Download E-Series, Extended Range and E

2011-2014
Ford E-Series and F-Series
Products
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/F-450/F-550/F-650
F-53/F-59
Revision History
-AA
Intital Release
2/2013
-AB
Revised
5/2013
-AC
Revised
7/2013
-AD
Revised
11/2013
-AE
Revised
3/2014
DIAGNOSTIC MANUAL
P-01B101-AE
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
Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Flow Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Bleed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Tank Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel Rail Pressure Control Module Supply Solenoid and Wiring . . . . . . . . . . . . . . . . . . . . . .12
SRM, CAN Bus Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electronic Fuel Pump Relay (A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Integrated Pressure Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
DIAGNOSTIC TESTS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
No Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Slow Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Over Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Engine Cranks, No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Engine Stumble, Stall, Rough Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Excess Flow Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Maximum Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Supply Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fuel System Fails to Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Fuel Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fuel Level Indication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Tank Solenoid Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Fuel Rail Pressure Control Module Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Integrated Pressure Temperature Sensor Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fuel Pump Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Fuel Pump Control Module Electrical Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Smart Relay Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fuel Level Sender Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fuel Level Interface Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
E-150/250/350 Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
E-150/250/350 Extended Range Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .53
E-450 Custom Body Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . .54
F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .55
Page iii
TABLE OF CONTENTS
F-650 Chassis Cab Wiring Harness and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . .56
F-450/550 Roush Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
F-650 Chassis Cab, Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
F-53/59 Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness . . . . . . . .60
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness . . . . . . . . .61
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . .62
E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness . . . . . . . . . .63
E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness . . . . . . . . . .64
E-450 Stripped Chassis CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . .66
F-250/350 Pickup, F-450/550 and F-650, Tank Solenoid Harness Electrical Schematic . . . .67
F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . .68
F-250/350 Pickup, FTPT Jumper Harness Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . .69
F-650 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
F-650 Fuel Tank Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
F-650 Underhood Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
F-53/59 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
F-53/59/250/350/450 Rear Frame Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .74
F-53/59/250/350/450 Underhood Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . .75
F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . .76
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
SS
Supply Solenoid
TS
Tank Solenoid
Page 5
TROUBLESHOOTING
Acronym or Abbreviation
Description
VMV
Vapor Management Valve
VPWR
Voltage Power
VREF
Voltage Reference
WOT
Wide Open Throttle
Diagnostic Trouble Code List
Code
Description
P0005
Fuel Shutoff Valve A Control Circuit Open
P0090
Fuel Pressure Regulator Circuit Open
P009B
Fuel Pressure Relief Control Circuit Open
P009E
Fuel Pressure Relief Control Performance Stuck Off
P009F
Fuel Pressure Relief Control Stuck On
P0148
Fuel Delivery Error
P0171
System Too Lean (Bank 1 and Bank 2)
P0174
System Too Lean (Bank 1 and Bank 2)
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
P025A
Fuel Pump Control Module Circuit Range/Performance A
P027A
Fuel Pump Control Module Circuit Range/Performance B
P03xx
Misfire
P0460
Fuel Level Sender A Circuit
P0461
Fuel Level Sender A Circuit Range/Performance
P0462
Fuel Level Sender A Circuit Low
P0463
Fuel Level Sender A Circuit High
P0627
Fuel Pump A Control Circuit Open
P116E
Exceeded Maximum Pressure
P2067
Fuel Level Sensor B Circuit Low
P2068
Fuel Level Sensor B Circuit High
P2195
Heated Exhaust Gas Oxygen Sensor Stuck
P2197
Heated Exhaust Gas Oxygen Sensor Stuck
P25B1
Fuel Level Sensor B Stuck
P2632
Fuel Pump B Control Circuit Open
P2665
Supply Solenoid Circuit Fault
P26B5
Fuel Shutoff Valve B Function Check
U0108
Lost Communication with Alternative Fuel Control Module
U0109
Lost Communication with Fuel Pump Control Module A
U016C
Lost Communication with Fuel Pump Control Module B
U0309
Alt Fuel Module-Wrong SRM
Page 6
TROUBLESHOOTING
Calibration Release OBD Summary Chart
OEM MY
HDE MY
Cert
OBD Class
Detail Chart
2011
N/A
Fed Only
PBGD-Ax & Bx
OBD II
E-Series
5.4L Group
2012
N/A
50S
PBGD-Cx & Dx
OBD II
E-Series
5.4L Group
2013
N/A
Fed
PBGD-Ax & Bx
OBD II
E-Series
5.4L Group
FED OBD
Identifier
2013
N/A
50S
PBGD-Cx & Dx
OBD II
E-Series
5.4L Group
Fuel Pump Codes
Added
2012
N/A
50S Only
PCDH-Ax & Bx
OBD II
F-Series
6.2L Group
2013
N/A
Fed
PCDH-Cx & Dx
OBD II
F-Series
6.2L Group
Fuel Pump Codes
Added
2013
N/A
50S
PCDH-Ax & Bx
OBD II
F-Series
6.2L Group
Fuel Pump Codes
Added
2011
2011
Fed
PBJC-Bx & Dx
Non-OBD
(EMD)
E-Series
6.8L HDE
OBD I / EMD Level
2012
2012
50S
PBJC-Ax & Cx
Non-OBD
(EMD)
E-Series
6.8L HDE
OBD I / EMD Level
2013
2013
50S
PDJC-Ax & Bx
EMD+
E-Series
6.8L HDE
Cat Monitor Added
2012
2011
Fed
PCEB-Ax
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2012
2012
Fed
PCEB-Ax
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2013
2012
Fed
PCEB-Ax
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2013
2013
50S
PDEB-Ax
EMD+
F-Series
6.8L HDE
Cat Monitor Added
2013
2012
Fed
PCEB-Sx
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2013
2013
50S
PDEB-Sx
EMD+
F-Series
6.8L HDE
Cat Monitor Added
2013
2012
Fed
PCEB-Mx
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2013
2013
50S
PDEB-Mx
EMD+
F-Series
6.8L HDE
Cat Monitor Added
2012
2012
Fed
PCFB-Ax
Non-OBD
(EMD)
F-Series
6.8L HDE
OBD I / EMD Level
2013
2013
50S
PDFB-Ax
EMD+
F-Series
6.8L HDE
Cat Monitor Added
Vehicle
E-Series
F-250/F-350
E-450
F-450/F-550
F-59
(Step Van)
F-53
(Motorhome)
F-650
Calibration
Comments
(03P150)
FED OBD
Identifier
Note: HDE MY - Heavy Duty Engine Model Year (Some HD products have different engine certifications within the vehicle
model year.)
