Printing From Undefined

2008
2008Ford
FordF550
F550Super
SuperDuty
Duty
2008
2008ENGINE
ENGINEPERFORMANCE
PERFORMANCEPinpoint
PinpointTests
Tests- -F-250-550
F-250-5506.4L
6.4LDiesel
DieselEngines
Engines
2008 ENGINE PERFORMANCE
Pinpoint Tests - F-250-550 6.4L Diesel Engines
PINPOINT TEST A: POWERTRAIN CONTROL MODULE (PCM) POWER RELAY

INTRODUCTION
NOTE: Regeneration may occur during normal operation. During regeneration, diagnostic procedures may display
biased values. If a regeneration occurs during diagnostic procedures, allow the process to complete before
continuing diagnostics.
This pinpoint test is intended to diagnose the following:
harness circuits: B+, ISP-R, PCMRC, VPWR and PWRGND

PCM power relay
PCM (12A650)
Fig. 1: Fuel Injector Control Module (FICM) Relay Connector (1 Of 2)

Courtesy of FORD MOTOR CO.
Pin Circuit
5 VPWR (Vehicle Power)
lunes, 21 de agosto lunes,

de 2017
2110:01:26
de agosto
p.m.
de 2017 10:00:32 p.m. Page
Page11 2011 Mitchell RepairInformation
2011 Mitchell
Company,
Repair Information
LLC. Company, LLC.
2008 Ford F550 Super Duty
2008 ENGINE PERFORMANCE Pinpoint Tests - F-250-550 6.4L Diesel Engines
2 PCMRC (PCM Relay Control)
Fig. 2: 58-Pin Body Connector

Pin Circuit
2, 4, 6 PWRGND (Power Ground)
1, 3, 5 VPWR (Vehicle Power)
12 ISP-R (Ignition Switch Position Run)
33 PCMRC (PCM Relay Control)
TEST PROCEDURE
A1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

Is DTC P0560 or P0563 present?
Yes No
GO to A2. GO to A3.
A2 DTCS P0560 AND P0563: CHECK THE BATTERY AND CHARGING SYSTEM
lunes, 21 de agosto de 2017 10:00:34 p.m. Page 2 2011 Mitchell Repair Information Company, LLC.
NOTE: DTC P0563 may set during a 24-volt jump start. DTC P0560 may set during crank with a low battery
condition.
Check the battery and charging system voltages. Refer to BATTERY, MOUNTING AND CABLES -- F-250-550 (SUPER DUTY
PICKUPS) .
Are the battery and charging system voltages within specifications?
A3 CHECK THE PCM POWER RELAY

Carry out the PCM power relay component test. Refer to the Wiring Diagrams Cell 149 Component Testing.
Did the PCM power relay pass the component test?
Yes No
INSTALL a new PCM Power Relay.
GO to A4.
CLEAR the DTCs. REPEAT the self-test.
A4 CHECK THE B+ CIRCUITS FOR VOLTAGE

Key in OFF position.
PCM Power Relay connector disconnected.
Measure the voltage between:
( + ) PCM
Power Relay
(-)
Connector,
Harness Side
B+ - Pin 1, 3 Ground
Are the voltages greater than 10 V?
Yes No
REPAIR the open circuit. CLEAR the
GO to A5.
DTCs. REPEAT the self-test.
A5 CHECK THE PCMRC CIRCUIT FOR AN OPEN

PCM-B connector disconnected.
Measure the resistance between:
Is the resistance less than 5 ohms?
A6 CHECK THE PCMRC CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
( + ) PCM-B
Connector, (-)
Harness Side
PCMRC - Pin
Ground
33
Is any voltage present?
Yes No
REPAIR the short circuit. CLEAR the
GO to A7.
A7 CHECK THE PCMRC CIRCUIT FOR A SHORT TO GROUND

( + ) PCM-B
Connector, (-)
Harness Side
PCMRC - Pin
Ground
33
Is the resistance greater than 10K ohms?
A8 CHECK THE ISP-R CIRCUIT FOR VOLTAGE

PCM Power Relay connector connected.
Key ON, engine OFF.
Is the voltage greater than 10 V?

