
PASS THRU
E
D
E
200MM
100MM
NO TAPE OR ADHESIVE
TAGS ON THIS SIDE OF THE
PASS THROUGH GROMMET
F
DO NOT COVER THIS LENGTH WITH ANY CONVOLUTE
F
G
G
1
H
H
I
5
A
B
J
K
9
6
A
10
I
PUMP-1
J
4A
B
K
100MM
DO NOT COVER
THIS LENGTH WITH
ANY CONVOLUTE
L
M
L
7
A
B
11
8
12
N
4B
A
B
N
THIS AREA TO BE FREE
OF TAPE.
2
DO NOT APPLY TAPE
ONTO THIS SEALING
SURFACE
O
1
2
3
4
M
PUMP-2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
100133b
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
O
39
Page 57
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series Extended Range and E-450 Electrical Schematic —
E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness Solenoid
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
A
WIRE NO.
4
5
6
7
B
C
D
E
DESCRIPTION
RED 16 AWG
BLACK 16 AWG
BLACK/ORANGE 18 AWG
YELLOW/WHITE 18 AWG
SOLENOID HARNESS
CIRCUIT
SUPPLY SOLENOID V+
SUPPLY SOLENOID VFUEL LEVEL SENDER VFUEL LEVEL SENDER V+
B
C
9
D
E
CONNECT TO THE
REAR HARNESS
F
G
F
1
CONNECT TO
TANK SOLENOID
100 mm
G
H
H
I
I
A B
J
K
A
4
B
5
J
K
L
L
M
M
6
C
N
B
N
O
O
D
7
A
P
P
Q
Q
R
R
CONNECT TO FUEL
LEVEL SENDER
S
S
T
T
U
U
6
V
V
W
100134b
1
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3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
W
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
Harness
F-250/350 Pickup, Underhood Harness Electrical Schematic
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
PWR_W
A
Connector
1
B
TO SRM
C
2
D
7
33
17
15
34
35
20
36
40
43
37
28
25
44
26
29
D
C
C
H
B
E
A
E
F
A
B
F
SUPPLY_SOL
D
FLOW_CNTL_ SOL
E
SUPPLY_SOL_RTN
G
F
BLEED_SOL
KEY_PWR_2
F6
C
FLOW_CNTL_SOL_RTN
E6
5A
F5
IPTS_PRES_OUT
E5
PWR_W_6
S4
F4
TO IPTS
4
D
F2
F3
3
46
20A
E4
2
11
TO FRPCM
SRM_PWR_1
10A
E3
8
3
1
IPTS_GND
F1
PWR_W_3
F
E2
E1
PWR_W_2
E
SRM_PWR
25A
5
31
S5
PWR_W_1
3
1
B
Connector
Connector
4
2
BLEED_SOL_RTN
PWR
Delphi Terminal
02984789
To Battery Positive
IPTS_PWR
A
2
IPTS_TEMP_OUT
1
G
H
I
I
CIT RELAY
A11CSQ 20A@14VDC
A2
J
A3
A4
A5
J
A1
A1 = 85
A2 = 86
A3 = 30
A4 = 87A
A5 = 87
K
K
Connector
8
16
R
N
9
1
35
TO FLIM
3
10
2
FG_RTN
O
11
4
12
P
13
5
FRAME GROUND (GND_R2)
DELPHI TERMINAL 02984626
14
Connector
F
6
FG_SND
FL_RTN_2
S3
FL_RTN_1
FL_SND
Q
TO REAR
FRAME
HARNESS
R
S
B
VPWR_RI
S
15
E
7
TANK_SOL_RTN
15
15
7
Q
FG_RTN_SRM
8
10
3
11
4
12
14
6
13
5
P
J1A
Connector
D
O
J1
J9
J2
J10
J3
J11
J4
J12
J5
J13
J6
J14
J7
J15
J8
J16
M
SRM_PWR_2
TO FORD HARNESS
12C508 (C1168)
S8
C
2
9
N
55
B
1
TO FORD AUX ENGINE
INLINE MODULE
L
A
ELECTRICAL
CENTER
(FUSE BOX)
M
S1
SOLENOID_PWR
Connector
D
51
C
Connector
16
27
KEY_PWR_1
L
A
VPWR_RO
T
T
Connector
U
GND3
A
FPM_2
GND1
V
PLUG
CAN-H_1(+)
Y
TO REAR
FRAME
HARNESS
V
W
F
E
FRAME GROUND (GND_R1)
DELPHI TERMINAL 02984172
PLUG
D
X
LAMP_RTN_1
U
X
Connector
23
C
W
47
B
PLUG
S2
GND2
TO CAN
HARNESS
B
CAN-H_1(-)
Z
100188a
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Y
Z
39
Page 59
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
A
B
B
Connector
5
C
C
CONNECT TO FORD HARNESS
CONNECTOR C2142
3
2
8
9
4
10
5
11
7
6
12
13
14
E
D
1
D
E
COVERED WITH 3/8" SPLIT CONVOLUTE
F
F
F
PLUG
E
H
PLUG
D
C
B
I
11
GND
J
5
FUSE_33
PLUG
12
A
10
CAN-H(-)_2
BRK_PED_POS
4
J
PLUG
CAN-H(+)_2
H
3
CAN-H(-)_1
I
G
2
CAN-H(+)_1
9
FUSE_18
PASS-THROUGH
8
1
G
6
K
13
GROMMET
K
7
NO CONVOLUTE,
TAPE ONLY THIS
AREA
14
TOW_BRK
Connector
L
L
9
CONNECT TO TRAILER
BRAKE MODULE
CONNECT TO ROUSH UNDERHOOD
HARNESS
M
M
Connector
1
N
N
100189a
1
Page 60
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, Rear Frame Harness Electrical Schematic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
A
TO ROUSH FPCM
(FUEL PUMP
CONTROL MODULE)_2
Connector
30
Connector
13
12
1
4
8
5
6
7
1
2
3
8
4
5
B
7
6
C