Page 7
TROUBLESHOOTING
Calibration Release OBD Summary Chart
E-Series 5.4L Group
E-150/E-250/E-350
F-Series 6.2L Group
F-250/F-350
2012
50S
2013
Fed
2013
50S
2012
50S
2013
Fed
2013
50S
Fuel Shutoff Valve A Control Circuit Open
1
1
1
1
1
1
P0090
Fuel Pressure Regulator Circuit Open
1
1
1
1
1
1
P009B
Fuel Pressure Relief Control Circuit Open
2
2
2
2
2
2
P009E
Fuel Pressure Relief Control Performance Stuck Off
2
2
2
2
2
2
P009F
Fuel Pressure Relief Control Stuck On
2
2
2
2
2
2
P0148
Fuel Delivery Error
1
1
1
1
1
1
P0171
System Too Lean (Bank 1 and Bank 2)
2
2
2
2
2
2
P0174
System Too Lean (Bank 1 and Bank 2)
2
2
2
2
2
2
P0182
Fuel Temperature Sensor (A) Circuit Low
2
2
2
2
2
2
P0183
Fuel Temperature Sensor (A) Circuit High
2
2
2
2
2
2
P0190
Fuel Pressure Sensor A Circuit
2
2
2
2
2
2
P0192
Fuel Pressure Sensor A Circuit Low
2
2
2
2
2
2
P0193
Fuel Pressure Sensor A Circuit High
2
2
2
2
2
2
P025A
Fuel Pump Control Module Circuit Range/Performance A
1
1
2
1
2
2
P025B
Electronic Fuel Pump Relay Invalid Control Data
1
1
2
1
2
2
P027A
Fuel Pump Control Module Circuit Range/Performance B
1
1
2
1
2
2
P027B
Electronic Fuel Pump Relay Invalid Control Data
1
1
2
1
2
2
P03xx
Misfire
2
2
2
2
2
2
P0460
Fuel Level Sender A Circuit
2
2
2
2
2
2
P0461
Fuel Level Sender A Circuit Range/Performance
2
2
2
2
2
2
P0462
Fuel Level Sender A Circuit Low
2
2
2
2
2
2
P0463
Fuel Level Sender A Circuit High
2
2
2
2
2
2
P0627
Fuel Pump A Control Circuit Open
1
1
2
1
2
2
P116E
Exceeded Maximum Pressure
1
1
1
1
1
1
P2195
Heated Exhaust Gas Oxygen Sensor Stuck
2
2
2
2
2
2
P2197
Heated Exhaust Gas Oxygen Sensor Stuck
2
2
2
2
2
2
P2632
Fuel Pump B Control Circuit Open
1
1
2
1
2
2
P2665
Supply Solenoid Circuit Fault
1
1
1
1
1
1
P26B5
Fuel Shutoff Valve B Function Check
1
1
1
1
1
1
U0108
Lost Communication with Alternative Fuel Control Module
2
2
2
2
2
2
U016C
Lost Communication with Fuel Pump Control Module B
1
1
2
1
2
2
U0309
Alt Fuel Module-Wrong SRM
2
2
2
2
2
2
Code
Descriptions
P0005
0
Code not present
1
DTC – non MIL
2
DTC – MIL (two trips)
Page 8
TROUBLESHOOTING
Calibration Release OBD Summary Chart
E-Series 6.8L HDE Group
E-450
Code
Descriptions
P0005
F-Series 6.8L HDE Group
F-450/550/650/53/59
2012 50S
2013+ 50S
2012 50S
2013+ 50S
Fuel Shutoff Valve A Control Circuit Open
1
1
1
1
P0090
Fuel Pressure Regulator Circuit Open
1
1
1
1
P009B
Fuel Pressure Relief Control Circuit Open
1
2
2
2
P009E
Fuel Pressure Relief Control Performance Stuck Off
1
2
2
2
P009F
Fuel Pressure Relief Control Stuck On
0
0
0
0
P0148
Fuel Delivery Error
1
1
1
1
P0171
System Too Lean (Bank 1 and Bank 2)
2
2
2
2
P0174
System Too Lean (Bank 1 and Bank 2)
2
2
2
2
P0182
Fuel Temperature Sensor (A) Circuit Low
1
2
2
2
P0183
Fuel Temperature Sensor (A) Circuit High
1
2
2
2
P0190
Fuel Pressure Sensor A Circuit
1
2
2
2
P0192
Fuel Pressure Sensor A Circuit Low
1
2
2
2
P0193
Fuel Pressure Sensor A Circuit High
1
2
2
2
P025A
Fuel Pump Control Module Circuit Range/Performance A
1
1
1
1
P025B
Electronic Fuel Pump Relay Invalid Control Data
1
1
1
1
P027A
Fuel Pump Control Module Circuit Range/Performance B
1
1
1
1
P027B
Electronic Fuel Pump Relay Invalid Control Data
1
1
1
1
P03xx
Misfire
1
1
1
1
P0460
Fuel Level Sender A Circuit
1
1
1
1
P0461
Fuel Level Sender A Circuit Range/Performance
0
0
0
0
P0462
Fuel Level Sender A Circuit Low
1
1
1
1
P0463
Fuel Level Sender A Circuit High
1
1
1
1
P0627
Fuel Pump A Control Circuit Open
1
1
1
1
P116E
Exceeded Maximum Pressure
1
1
1
1
P2195
Heated Exhaust Gas Oxygen Sensor Stuck
2
2
2
2
P2197
Heated Exhaust Gas Oxygen Sensor Stuck
2
2
2
2
P2632
Fuel Pump B Control Circuit Open
1
1
1
1
P2665
Supply Solenoid Circuit Fault
1
1
1
1
P26B5
Fuel Shutoff Valve B Function Check
1
1
1
1
U0108
Lost Communication with Alternative Fuel Control Module
2
2
2
2
U016C
Lost Communication with Fuel Pump Control Module B
1
1
1
1
U0309
Alt Fuel Module-Wrong SRM
2
2
2
2
0
Code not present
1
DTC – non MIL
2
DTC – MIL (two trips)
Page 9
TROUBLESHOOTING
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.
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.
Page 10
TROUBLESHOOTING
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 11
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 12
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.
U0309 — Alternate Fuel Module-Wrong SRM
Description
Alternate Fuel Module (SRM) is not broadcasting over vehicle communication link the expected
SRM module identifier. A U0309 code should only be expected during initial build or during
service replacement of the SRM module.
Possible Causes
앫 Incorrect SRM was installed into the vehicle for initial build or during service of the SRM
앫 Loss of CAN communications between the SRM and PCM
Symptom
앫 MIL light
앫 Fuel gage may not read full or empty correctly
Diagnostic Aid
앫 Verify to latest calibration
앫 Verify SRM part number is correct for vehicle type and tank
앫 Verify that no other DTCs are set related to CAN communications
앫 Inspect CAN harness for connection issues and integrity
Action
Replace SRM to correct type or fix any CAN communication DTCs or wiring/connection concerns.