GO to A9.
A9 CHECK THE ISP-R CIRCUIT FOR A SHORT TO VOLTAGE

( + ) PCM-B
Connector, (-)
Harness Side
ISP-R - Pin 12 Ground
Yes No
GO to A10.
A10 CHECK THE VPWR CIRCUIT FOR AN OPEN

Are the resistances less than 5 ohms?
A11 CHECK THE PWRGND CIRCUITS FOR AN OPEN

Yes No
GO to A12.
A12 CHECK FOR CORRECT PCM OPERATION

Disconnect all the PCM connectors.
Visually inspect for:
pushed out pins
corrosion
Connect all the PCM connectors and make sure they seat correctly.
Carry out the PCM self-test and verify the concern is still present.
Is the concern still present?
Yes No
INSTALL a new PCM. REFER
The system is operating correctly at this
toFLASH ELECTRICALLY
time. The concern may have been caused
ERASABLE PROGRAMMABLE
by a loose or corroded connector.
READ ONLY MEMORY (EEPROM) .
PINPOINT TEST AA: POWERTRAIN CONTROL MODULE (PCM) READ ONLY MEMORY (ROM)
FAILURE
INTRODUCTION
incorrect PCM calibration

PCM (12A650)
TEST PROCEDURE
AA1 DIAGNOSTIC TROUBLE CODE (DTC) P0605: PRELIMINARY DIAGNOSIS

Key ON, engine OFF.
Carry out the KOEO self-test.
Is DTC P0605 present?
GO to AA2. Unable to duplicate the condition. CHECK for a loose connection, and damaged or
corroded terminals. WIGGLE the harness attempting to recreate the concern. REPAIR as
necessary. REFER toNO DIAGNOSTIC TROUBLE CODES (DTCS) PRESENT
SYMPTOM CHART INDEX , if a driveability concern exists.
AA2 PROGRAM THE PCM

Program the PCM. Refer toFLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) .
Clear the DTCs.

AA3 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AC: ON-BOARD DIAGNOSTIC (OBD) SYSTEMS READINESS TEST NOT COMPLETE
INTRODUCTION
drive conditions not satisfied

keep alive memory (KAM) cleared
TEST PROCEDURE
AC1 DIAGNOSTIC TROUBLE CODE (DTC) P1000: PRELIMINARY DIAGNOSIS
NOTE: If the voltage to the powertrain control module (PCM) is disconnected, DTC P1000 is set until the OBD
monitors have run and cleared.
DTC P1000 indicates that the operating conditions have not been satisfied for all of the OBD monitors to run.
Key ON, engine OFF.
Carry out the self-test.
Are any DTCs present other than P1000?
AC2 CARRY OUT THE DIESEL DRIVE CYCLE TEST

Disengage the power take off (PTO), if equipped.
Carry out the diesel drive cycle test. Refer toON BOARD DIAGNOSTIC (OBD) DRIVE CYCLE .
Is the P1000 cleared?
AC3 CHECK FOR CORRECT PCM OPERATION

corrosion
pushed out pins
Carry out the network test and verify the concern is still present.
Yes No
PINPOINT TEST AD: POWERTRAIN CONTROL MODULE (PCM) RESET

INTRODUCTION
loose, damaged or corroded connections

harness circuits: VPWR and PWRGND

TEST PROCEDURE
AD1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

Access and record any DTCs.
Record the freeze frame data.
Clear the DTCs.
Carry out the KOEO and KOER self-test.
Are any DTCs present?
Yes No
REFER toDIAGNOSTIC TROUBLE
CODE (DTC) CHARTS AND GO to AD2.
DESCRIPTIONS .
AD2 CHECK THE VPWR CIRCUITS FOR VOLTAGE

Key ON, engine OFF.
Check for loose connections. Check for damaged pins or corrosion. Wiggle the harness while taking the measurements.
AD3 CHECK THE PWRGND CIRCUITS FOR AN OPEN

Yes No
Unable to duplicate the condition.
CHECK for a loose connection, and
damaged or corroded terminals.
WIGGLE the harness attempting to
recreate the concern. REPAIR as
necessary. REFER toNO DIAGNOSTIC
TROUBLE CODES (DTCS)
PRESENT SYMPTOM CHART
INDEX , if a driveability concern exists.
PINPOINT TEST AE: UNABLE TO ACTIVATE SELF-TEST/NETWORK COMMUNICATION ERROR