ENS_2
SHILED_3
GND_2
PLUG
FPC_2
VPWR_2
PLUG
SHILED_4
C
ENS_3
B
PLUG
VPWR_RI
D
3
TO ROUSH FPCM
(FUEL PUMP
CONTROL MODULE)_1
VPWR_RO
VPWR_P2
A
C
2
GND_3
B
Connector
FPC_3
TO UNDERHOOD
HARNESS
D
E
7
6
ENS_1
F
E
D
8
PLUG
FPM_1
4
GND_1
S3
FPC_1
CONNECT
TO FORD
HARNESS
FPCM
3
S5
S2
2
PLUG
VPWR_RI
VPWR_1
1
G
E
1
5
PLUG
F
r
Connector
S4
F
G
S1
Connector
41
H
H
A
SHILED_5
S6
K
D
C
B
3
2
B
SHILED_1
A
L
21
TO FUEL
TANK_SENDER_SOLONOID
1
Connector
Connector
27
24
M
TO
FUEL_TANK_1_PWR
TO
FUEL_TANK_2_PWR
N
A_FPPWR_1
A_FPRTN_1
SHILED_2
K
A
Connector
FG_RTN
PLUG
4
FG_SND
PLUG
M
J
A
B
L
A_FPPWR_2
SHILED FRAME
GROUND (GND3)
DELPHI TERMINAL
02984626
A_FPRTN_2
A_SOL_1
A_SOLRTN_1
A_FLS_1
J
I
PLUG
TO UNDERHOOD
HARNESS
A_FLSRTN_1
B
I
N
Connector
9
O
O
CONNECT TO
FORD HARNESS
FUEL PUMP
MODULE
P
100190a
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
P
39
Page 61
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, Tank Solenoid Harness Electrical Schematic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
A
A
WIRE NO.
4
5
6
7
B
C
D
DESCRIPTION
RED 16 AWG
BLACK 16 AWG
BLACK/ORANGE 18 AWG
YELLOW/WHITE 18 AWG
CIRCUIT
SUPPLY SOLENOID V+
SUPPLY SOLENOID VFUEL LEVEL SENDER VFUEL LEVEL SENDER V+
B
C
D
9
E
E
F
F
CONNECT TO
REAR FRAME HARNESS
G
H
1
G
CONNECT TO
TANK (FUEL SUPPLY)
SOLENOID
100 mm
H
I
I
J
J
A B
K
L
M
A
4
B
5
K
L
M
N
N
6
D
7
O
P
A
P
C
B
O
Q
Q
R
R
12162000
S
CONNECT TO FUEL
LEVEL SENDER
FUEL LEVEL SENDER
CONNECTOR FROM TANK
S
T
T
U
U
6
V
V
W
100191a
1
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3
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5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
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22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
W
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
CONNECT TO TANK
SOLENOID HARNESS
A
A
B
B
Connector
16
CONNECT TO REAR
FRAME HARNESS
C
PUMP_1
C
A
Connector
D
D
B
1A
FUEL_PUMP_1_PWR
A
E
B
F
F
A
FUEL_PUMP_2_PWR
FUEL_PUMP_2_RTN
SHIELD_1
Connector
H
1B
G
S1
B
SHIELD_3
SHIELD_2
A
B
G
E
FUEL_PUMP_1_RTN
H
Connector
CONNECT TO REAR
FRAME HARNESS
I
13
SHILED FRAME GROUND (GND)
DELPHI TERMINAL 02984626
J
I
PUMP_2
J
CONNECT TO TANK
SOLENOID HARNESS
C
FUEL_LEVEL _SENDER RETURN
A
TANK (FUEL SUPPLY) SOLENOID_POWER
L
B
N
TANK (FUEL SUPPLY) SOLENOID _RETURN
A
M
B
L
K
C
FUEL_LEVEL _SENDER POWER
D
D
K
M
Connector
Connector
4
9
N
O
O
CONNECT TO TANK
SOLENOID HARNESS
CONNECT TO REAR
FRAME HARNESS
P
1
2
3
4
5
6
7
100192a
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
P
39
Page 63
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, FTPT Jumper Harness Electrical Schematic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
3
FTP_REF
2
C
SIGRTN
FTP
FTP
1
D
SIGRTN
3
FTP_REF
B
B
2
A
C
1
A
D
E
r
Connector
F
Connector
F
1
4
VERSION DEPENDS ON
TANK CONFIGURATION
G
G
CONNECT TO FTPT
CONNECT TO FORD HARNESS (14405)
E
H
H
I
I
FTP_REF
A
L
SIG_RTN
SIG_RTN
FTP
FTP
3
B
K
J
2
J
K
1
C
FTP_REF
L
M
M
Connector
1
N
N
Connector
6
O
CONNECT TO FTPT
O
CONNECT TO FORD HARNESS (14405)
P
100193a
1
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3
4
5
6
7
8
9
10
11
12
13
14
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16
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©2013 by ROUSH CleanTech.
All rights reserved.
The information in this publication was accurate and effective at the time the publication was
approved for publishing and is subject to change without notice or liability. ROUSH CleanTech
reserves the right to revise the information herein and to make changes and discontinue production of described parts at any time.
LocTite567® and LocTite242® are registered trademarks of Henkel.