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.
Page 13
TROUBLESHOOTING
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
앫 Vehicle operated in a low voltage condition
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.
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 14
TROUBLESHOOTING
Electronic Fuel Pump Relay (A/B)
U0109, U016C — Lost Communication with Fuel Pump Control Module A/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.
P025A, 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
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 15
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 16
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 17
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 (P2067) — Fuel Level Sender A (B) Circuit Low
Description
This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable
sender value.
Possible Causes
앫 Fuel level sender wiring shorted to ground
앫 Damaged Fuel Level Sender
앫 Smart Relay Module
Symptom
P0462 — Fuel gauge may read empty all the time
P2067 — Fuel gauge will only show primary tank
Diagnostic Aid
Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument
Cluster.
Action
Refer to the following tests located later in this manual.
앫 SRM Electrical Test
앫 Fuel Level Sender Test
앫 Fuel Level Interface Module
Page 18
TROUBLESHOOTING
P0463 (P2068) — Fuel Level Sender A (B) Circuit High
Description
This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable
sender value.
Possible Causes
앫 Fuel level sender wiring is disconnected or shorted to above 5 volts
앫 Damaged Fuel Level Sender
앫 Smart Relay Module
Symptom
P0463 — Fuel gauge may read full all the time
P2068 — Fuel gauge will only show primary tank
Diagnostic Aid
Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument
Cluster.
Action
Refer to the following tests located later in this manual.
앫 SRM Electrical Test
앫 Fuel Level Sender Test
앫 Fuel Level Interface Module
P25B1 — Fuel Level Sensor B Stuck
Description
Failed transfer of fuel from secondary tank B to primary tank A. Failure code sets if a transfer is not
detected by sender movement in 3 transfer attempts.
Possible Causes
Secondary tank transfer failure causes:
앫 Tank supply solenoid did not open
앫 Manual valve closed
앫 Excess flow valve trips on transfer attempts
앫 Blown fuse
앫 Electrical fault or relay failure that supplies the tank solenoid or pumps
앫 SRM hardware failure
앫 Sender arm stuck
앫 Sender signal out of range
앫 Fuel transfer line between secondary and primary tank kinked or plugged
앫 High differential of pressure when the primary tank greater than ~60 psi over secondary tank
(typically caused by higher temperatures in the primary tank)
Primary tank transfer failure causes:
앫 Faulty transfer OPD connected to transfer line
Symptom
앫 Fuel indication is only based on primary tank sender
앫 Customer does not achieve expected driving range
앫 Short fuel fills (only adds fuel to primary tank)
앫 Cluster fuel gauge may indicate inconsistent behavior
Diagnostic Aid
Check all electrical connectors and voltage supply to the secondary tank valve and fuel pumps.
Verify that the secondary tank sender voltages (or resistances) are in the expected range. Verify
that no other primary or secondary tank out-of-range codes are set (P0462, P0463, P2067,
P2068).
Action
Refer to the Secondary Tank – Fuel Will Not Transfer Troubleshooting.
Page 19
TROUBLESHOOTING
Secondary Tank – Fuel Will Not Transfer
F-650 vehicles can be equipped with a unique
ROUSH CleanTech liquid propane autogas
storage system which includes two fuel tanks.
The system operates as if it were just one large
tank. A few key points about the system:
•
The engine is always running from the
driver's side tank. All fuel to the engine, and
the excess fuel returning to the tank, is only
connected to this tank.
•
The passenger's side tank is used to store
extra fuel only. When the driver's side tank
fuel level drops, the system will activate fuel
pumps in passenger's side tank to transfer
fuel automatically.
•
Both tanks are filled at the same time from
the single fuel filler located on the driver's
side. There is a ball valve on the fill line for
the right-hand tank, which is used for
periodic inspections only. It should always be
open during normal operation in order to use
the full system capacity.
The ROUSH CleanTech control system reads the
usable fuel level in each tank and adds them
together to provide a single reading for the
instrument cluster. However, if the system
detects a failure in the fuel transfer system which
may interfere with the ability to transfer fuel, it will
provide a reading based on the driver's side tank
only. This ensures that the driver is warned before
the vehicle runs out of fuel. If this occurs, the
vehicle is fully usable, but should be serviced in
order to restore full function and use of the full
system fuel capacity.
The fuel transfer line from the passenger's side
tank is connected to a dedicated overfill
prevention device (OPD) on the driver's side tank.
This is a safety device which ensures that even if
there is a fault in the control system, it is not
possible for the driver's side tank to overfill during
transfers.
Page 20
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
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.
Page 21
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. Yes — Vehicle not on level ground.
Diagnostic is complete.
Does the vehicle fuel tank fill?
No — Drive vehicle until fuel gauge
indicates less than 1/2 full and go to Step
8.
Page 22
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 Indication 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
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.
Page 23
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.
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.
b.
c.
Page 24
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.
a.
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.
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
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.
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.
Page 25
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
Page 26
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.
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
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.
Page 27
TROUBLESHOOTING
Engine Cranks, No Start
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and 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 Code
List.
No — Refer to Ford service manual DTC
chart.
4
Check fuel pressure.
Yes — Go to Step 11.
No — Go to Step 5.
a.
5
b.
Measure and record fuel rail and fuel tank pressure, Key ON
Engine OFF (KOEO).
While monitoring fuel pressure, attempt to start engine.
c.
Record the highest pressure observed.
d.
Does fuel pressure rise 25 psi (172 kPa) before engine crank?
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.
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.
Page 28
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?
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
Yes — Refer to the Integrated Pressure
Does temperature and pressure make sense to verification procedure? 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.
a.
13
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 13.
Yes — Replace fuel pump assembly.
No — Replace hose assemblies as
needed.
Page 29
TROUBLESHOOTING
Engine Stumble, Stall, Rough Idle
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and 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 Code List.
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 Engine OFF (KOEO).
Measure fuel rail pressure with Key ON 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.
Page 30
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.
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
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.
Page 31
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 Wiring
Diagrams and 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 Code
List.
No — Refer to the Ford service manual
DTC chart.
4
Check fuel pressure.
Yes — Go to Step 11.
No — Go to Step 5.
a.
Page 32
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?
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 33
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 Key ON 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
Page 34
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.
TROUBLESHOOTING
Fuel Pressure Drop
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and 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 35
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 36
TROUBLESHOOTING
Tank Solenoid Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
PBT/ASA-GF20
1
2
32
44
18
29
3
15
6
4
1
5
3
2 4
3
5
1
2 4
3
31
5
30
E
D
B
44
1
2
3
3
E
1
5
A
2 4
1
FUSE BOX
5
2 4
1
F
1
15
45
46
A1
16
17
F
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 37
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 ground circuit continuity from solenoid harness to smart
relay module (SRM) connector.
a.
b.