INTRODUCTION
unable to communicate with the powertrain control module (PCM)

unable to activate the PCM self-test
harness circuits VPWR, ISP-R, PCMRC and PWRGND
Fig. 4: Powertrain Control Module (PCM) (1 Of 2)

Pin Circuit
3 SIGRTN (Signal Return)
1 VREF (Reference Voltage)

TEST PROCEDURE
AE1 DIAGNOSTIC TROUBLE CODE (DTC) P2545: PRELIMINARY DIAGNOSIS

Carry out a visual inspection.
Retrieve and record any continuous and on-demand DTCs.
Clear all the DTCs.
AE2 CARRY OUT A VEHICLE INSPECTION AND VERIFY THE SELF-TEST PROCEDURE
Check the battery voltage. Refer to BATTERY, MOUNTING AND CABLES -- F-250-550 (SUPER DUTY PICKUPS) .
Verify that the correct procedure was used to activate the self-test for the scan tool. Refer toQUICK TEST DESCRIPTION .
Was the correct self-test procedure used?
AE3 CARRY OUT THE NETWORK TEST

Key ON, engine OFF.
Carry out the network test.
Do all modules indicate pass?
AE4 CHECK THE VREF CIRCUIT FOR VOLTAGE

EGR Valve connector disconnected.
Key ON, engine OFF.
Is the voltage between 4 - 6 V?
AE5 CHECK THE ISP-R CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
( + ) PCM-B
Connector, (-)
Harness Side
ISP-R - Pin 12 Ground
AE6 CHECK THE PCM VPWR CIRCUITS FOR VOLTAGE

Connect a 5 amp fused jumper wire between the following:
Key ON, engine OFF.

AE7 CHECK THE PWRGND CIRCUITS FOR AN OPEN

( + ) PCM-B
Connector, (-)
Harness Side
PWRGND - Pin
Ground
2, 4, 6
AE8 CHECK FOR CORRECT PCM OPERATION

corrosion
pushed out pins
Carry out the network test and verify the concern is still present.
PINPOINT TEST AF: GLOW PLUG SYSTEM

INTRODUCTION
stripe on the glow plug control module housing for visual verification. The
stripe should line up with the black connector.
CAUTION: When disconnecting the green and black connectors at the glow plug control module it is suggested that
the module be unbolted from the mounting bracket first and then the connectors disconnected. This
allows for easier disconnect and prevents damage to the connector terminals.
NOTE: The wait-to-start indicator ON time is independent from the glow plug control module.
NOTE: Make sure that the vehicle batteries are fully charged prior to carrying out the glow plug monitor self-test.
glow plugs
glow plug control module (GPCM)
powertrain control module (PCM) (12A650)
Fig. 6: Glow Plug Control Module-Black (GPCM-Black) Connector

Fig. 7: Glow Plug Control Module-Green (GPCM-Green) Connector
Fig. 8: 96-Pin Engine Connector

TEST PROCEDURE
AF1 PRELIMINARY DIAGNOSIS

Key ON, engine OFF.
Carry out the KOER Glow Plug Monitor self-test.
Are DTCs P0670, P0671, P0672, P0673, P0674, P0675, P0676, P0677, P0678, or P0684 present?
Yes No
For DTCs P0671, P0672, P0673, P0674, damaged or corroded terminals.
P0675, P0676, P0677 or P0678, GO to WIGGLE the harness attempting to
AF2. recreate the concern. REPAIR as
For DTC P0670, GO to AF7. necessary. REFER toNO DIAGNOSTIC
For DTC P0684, GO to AF12. TROUBLE CODES (DTCS)
AF2 DIAGNOSTIC TROUBLE CODES (DTCS) P0671, P0672, P0673, P0674, P0675, P0676, P0677, OR P0678

Glow Plug connector disconnected.
Check for loose, damaged, or backed out terminals.
Is the resistance between 0.5 ohm - 2 ohms?
GLOW PLUG SYSTEM -- F-250-550

GO to AF3. (SUPER DUTY PICKUPS) .
AF3 CHECK THE GLOW PLUG VOLTAGE

Disconnect the suspect GPCM connector.
Key ON, engine OFF.
( + ) Suspect
GPCM
(-)
Connector,
Harness Side
VBAT Ground
AF4 CHECK THE GLOW PLUG CIRCUIT FOR AN OPEN

AF5 CHECK THE GLOW PLUG CIRCUIT FOR A SHORT TO GROUND

Connector,
Harness Side
Suspect Glow
Ground
Plug
Yes No
GO to AF6.
AF6 CHECK THE GLOW PLUG CIRCUIT FOR A SHORT TO VOLTAGE
Key ON, engine OFF.

Is any voltage indicated?
AF7 DTC P0670: CHECK THE GPE CIRCUIT FOR AN OPEN IN THE HARNESS
PCM-E connector disconnected.
GPCM-Green connector disconnected.
Yes No
GO to AF8.
AF8 CHECK THE GPE CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
( + ) GPCM-
Green
(-)
Connector,
Harness Side
GPE - Pin 8 Ground
Yes No
GO to AF9.
AF9 CHECK THE GPE CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
AF10 CHECK THE GPCM FOR VOLTAGE

GPCM-Black connector disconnected.
Key ON, engine OFF.
Connector,
(-)
Harness Side
VPWR - Pin 9 Ground
Yes No
GO to AF11.
AF11 CHECK THE GPE CONTROL CIRCUIT
NOTE: With the key ON, engine OFF the PCM provides a path to ground for the GPE circuit.

GPCM-Black connector connected.
PCM-E connector connected.
Key ON, engine OFF.

AF12 DTC P0684: CHECK THE GPD CIRCUIT FOR AN OPEN IN THE HARNESS
GPCM-Green connector disconnected.
Green ( - ) PCM-E
Connector, Connector,
Harness Side Harness Side
GPD - Pin 9 GPD - Pin 83
Yes No
GO to AF13.
AF13 CHECK THE GPD CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
( + ) GPCM-
Green
(-)
Connector,
Harness Side
GPD - Pin 9 Ground
AF14 CHECK THE GPD CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
AF15 CHECK THE GPCM FOR VOLTAGE

GPCM-Black connector disconnected.
Key ON, engine OFF.
( + ) GPCM-
Black
(-)
Connector,
Harness Side
VPWR - Pin 9 Ground
Yes No
GO to AF16.
AF16 CHECK THE GPCM OPERATION

GPCM-Black connector connected.
GPCM-Green connector connected.
Key ON, engine OFF.

AF17 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST AG: ACCELERATOR PEDAL POSITION (APP) SENSOR

INTRODUCTION
APP sensor (9F836)

harness circuits: APP1, APP2, SIGRTN, and VREF
Fig. 9: Accelerator Pedal Position (APP) Sensor Connector


TEST PROCEDURE
AG1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P060D, P2122, P2123, P2127, P2128, OR P2138
Retrieve and record all DTCs.
Clear the DTCs.
Are DTCs P060D, P2122, P2123, P2127, P2128 or P2138 present?
Yes No
GO to AG2. recreate the concern. REPAIR as
AG2 CHECK THE ACCELERATOR PEDAL FOR OBSTRUCTION

Key ON, engine OFF.
Press the accelerator pedal fully to the floor and release.
Does the pedal move freely to the floor and back?
AG3 CHECK THE APP SENSOR SIGNAL VOLTAGE RANGES FOR THE ACCELERATOR PEDAL FULLY APPLIED AND
RELEASED POSITIONS
Access the PCM and monitor the APP1 and APP2 PIDs.
Press the accelerator pedal fully to the floor and release.
Are both APP sensor signals out of range for the pedal fully applied and released positions?
AG4 CHECK THE VREF VOLTAGE TO APP SENSOR