Page 38
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 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.
TROUBLESHOOTING
Fuel Rail Pressure Control Module
Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
4
30
31
PBT/ASA-GF20
1
2
32
44
29
3
15
5
3
5
2 4
1
46
18
6
4
3
3
5
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
45
11
46
A1
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
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.
Page 39
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 solenoid ground circuit continuity.
a.
b.
Page 40
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 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.
TROUBLESHOOTING
Integrated Pressure Temperature
Sensor Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and 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.
3
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?
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?
Yes — Refer to the Smart
Relay Module Electrical
Test procedure.
No — Repair circuit wiring.
Page 41
TROUBLESHOOTING
Fuel Pump Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and 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 42
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 43
TROUBLESHOOTING
Fuel Pump Control Module
Electrical Continuity Test
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
7
E4
F
A5
3
F
C
2 4
5
1
5
6
4
3
3
5
1
2 4
B
A
2 4
2
3
3
E
1
5
5
1
15
1
2 4
D
FUSE BOX
Figure 8 — Underhood Harness Connectors
8
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 44
D
C
B
A
100077a
A3
1
E
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 45
TROUBLESHOOTING
Smart Relay Module Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
9
E1-E2
31
4
5
3
2
E
1
6
1
3
5
2 4
1
F
FUSE BOX
1
3
PBT/ASA-GF20
5
2 4
3
5
1
31
1
2
32
44
18
29
3
15
45
46
A1
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 46
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 47
TROUBLESHOOTING
Fuel Level Sender Electrical Check
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
11
1
15
30
31
PBT/ASA-GF20
1
2
32
44
18
29
3
15
45
46
A1
16
17
3
F
E
Figure 12 — Underhood Harness Connectors
12
21
30
A
B
C
A
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 48
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 49
TROUBLESHOOTING
Fuel Level Interface Module
Electrical Test
For harness and connector layout diagrams and
system electrical schematics, refer to Wiring
Diagrams and Electrical Schematics.
CONNECTORS
14
15
1
35
37
30
31
PBT/ASA-GF20
1
2
32
44
18
29
3
15
2
45
30
A
B
C
D
E
F
46
A1
16
9
17
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-26,
connector 1.
c.
Is there good continuity in the circuit?
Check FLIM circuit wiring for continuity to SRM.
a.
b.
3
Check FLIM circuit wiring for continuity to SRM.
a.
b.
4
5
Page 50
Check underhood harness continuity between pin-B, connector 35 and pin-37,
connector 1.
Is there good continuity in the circuit?
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.
Disconnect underhood harness connector 15 to rear frame harness.
Check underhood harness continuity between pin-D, connector 35 and pin-F,
connector 15.
c.
Is there good continuity in the circuit?
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?
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.
Yes — Refer to the Smart
Relay Module Electrical
Test procedure.
No — Repair circuit wiring.
WIRING DIAGRAMS AND SCHEMATICS
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
Page 51
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
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 52
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
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 53
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Custom Body 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 54
100153a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
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 55
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Chassis Cab Wiring Harness and Connector Layout
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
FB
C4
C3
C3
C1 C2
BATTERY
G1
C19
C7
C6
C8
C9
C13 C13
UNDERHOOD HARNESS
IN-TANK HARNESS
TANK SOLENOID HARNESS
FUEL TANK JUMPER HARNESS
CAN HARNESS
IN-TANK HARNESS (LH AND RH)
1
FUEL PUMP #1 INLINE 2-PIN
4
FUEL PUMP #2 INLINE 2-PIN
7
GROMMET
UNDERHOOD HARNESS
C3
UNDERHOOD/CAN INLINE
CONNECTOR 2-PIN
C4
SRM 46-PIN
7
T2
–
T3
C11 1
C13 C13 C12 4
C19
T4
C11 1
C12 4
T1
C15 C14
C10 C16 C15 C14
C5
Page 56
+
C18
C18
7
UNDERHOOD HARNESS (CONT.)
C5
IPTS 4-PIN
C6
FRPCM 6-PIN
C7
FLIM 4-PIN
C8
FORD EFPR 8-PIN
C9
RCT EFPR 8-PIN
C10 TO FORD INLINE CONNECTOR 8-PIN
C11 UNDERHOOD/IN-TANK FP#1 INLINE
(LEFT TANK) 2-PIN
C12 UNDERHOOD/IN-TANK FP#2 INLINE
(LEFT TANK) 2-PIN
C13 TANK SOLENOID INLINE CONNECTOR
(LEFT TANK) 4-PIN
C14 UNDERHOOD/FUEL TANK JUMPER
INLINE CONNECTOR 2, 4-PIN
UNDERHOOD HARNESS (CONT.)
C15 UNDERHOOD/FUEL TANK JUMPER
INLINE CONNECTOR 1, 4-PIN
C16 UNDERHOOD/FUEL PUMP AND
SENDER INLINE CONNECTOR 4-PIN
FB
AUX FUSE BOX
T1
PWR #1 RING TERMINAL
T2
PWR #2 RING TERMINAL
T3
GROUND RING TERMINAL
T4
TERMINAL INSERTED IN SPLICE PACK
TANK SOLENOID HARNESS (LH AND RH)
C13 UNDERHOOD/TANK SOLENOID INLINE
CONNECTOR 4-PIN
C18 SUPPLY VALVE SOLENOID 2-PIN
C19 FUEL SENDER 2-PIN
FUEL TANK JUMPER HARNESS
C11 FUEL TANK JUMPER/IN-TANK INLINE 1
(RIGHT TANK) 2-PIN
C12 FUEL TANK JUMPER/IN-TANK INLINE 2
(RIGHT TANK) 2-PIN
C13 FUEL TANK JUMPER/TANK SOLENOID INLINE
(RIGHT TANK) 4-PIN
C14 FUEL TANK JUMPER/UNDERHOOD INLINE 2, 4-PIN
C15 FUEL TANK JUMPER/UNDERHOOD INLINE 1, 4-PIN
CAN HARNESS
C1
BODY MODULE 12-PIN
C2
TO FORD HARNESS CONNECTOR 12-PIN
C3
CAN/UNDERHOOD IN-LINE CONNECTOR 2-PIN
G1
GROMMET
100254a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-450/550 Roush Wiring Harnesses (Note: This wiring harness print does not include the attachment locations for the ROUSH CleanTech tank jumper harness to the rear chassis harness.)