APP Sensor connector disconnected.
Key ON, engine OFF.
( + ) APP ( - ) APP
Sensor Sensor
SIGRTN - Pin
VREF - Pin 6, 7
1, 3
Are the voltages between 4 - 6 V?
AG5 CHECK THE ACCELERATOR PEDAL CONFIGURATION AND APP SENSOR HOUSING
Check the configuration of the accelerator pedal and determine the color of the APP sensor housing.
Is the vehicle equipped with an adjustable accelerator pedal?
AG6 VEHICLES WITH AN ADJUSTABLE ACCELERATOR PEDAL: CHECK THE APP SENSOR FOR THE CORRECT
RESISTANCE

Component Component (ohms) (ohms)

Side Side
APP1 VREF 550 1,390
APP1 SIGRTN 1,030 2,590
APP1 APPS2 2,125 5,335
APP2 VREF 1,785 4,480
APP2 SIGRTN 1,475 3,705
VREF SIGRTN 780 1,955
Are all the resistances within specifications?
AG7 VEHICLES WITH A FIXED ACCELERATOR PEDAL AND A WHITE APP SENSOR HOUSING: CHECK THE APP
SENSOR FOR THE CORRECT RESISTANCE

to AG9. ACCELERATION CONTROL -- F-

For DTCs P2127 or P2128, GO to AG13. 250-550 (SUPER DUTY PICKUPS) .
For DTC P2138, GO to AG17. CLEAR the DTCs. REPEAT the self-test.
AG8 ALL OTHERS: CHECK THE APP SENSOR FOR THE CORRECT RESISTANCE
NOTE: Make sure the accelerator pedal is fully released when taking the resistance measurements.

(+) APP (-) APP

Sensor Sensor Minimum Maximum
Connector, Connector, Resistance Resistance
Component Component (ohms) (ohms)
Side Side
APP1 VREF 600 1,370
APP1 SIGRTN 720 1,660
APP1 APP2 1,300 2,960
APP2 VREF 750 1,720
APP2 SIGRTN 660 1,520
VREF SIGRTN 200 470
AG9 CHECK THE APP1 CIRCUIT FOR AN OPEN IN THE HARNESS

Yes No
GO to AG10.
AG10 CHECK THE APP1 CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
( + ) APP
Sensor
(-)
Connector,
Harness Side
APP1 - Pin 2 Ground
AG11 CHECK THE APP1 CIRCUIT FOR A SHORT IN THE HARNESS

Are the resistances greater than 10K ohms?
AG12 CHECK THE APP1 CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
APP1 - Pin 2 Ground
Yes No
REPAIR the short circuit. CLEAR the For DTC P060D, GO to AG13.
DTCs. REPEAT the self-test. For all others, GO to AG19.
AG13 CHECK THE APP2 CIRCUIT FOR AN OPEN IN THE HARNESS

( + ) APP
( - ) PCM-B
Sensor
Connector,
Connector,
Harness Side
Harness Side
APP2 - Pin 5 APP2 - Pin 28
AG14 CHECK THE APP2 CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
AG15 CHECK THE APP2 CIRCUIT FOR A SHORT IN THE HARNESS

Sensor Sensor
SIGRTN - Pin
APP2 - Pin 5
1, 3
APP2 - Pin 5 VREF - Pin 6, 7
Yes No
GO to AG16.
AG16 CHECK THE APP2 CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
AG17 CHECK FOR A SHORT BETWEEN THE APP1 AND APP2 CIRCUITS
For DTC P060D, GO to AG18. REPAIR the short circuit. CLEAR the
For all others, GO to AG19. DTCs. REPEAT the self-test.
AG18 CHECK THE PCM FOR THE LATEST CALIBRATION

Program the PCM to the latest calibration.
Key ON, engine running.
Increase the engine speed to 2,000 RPM for 5 seconds.
Is DTC P060D present?
Yes No
The test is complete and no concerns are
GO to AG19.
present.
AG19 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AH: COOLING FAN

INTRODUCTION
cooling fan
fan speed sensor
harness circuits
Fig. 11: Cooling Fan Circuit


TEST PROCEDURE
AH1 PRELIMINARY DIAGNOSIS

Carry out the PCM self-test.
Yes No
For DTC P0494, P0495, P0528, P0529,
GO to AH2.
For DTC P0480, P0691, P0692, GO to
AH3. GO to AH2.
For all others, REFER toDIAGNOSTIC
TROUBLE CODE (DTC) CHARTS
AND DESCRIPTIONS .
AH2 CHECK THE COOLING FAN FOR MECHANICAL BINDING

Manually rotate the cooling fan.
Does the fan clutch rotation feel rough or binding?
AH3 CHECK THE COOLING FAN OPERATION
PCM, varies depending on operating conditions such as temperature,

engine speed and starting fan speed. The reaction time can be from
seconds to several minutes depending on the test conditions.