TO ROUSH FPCM MODULE
FUEL PUMP CONTROL
MODULE 2
SRM
TO IPTS
TO FORD FPCM MODULE
FUEL PUMP CONTROL
MODULE 1
TO
SOLENOID
MODULE
BATTERY
POSITIVE
UNDERHOOD
HARNESS
TO FLM
REAR CHASSIS
HARNESS
FUSE BOX
TO FORD FUEL PUMP
HARNESS CONNECTOR
TO REAR
FRAME
HARNESS
MODULE
GROUND
TO ROUSH
UNDERHOOD
HARNESS
FRAME
GROUND
TO FUEL
TANK 1 PWR
SYSTEM
GROUND
TO REAR
FRAME
HARNESS
TO ROUSH
UNDERHOOD
HARNESS
TO CAN
HARNESS
TO FORD AUX
ENGINE INLINE
MODULE
TO FORD
HARNESS
FORD
HARNESS
CONNECTOR
CONNECT TO
FORD HARNESS
FPCM
TO FUEL TANK
SENDER
SOLENOID
TO FUEL
TANK 2 PWR
CAN HARNESS
TRAILER BRAKE
MODULE CONNECTOR
(IF EQUIPPED)
TO ROUSH
HARNESS
TO ROUSH
HARNESS
FUEL TANK JUMPER HARNESS
TO ROUSH
HARNESS
TO ROUSH
HARNESS
TO ROUSH
HARNESS
TO ROUSH
HARNESS
100257a
Page 57
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Chassis Cab, Roush Wiring Harnesses
BODY MODULE
(12-PIN)
C1
CAN HARNESS
CAN/UNDERHOOD
INLINE CONNECTOR
(2-PIN)
C3-F
TANK JUMPER
HARNESS
UNDERHOOD/
FUEL TANK JUMPER
INLINE CONNECTOR
C15
FUEL TANK JUMPER/
IN-TANK INLINE 2
(RH TANK)
C12-M
FORD EFPR
C8
FORD HARNESS
CONNECTOR
(12-PIN)
C2
GROMMET
SRM
C4
IPTS
C5
UNDERHOOD/
FUEL TANK JUMPER
INLINE CONNECTOR
C14
ROUSH EFPR
C9
FRPCM
C6
UH/CAN
Inline
C3
IN-TANK INLINE 1
(RH TANK)
C11-M
UH/FORD
Inline
C10
FUEL TANK JUMPER/
TANK SOLENOID
INLINE (RH TANK)
C13-F
UH/TANK
JUMPER
Inline 1
C15
UH/TANK
JUMPER
Inline 2
C14
FLIM
C7
FUSE_BOX
UH/TANK
SOLENOID
INLINE
C13
(LH TANK)
UNDERHOOD
HARNESS
GND-BATT
A
A
R_PWR_1
R_PWR_2
C4-M
C4-F
FUEL SENDER
(4-PIN)
C19
A
B
UH/FORD
INLINE
C16
UH/IN-TANK
INLINE 2
(FUEL PUMP)
C12
(LH TANK)
UH/IN-TANK
INLINE 1
(FUEL PUMP)
C11
(LH TANK)
B
TO SPLICE
PACK
(PIN D)
TERMINAL
Page 58
TANK SOLENOID/
UNDERHOOD INLINE
(4-PIN)
C13-M
TANK SOLENOID HARNESS
(LONG AND SHORT TANKS)
A
SUPPLY
VALVE
SOLENOID
(2-PIN)
C18
100255a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59 Roush Wiring Harnesses
Page 59
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness
PWR_W
30
18
2
Connector
E2
F6
F4
FUSE 5
FUSE 6
F3
F2
FUSE 3
FUSE 4
D5
26
29
1
E4
F3
F4
E6
F6 5A
F6
3
4
SRM_PWR_1
IPTS_PWR
F3 20A
E3
2
46
F2
F1
D
D4
D1
FUSE 1
FUSE 2
RELAY D
E
C
KEY_PWR_2
D2
F1
25
44
F
B
A
SUPPLY_SOL
E1
F5
40
28
BLEED_SOL
A4
A1
B1
E3
D3
F5
A5
43
37
TO SOLENOID
MODULE
TO IPTS
FLOW_CNTL_ SOL
E4
A3
20
36
3
SUPPLY_SOL_RTN
E5
B4
17
35
2
FLOW_CNTL_SOL_RTN
B5
15
34
1
TO SRM
11
8
4
17
F2 10A
E5
A2
B2
B3
PWR_W_3
7
33
16
Connector
BLEED_SOL_RTN
C4
C1
E6
RELAY A
RELAY B
C2
S4
SRM_PWR
E2
E1
5
1
IPTS_TEMP_OUT
RELAY C
PWR_W_2
15
3
Connector
Connector
IPTS_GND
PWR_W_1
3
31
S5
F1 25A
2
46
A1
PWR_W_6
27
ELECTRICAL CENTER
(FUSE BOX)
C5
45
29
PBT/ASA-GF20
1
C3
44
32
31
IPTS_PRES_OUT
PWR
To Battery
Positive
RELAY A
Normally Open
12V/20A Relay
A3
A5
A2
A4
A1
S1
SOLENOID_PWR
SRM_PWR_2
A
Connector
FG_RTN_SRM
FG_RTN
C
R2
FRAME GROUND
(GND_R2)
D
FG_SND
F
TANK_SOL_RTN
FL_RTN_2
S3
35
B
TO FUEL
LEVEL
BLACK BOX
Connector
15
E
FL_RTN_1
D
FL_SND
C
VPWR_RI
TO REAR
FRAME
HARNESS
B
VPWR_RO
A
Connector
R1
GND3
GND1
S2
GND2
B
PLUG
FPM_2
A
LAMP_RTN_1
PLUG
FRAME GROUND
(GND_R1)
PLUG
CAN-H_1(+)
CAN-H_1(-)
KEY_PWR_1
47
TO REAR
FRAME
HARNESS
F
E
D
C
B
A
Connector
23
TO CAN
HARNESS
100130c
Page 60
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness
7
1
Connector
5
14
8
7
13
12
4
11
3
10
2
9
CONNECT TO FORD HARNESS
CONNECTOR C2142
1
8
FUSE_33_2
14
5
6
D
C
1
FUSE_18
CAN-H(+)_1
F
E
D
C
B
A
Connector
9
CONNECT TO ROUSH UNDERHOOD
HARNESS
A
1
8
2
PLUG
9
CAN-H(-)_1
PLUG
3
BRK_PED_POS
PLUG
10
4
CAN-H(+)_2
GND
CAN-H(-)_2
KEY_PWR_1
FUSE_33_1
11
5
12
6
S1
F
8
13
TOW_BRK
7
14
Connector
7
14
1
CONNECT TO TRAILER
BRAKE MODULE
100131b
Page 61
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness
2
5
3
4
8
5
6
7
ENS_2
1
SHIELD_3
7
GND_2
6
PLUG
5
FPC_2
8
VPWR_2
4
GND_3
PLUG
8
5
3
FPC_3
VPWR_P2
2
TO FORD FPCM
MODULE (FUEL
PUMP CONTROL
MODULE)_1
8
PLUG
FPM_2
FPM_1
PLUG
7
ENS_1
S4
30
6
GND_1
2
PLUG
VPWR_RI
VPWR_1
CONNECT
TO FORD
HARNESS
FPCM
1
S1
VPWR_RI
4
S5
B
C
3
S2
VPWR_RO
1
4
FPC_1
8
A
Connector
5
PLUG
S3
1
B
Connector
Connector
5
A
1
12
1
TO ROUSH UNDERHOOD
HARNESS
4
13
8
41
TO ROUSH UNDERHOOD
HARNESS
1
SHIELD_4
Connector
4
Connector
ENS_3
TO ROUSH FPCM
MODULE (FUEL
PUMP CONTROL
MODULE)_2
D
S6
SHIELD_5
E
C
B
FG_SND
2
A
B
SHIELD_1
A_FPPWR_1
A
Connector
21
PLUG
PLUG
PLUG
3
A_FPRTN_1
A
B
4
SHIELD_2
A_FPRTN_2
FRAME GROUND
(SHIELD)
A_FPPWR_2
A_SOL_1
A_SOLRTN_1
A_FLS_1
D
A_FLSRTN_1
F
Connector
1
Connector
27
TO FUEL
TANK_SENDER_SOLENOID
TO
FUEL_TANK_2_PWR
24
TO
FUEL_TANK_1_PWR
Connector
9
CONNECT TO
FORD HARNESS
FUEL PUMP
MODULE
Page 62
100132b
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness
IN-TANK
HARNESS
PASS THRU
1
A
B
A
B
INLINE FUEL PUMP-1 (V+)
INLINE FUEL PUMP-1 (V-)
FUEL PUMP-1 (V+)
FUEL PUMP-1 (V-)
INLINE FUEL PUMP-2 (V+)
FUEL PUMP-2 (V+)
INLINE FUEL PUMP-2 (V-)
FUEL PUMP-2 (V-)
A
PUMP-1
B
4A
A
B
4B
PUMP-2
2
100133b
Page 63
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness
9
CONNECT TO THE
REAR HARNESS
CONNECT TO
TANK SOLENOID
1
A
B
A
SUPPLY SOLENOID V+
B
SUPPLY SOLENOID V-
C
FUEL LEVEL SENDER V-
B
D
FUEL LEVEL SENDER V+
A
CONNECT TO FUEL
LEVEL SENDER
6
100134b
Page 64
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Stripped Chassis CAN Harness
B
F
D
C
A
A
C2-F
C
D
E
F
CAN-H (-)
CAN-H (+)
KEY_PWR
PLUG
PLUG
PLUG
SP1
VDB05C
VDB05A
SP2
VDB04C
VDB04A
SP3
CBB80C
CBB80A
VDB05B
VDB04B
CBB80B
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
1
2
1
3
1
1
3
3
3
4
4
6
5
6
2
4
C1-F
4
6
C1-M
5
6
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
VDB05D
VDB04D
CBB80D
PIN-34
PIN-21
PIN-23
100262a
Page 65
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic
Connector
5
CONNECT TO FORD HARNESS
CONNECTOR C2142
7
14
5
6
13
12
4
11
3
10
1
2
9
8
FUSE_18
PASS-THROUGH
F
PLUG
E
PLUG
D
PLUG
C
CAN-H(+)_2
B
A
CAN-H(+)_1
9
3
BRK_PED_POS
10
4
GND
CAN-H(-)_2
FUSE_33
PLUG
11
5
12
6
13
TOW_BRK
CONNECT TO ROUSH UNDERHOOD
HARNESS
8
2
9
CAN-H(-)_1
GROMMET
Connector
1
7
14
CONNECT TO TRAILER
BRAKE MODULE
Connector
1
100189a
Page 66
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, F-450/550 and F-650, Tank Solenoid Harness Electrical Schematic
9
CONNECT TO
REAR FRAME HARNESS
CONNECT TO
TANK (FUEL SUPPLY)
SOLENOID
1
A
A
SUPPLY SOLENOID V+
B
SUPPLY SOLENOID V-
C
D
FUEL LEVEL SENDER VFUEL LEVEL SENDER V+
B
B
A
CONNECT TO FUEL
LEVEL SENDER
6
FUEL LEVEL SENDER
CONNECTOR FROM TANK
100191a
Page 67
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic
CONNECT TO TANK
SOLENOID HARNESS
Connector
16
CONNECT TO REAR
FRAME HARNESS
PUMP_1
Connector
A
1A
B
FUEL_PUMP_1_PWR
A
FUEL_PUMP_1_RTN
B
FUEL_PUMP_2_PWR
A
FUEL_PUMP_2_RTN
B
SHIELD_1
SHIELD_3
SHIELD_2
Connector
1B
A
S1
B
Connector
CONNECT TO REAR
FRAME HARNESS
13
FRAME GROUND
(SHIELD)
PUMP_2
CONNECT TO TANK
SOLENOID HARNESS
D
C
B
A
FUEL_LEVEL _SENDER RETURN
TANK (FUEL SUPPLY) SOLENOID _RETURN
TANK (FUEL SUPPLY) SOLENOID_POWER
D
C
B
A
Connector
Connector
4
9
CONNECT TO REAR
FRAME HARNESS
Page 68
FUEL_LEVEL _SENDER POWER
CONNECT TO TANK
SOLENOID HARNESS
100192a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, FTPT Jumper Harness Electrical Harness
3
2
1
FTP_REF
FTP_REF
SIGRTN
SIGRTN
FTP
FTP
3
2
1
r
Connector
Connector
1
4
VERSION DEPENDS ON
TANK CONFIGURATION
CONNECT TO FTPT
CONNECT TO FORD HARNESS (14405)
C
B
A
FTP_REF
SIG_RTN
FTP
FTP_REF
SIG_RTN
FTP
3
2
1
Connector
1
Connector
6
CONNECT TO FORD HARNESS (14405)
CONNECT TO FTPT
100193a
Page 69
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 CAN Harness
7
12
6
1
1
2
3
4
5
6
7
8
9
10
11
12
MSCAN(-)
MSCAN(+)
LAPI
SBIC
PBPS
HIP-1
HSCAN(-)
HSCAN(+)
HIP-2
HIP-3
SCS
NOT USED
1909A
1908A
SP1909
SP1908
1
2
3
4
5
6
7
8
9
10
11
12
2181
2180
218
450
338
14
1909B
1908B
1045A
1045B
151
ZA100
12
1
7
6
C1_FORD_HARNESS_CONN
C1
FORD_Gateway_Module
1909C
1908C
A
B
C3-F
Page 70
100261a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Fuel Tank Jumper Harness
A
B
C11- M
B
A
B_FPPWR_1
B
B_FPRTN_1
C
B_FPPWR_2
D
B_FPRTN_2
C
A
D
C14- M
A
B
C12- M
C15- F
A
B_SOLPWR
A
B
B_SOLRTN
B
C
B_FLRTN
C
D
B_FLSND
D
C13_F
100264a
Page 71
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Underhood Harness Electrical Schematic
BATTERY +
R_PWR_1
PWR_W
T4
1
C4-F
TERMINAL
C4-M
T1
BATTERY +
R_PWR_2
PUMP_PWR
1
T2
SEC_TANK_PUMP_1
SEC_TANK_PUMP_2
ELECTRICAL CENTER
(FUSE BOX)
RELAY C
C5
C2
C1
PUMP_R2
C3
PUMP_PWR_3
C3
S16
B1
GND_12
A2
PWR_W_6
A3
PIN2
E1
F1
PWR_W_2
1
S12
3
FG_SND
F3
PUMP_PWR_4
S17
E5
PUMP_PWR_5
FUSE_1_25A
F5
FUSE 6
B
F4
F3
F2
F5
D2
D5
F1
A
FUSE_2_10A
FUSE 3
A
A
FUSE_3_20A
FUSE_4_20A
A
FUSE_5_20A
FUSE 4
FUSE 2
RELAY D
B
PRI_FUEL_TANK
B
B
B
DEV432
A
FUSE_6_5A
B
FUSE BOX
S8
1
VPWR
VPWR_1
2
PLUG
3
FUEL PUMP COMM.