Access the PCM and monitor the FANSS and RPM PIDs.
Engine at normal operating temperature.
Increase the engine speed to 2,500 RPM.
Access the PCM and control the FANDC PID.
Decrease the commanded cooling fan duty cycle to 0%.
Allow the fan speed to stabilize below 600 RPM.
Access the PCM and control the FANDC PID.

Increase the commanded cooling fan duty cycle to 100%.
Does the fan speed change and does the FANSS PID indicate an RPM change?
AH4 CHECK THE COOLING FAN RESISTANCE

Cooling Fan connector disconnected.
Is the resistance between 6 - 10 ohms?
Yes No
INSTALL a new Cooling Fan. REFER to
ENGINE COOLING -- F-250-550
GO to AH5.
(SUPER DUTY PICKUPS) .
AH5 CHECK THE FCV CIRCUIT FOR AN INTERNAL SHORT TO GROUND

( + ) Cooling
Fan Connector,
(-)
Component
Side
FCV - Pin 1 Ground
Yes No
GO to AH6.
AH6 CHECK THE VPWR CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
Is the voltage greater than 10.5 V?
AH7 CHECK THE FCV CIRCUIT FOR AN OPEN IN THE HARNESS

( + ) Cooling ( - ) PCM-E
Fan Connector, Connector,
FCV - Pin 1 FCV - Pin 95,96
Yes No
GO to AH8.
AH8 CHECK THE FCV CIRCUIT FOR A SHORT TO GROUND IN HARNESS
AH9 CHECK THE FCV CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
AH10 CHECK THE FAN SPEED SENSOR FOR VOLTAGE

Key ON, engine OFF.
Cooling Fan connector disconnected.
( + ) Cooling ( - ) Cooling
Fan Connector, Fan Connector,
VBPWR - Pin 5 VBGND - Pin 3
Yes No
GO to AH15. GO to AH11.
AH11 CHECK THE VBPWR CIRCUIT FOR VOLTAGE

( + ) Cooling
Fan Connector, (-)
Harness Side
VBPWR - Pin 5 Ground
AH12 CHECK THE VBPWR CIRCUIT FOR AN OPEN

AH13 CHECK THE VBPWR CIRCUIT FOR A SHORT TO GROUND

( + ) Cooling
Fan Connector, (-)
Harness Side
VBPWR - Pin 5 Ground
Yes No
GO to AH19.
AH14 CHECK THE VEHICLE BUFFER GROUND VBGND CIRCUIT FOR AN OPEN
AH15 CHECK THE FAN SPEED SENSOR SIGNAL CIRCUIT FOR AN OPEN
Yes No
GO to AH16.
AH16 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO GROUND

( + ) Cooling
Fan Connector, (-)
Harness Side
FSS - Pin 4 Ground
Yes No
GO to AH17.
AH17 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
AH18 CHECK THE SIGNAL CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
Yes No
GO to AH19.
AH19 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AI: BRAKE PEDAL POSITION (BPP) SWITCH

INTRODUCTION
BPP switch
harness circuits BPP and B+
Fig. 13: Brake Pedal Position (BPP) Switch Connector - B


TEST PROCEDURE
AI1 CHECK THE CYCLING OF THE BPP SWITCH

Key ON, engine OFF.
Access the PCM and monitor the BOO PID.
Does the BOO PID indicate ON?
GO to AI2. GO to AI4.
AI2 CHECK THE BPP SWITCH

BPP Switch connector disconnected.
Key ON, engine OFF.
Yes No
INSTALL a new BPP switch. CLEAR
GO to AI3.
the DTCs. REPEAT the self-test.
AI3 CHECK THE BPP SWITCH SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
Key ON, engine OFF.
AI4 CHECK THE BPP SWITCH OPERATION

Apply and release the brake pedal.
Does the BOO PID state change when the brake pedal is fully applied and released?

INDEX .
AI5 CHECK THE BPP SWITCH FOR VOLTAGE

BPP Switch connector disconnected.
( + ) BPP
Switch
(-)
Connector,
Harness Side
B+ - Pin 3 Ground
AI6 CHECK THE BPP SWITCH SIGNAL

Key ON, engine OFF.
AI7 CHECK THE BPP SWITCH INPUT CIRCUIT FOR AN OPEN

( + ) BPP
( - ) PCM-B
Switch
Connector,
Connector,
Harness Side
Harness Side
BPP - Pin 4 BPP - Pin 29
Yes No
GO to AI8.
AI8 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AK: TURBOCHARGER ACTUATOR

INTRODUCTION
harness circuits: VPWR, PWRGND, CAN+ and CAN-

turbocharger actuator (9G730)
Fig. 15: Turbocharger Actuator (9G730)

Fig. 16: Data Link Connector

TEST PROCEDURE
AK1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P132A, P132B, P132C, P138D, P179A OR
P2563
Clear the DTCs.
Are DTCs P132A, P132B, P132C, P138D, P179A or P2563 present?
AK2 TURBOCHARGER ACTUATOR VISUAL INSPECTION

Inspect the turbocharger actuator linkage for damage.
Inspect for obstructions in the turbocharger actuator linkage travel.
Are there any concerns found during the visual inspection?
AK3 CARRY OUT THE TURBOCHARGER ACTUATOR SELF-TEST
Key ON, engine OFF.

Does the turbocharger actuator linkage move and return to the starting position?
AK4 CHECK THE MECHANICAL OPERATION OF THE TURBOCHARGER ACTUATOR

Manually move the turbocharger actuator linkage toward the front of the vehicle.
Release the turbocharger actuator linkage.
Does the actuator linkage move and quickly return to the start position when released?
Yes No
For DTC P138D, GO to AK9.
GO to AK10.
For all others, GO to AK5.
AK5 CHECK THE ELECTRICAL OPERATION OF THE TURBOCHARGER ACTUATOR

Access the PCM and control the VGTDC PID.
Increase the commanded turbocharger actuator duty cycle to 100%.
Decrease the commanded turbocharger actuator duty cycle to 0%.
Does the turbocharger actuator operate as commanded?
AK6 CHECK THE TURBOCHARGER ACTUATOR VPWR CIRCUIT FOR AN OPEN IN THE HARNESS
Turbocharger Actuator connector disconnected.
PCM-B connector connected.
Key ON, engine OFF.
AK7 CHECK THE PWRGND CIRCUIT FOR AN OPEN

(+)
Turbocharger
( - ) Vehicle
Actuator
Battery
Connector,
Harness Side
PWRGND - Pin Negative
2 terminal
AK8 CHECK THE CAN+ AND CAN- CIRCUITS FOR AN OPEN

Turbocharger Actuator connector disconnected.
AK9 THE TURBOCHARGER ACTUATOR TEMPERATURE HAS EXCEEDED THE MAXIMUM CALIBRATED LIMIT
Check for the following:

Fuel cooling system concerns
Engine cooling system concerns
GVWR has been exceeded
Modifications to the electronic engine control (EEC) system
Is a concern present?
Yes No
For fuel cooling system concerns,
REFER to FUEL SYSTEM -
GENERAL INFORMATION -
GASOLINE AND DIESEL -- F-250-
550 (SUPER DUTY PICKUPS) for
diagnosis and testing.
For cooling system concerns, REFER to
GO to AK11.
(SUPER DUTY PICKUPS) for
diagnosis and testing. CLEAR the DTCs.
REPEAT the self-test.
For the GVWR has been exceeded,
RETURN the vehicle to the customer
with information about the DTC.
For modifications, REPAIR as necessary.
AK10 CHECK FOR STUCK TURBOCHARGER VANES

Disconnect the turbocharger actuator linkage.
Manually move the vane actuator.
Do the vanes move freely?
AK11 CHECK FOR CORRECT TURBOCHARGER ACTUATOR OPERATION