A_FPRTN_2
5
FUEL PUMP PWR
FUEL PUMP MONITOR
FORD_GND_1
ENS_1
S4
ENS_3
8
FUEL PUMP RETURN
FPC_1
S5
FORD_GND_3
6
ENS
S2
FPC_3
4
GND
FPM_1
7
DRAIN_4
C9
ROUSH EFPR
VPWR_2
4
GND_1
3
15
31
2
PIN9
PIN12
NOT USED
PIN13
NOT USED
13
PIN1
PLUG
1
PIN16
PLUG
PIN20
NOT USED
FUEL LEVEL SENDER # 1
45
16
PIN21
NOT USED
PIN22
NOT USED
PIN23
NOT USED
PIN24
NOT USED
NOT USED
NOT USED
PIN39
SPARE OUTPUT_2
BLEED SOLENOID
SPARE INPUT_3
NOT USED
PIN30
PLUG
PIN4
NOT USED
PIN32
NOT USED
PIN42
NOT USED
PIN27
NOT USED
SPARE OUTPUT_1
NOT USED
FUEL LEVEL SENDER # 2
NOT USED
FORD CAN+
24
S1
39
36
BLEED_SOL
17
BLEED_SOL_RTN
FLOW_SOL_RTN
29
30
A
B
C
D
E
F
42
27
D
C
C
SUPPLY_SOL
FLOW_CNTL_SOL
BLEED_SOL
46
A_FPRTN_1
A_FPPWR_1
DRAIN_3
STERM_1
A
A
B
B
C11
PRI FUEL PUMP 1
S6
DRAIN_2
BLEED_SOL_RTN
STERM_2
FLOW_CNTL_SOL_RTN
SUPPLY_SOL_RTN
B
PIN2
A
PIN1
C12
PRI FUEL PUMP 2
B_SOL_1
B_FLSND
IP_TEMP
A
IP_PRES
IP_PWR
A_FLRTN
FL_RTN
41
45
C8
FORD EFPR
GND_4
35
28
A_FPRTN_2
B
D
C6
FRPCM
4
32
44
PLUG
SUPPLY _SOL
FLOW_CNTL_SOL
A
C13
PRIMARY TANK SOLENOID HARNESS
23
43
FORD CANFUEL TANK SOLENOID
SUPPLY SOLENOID
FL_SND
22
40
XDRG
C4
SRM MODULE
B
3
21
25
XDRP +5V
A
A_TANK_SOL
7
FUEL RAIL PRESSURE
PIN45
20
19
PIN8
GND
16
5
FUEL RAIL TEMPERATURE
PIN41
14
PIN7
8 PLUG
KEY ON PWR
C7
FUEL LEVEL INTERFACE MODULE
12
33
FLOW CONTROL SOLENOID
PWM DUTY CYCLE
C
FG_RTN
S10
9
FUEL GAUGE SENDER SGN
B
A
SRM_PWR_2
18
SPARE INPUT_2
PIN19
D
FG_RTN_SRM
SRM_PWR_1
DRAIN_1
38
NOT USED
NOT USED
SPARE INPUT_1
A_FPPWR_2
8
37
2
BATT+
B_FPPWR_B
NOT USED
6
GND_4
PIN8
FUEL LEVEL OUTPUT (PWM)
STERM_3
FPM_2
11
PIN5
7
PIN3
FUEL PUMP RETURN
FUEL PUMP PWR
5
34
NOT USED
NOT USED
PIN38
8
26
PIN6
PIN6
5 PLUG
S9
PIN11
PIN4
6
FUEL PUMP COMM.
VPWR
1
31
FUEL PUMP RELAY
PIN2
4
PLUG NOT_USED_1
ENS
GND
6
EFPR DIAGNOSTIC FEEDBACK
PIN1
2 PLUG
3
FUEL PUMP MONITOR
2
WAKE
1
C10
FORD FUEL TANK
HARNESS
STERM_4
7
GROUND
CAN-H(+)
CAN-H(-)
A
B
3
A
B
C3
CAN
SUPP_SOL_RTN
2
4
S3
IP_GND
1
TEMP OUT
PRESSURE OUPUT
PWR
GND
C5
IPTS SENSOR
B_FLRTN
A
D
D
C
C
B_FPPWR_1
A
A
B
B
B_FPPWR_2
C
C
B_FPRTN_1
B
B
D
D
C15
FUEL TANK JUMPER
B_SOLRTN
FG_RTN
D4
D1
FUSE 1
F6
VPWR_P2
NOT_USED_1
A4
A1
E1
DEV434
E6
PUMP_ACTIVE
S13
Page 72
E2
F4
PUMP_PWR_6
C16
FORD FUEL
TANK HARNESS
E3
F2
E3
E4
2
A
E2
4
E4
A5
B1
FUSE 5
ENS_2
PLUG
E5
A2
A3
B4
A1
VPWR_RI
PLUG
PIN3
B5
D3
F6
FPC_2
FORD_GND_2
PLUG
PIN4
E6
A5
PWR_W_1
PIN1
B3
C4
B3
PUMP_PWR_2
S14
B2
C1
desc
B2
PUMP_R1
C5
RELAY_B
RELAY_C
B5
S11
RELAY A
RELAY B
C2
PU_AC_2
S15
B_FPRTN_2
C14
FUEL TANK JUMPER
S7
GND
GND-BATT
T3
100269a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59 CAN Harness
B
F
D
C
A
A
C2-F
C
D
E
F
CAN-H (-)
CAN-H (+)
KEY_PWR
PLUG
PLUG
PLUG
SP1
1909C
1909A
SP2
1908C
1908A
SP3
298C
298A
1909B
1908B
298B
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
6
5
6
1
4
4
1
3
3
8
8
5
7
4
5
8
C1-M
8
5
C1-F
7
4
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
1909D
1908D
298D
PIN-5
PIN-4
PIN-13
100263a
Page 73
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/250/350/450 Rear Frame Harness Electrical Schematic
TO ROUSH FPCM MODULE (FUEL
PUMP CONTROL MODULE)
4
TO FORD FPCM MODULE (FUEL
PUMP CONTROL MODULE)
1
4
1
Connector
Connector
13
12
TO ROUSH UNDERHOOD HARNESS
INLINE CONNECTOR
8
1
4
5
8
6
8
7
1
5
2
3
4
5
8
6
7
ENS_2
SHILED_3
GND_2
PLUG
FPC_2
VPWR_2
SHILED_4
GND_3
PLUG
ENS_3
C
FPC_3
VPWR_P2
VPWR_RI
B
CONNECT TO FORD FPCM
HARNESS CONNECTOR
PLUG
FL_SRTN
FPM_1
E
ENS_1
F
S4
6
PLUG
GND_1
S3
S5
FPC_1
1
B
Connector
9
4
PLUG
3
PLUG
2
1
D
C
B
A_SOL_1
FRAME GROUND
(SHIELD)
B
A
B
SHILED_1
A_FPRTN_1
A_SOLRTN_1
A_FLS_1
CONNECT TO FORD FUEL PUMP
HARNESS INLINE CONNECTOR
A_FLSRTN_1
RING TERMINAL
GND
A_FPPWR_1
SHIELD_5
S6
SHILED_2
FPM_2
A_FPPWR_2
A
A_FPRTN_2
41
4
Connector
2
8
VPWR_1
S1
1
3
PLUG
VPWR_RI
Connector
5
4
S2
TO ROUSH UNDERHOOD HARNESS
INLINE CONNECTOR
8
7
1
D
5
30
3
VPWR_RO
A
Connector
5
2
A
A
FG_SND
PLUG
GRAY
BLACK
Connector
Connector
27
24
Connector
21
TO FUEL TANK JUMPER
HARNESS INLINE CONNECTOR
Page 74
TO FUEL TANK JUMPER
HARNESS INLINE CONNECTORS
100266a
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/250/350/450 Underhood Harness Electrical Schematic
PWR_W
44
18
29
3
15
45
46
A1
PBT/ASA-GF20
1
2
2
Connector
B5
E6
E5
E4
B4
A2
A3
E3
E2
F5
D2
F2
FUSE 3
FUSE 4
F1
D5
D4
28
44
26
29
1
2
4
46
D1
FUSE 1
A2
A4
A1
E4
KEY_PWR_2
D
RELAY D
PWR_W_6
Connector
51
TO FORD AUX ENGINE
INLINE MODULE
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
16
J1
J9
J2
J10
J3
J11
J4
J12
J5
J13
J6
J14
J7
J15
J8
J16
55
TO FORD HARNESS
12C508 (C1168)
S8
J1A
SRM_PWR_2
1
FG_RTN_SRM
9
2
FG_RTN
10
F
B
A
S1
SOLENOID_PWR
Connector
E
C
A1 = 85
A2 = 86
A3 = 30
A4 = 87A
A5 = 87
FUSE 2
11
Initial Print A.A
20111403
SRM_PWR_1
F2
F6
3
RELAY
NO CONTACT
20A@14VDC
A3
FUSE 5
FUSE 6
F3
37
25
A4
A5
F4
36
40
A1
E1
D3
F6
A5
B1
35
43
BLEED_SOL
B2
B3
C1
34
17
Connector
TO SOLENOID
MODULE
FLOW_CNTL_SOL_RTN
C4
5A
20A
33
15
TO IPTS
BLEED_SOL_RTN
C5
F5
E3
KEY_PWR_1
C2
C3
RELAY A
PWR_W_3
10A
31
10
IPTS_TEMP_OUT
RELAY B
S4
F1
S5
SRM_PWR
E2
3
11
A
B
C
Connector
35
TO FLIM
D
4
12
5
13
GND_R2
6
FRAME GROUND
14
FG_SND
7
15
TANK_SOL_RTN
8
S3
FL_RTN_2
16
FL_RTN_1
FL_SND
VPWR_RI
VPWR_RO
F
E
D
C
Connector
15
TO REAR
FRAME
HARNESS
B
A
Connector
B
FPM_2
S2
GND2
GND3
GND1
RELAY C
PWR_W_2
25A
7
3
IPTS_PRES_OUT
ELECTRICAL CENTER
(FUSE BOX)
E1
5
IPTS_GND
PWR_W_1
3
8
1
17
16
2
27
Connector
4
TO SRM
SUPPLY_SOL
32
31
FLOW_CNTL_ SOL
1
SUPPLY_SOL_RTN
30
Connector
IPTS_PWR
PWR
To Battery
Positive
Connector
GND
PLUG
F
PLUG
E
PLUG
D
CAN-H_1(+)
CAN-H_1(-)
FRAME GROUND
PLUG
C
B
A
A
47
TO REAR
FRAME
HARNESS
Connector
23
TO CAN
HARNESS
100267a
Page 75
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic
CONNECT TO IN-TANK HARNESS
INLINE CONNECTOR
CONNECT TO REAR FRAME
HARNESS INLINE CONNECTOR
Connector
A
1A
B
FUEL_PUMP_PWR_1
BLACK
A
1B
16
B
BLACK
Connector
Connector
A
FUEL_PUMP_RTN_1
B
FUEL_PUMP_PWR_2
A
FUEL_PUMP_RTN_2
13
B
SHIELD_1
SHIELD_3
SHIELD_2
GRAY
CONNECT TO REAR FRAME
HARNESS INLINE CONNECTOR
Connector
S1
Connector
GND
GRAY
CONNECT TO IN-TANK HARNESS
INLINE CONNECTOR
FRAME GROUND
(SHIELD)
D
Connector
4
C
FUEL_LEVEL _RTN
B
SOLENOID _RTN
A
SOLENOID_SPLY
CONNECT TO REAR FRAME
HARNESS INLINE CONNECTOR
Page 76
FUEL_LEVEL _SPLY
D
C
B
Connector
9
A
CONNECT TO TANK HARNESS
INLINE CONNECTOR
100268a
©2014 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.