Disconnect the turbocharger actuator harness connector.
pushed out pins
corrosion
Connect the turbocharger actuator connector and make sure it seats correctly.
PINPOINT TEST AL: TRANSMISSION RANGE CIRCUIT

INTRODUCTION
TEST PROCEDURE
AL1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P1705

Clear the DTCs.
PINPOINT TEST AM: AIR CONDITIONING (A/C) CLUTCH

INTRODUCTION
TEST PROCEDURE
AM1 DIAGNOSTIC TROUBLE CODE (DTC) P1464: CHECK THE A/C CLUTCH SWITCH (ACCS) PID
NOTE: Verify the A/C and defrost were off during the self-test. If the A/C or defrost were on, turn them off and
repeat the self-test.
Key ON, engine OFF.

A/C and defrost OFF.
Access the PCM and monitor the ACCS PID.

Is the ACCS PID ON?
PINPOINT TEST AN: POWER TAKE-OFF (PTO) CONTROL

INTRODUCTION
harness circuit PTO


Pin Circuit
30 PTO (Power Take Off)
TEST PROCEDURE
AN1 VERIFY CORRECT PTO OPERATION

Disconnect the PTO system or auxiliary idle control.
AN2 CHECK THE PTO INPUT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
AN3 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST AR: MISFIRE

INTRODUCTION
This pinpoint test is intended to diagnose the misfire detection monitor.
Clearing the powertrain control module (PCM) diagnostic trouble codes (DTCs) erases any PCM recorded freeze frame data. Make sure to record
any PCM freeze frame information before proceeding.
Fig. 18: Fuel Injector Power & Ground Circuit (1 Of 3)



TEST PROCEDURE
AR1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308
Retrieve the continuous memory DTCs.
Are DTCs P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 or P0308 present?
Yes No
GO to AR3. GO to AR2.
AR2 RECREATE THE MISFIRE SYMPTOM USING FREEZE FRAME AND CUSTOMER INFORMATION
NOTE: To recreate the original conditions that set the DTC or caused the symptom, the vehicle may require
driving.
Access the misfire freeze frame data (if available) and record the operating conditions.
Obtain information from the customer information worksheet or any other available data from the customer.
Recreate the misfire symptom using the freeze frame and customer information.
Can the symptom be recreated?
AR3 CHECK FOR OTHER NON-MISFIRE CONTINUOUS MEMORY DTCS

Are there any non-misfire continuous memory DTCs present?
AR4 CHECK FOR ANY KEY ON ENGINE OFF (KOEO) SELF-TEST AND INJECTOR ELECTRICAL SELF-TEST DTCS
Carry out the KOEO self-test and the injector electrical self-test.
Yes No
DISREGARD the current diagnostic
trouble code (DTC) at this time.
DIAGNOSE the next DTC. GO
GO to AR5.
toDIAGNOSTIC TROUBLE CODE
(DTC) CHARTS AND
DESCRIPTIONS .
AR5 CHECK FOR ANY KEY ON ENGINE RUNNING (KOER) SELF-TEST DTCS
Carry out the KOER self-test.
Yes No
GO to AR6.
(DTC) CHARTS AND
DESCRIPTIONS .
AR6 RELATIVE COMPRESSION TEST

Carry out the Relative Compression Test. Refer to the scan tool manufacturer's article for specific information on the scan tool setup,
operation, and specific cables and/or adapters required.
Do all cylinders pass the test?
AR7 CYLINDER POWER BALANCE CHECK

Carry out the Power Balance Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
Are all cylinders contributing correctly during the power balance test?
AR8 CARRY OUT THE ELECTRIC FUEL PUMP PRESSURE TEST

Carry out the Electric Fuel Pump Pressure Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
Is the fuel pressure within specification?
Yes No
REPAIR as necessary.
GO to AR9.
AR9 CARRY OUT THE HIGH PRESSURE FUEL TEST

Are any concerns present?
Yes No
GO to AR10.
AR10 CHECK THE CRANKCASE PRESSURE

Carry out the Crankcase Pressure Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
Yes No
GO to AR15.
AR11 CHECK THE SUSPECT INJECTOR RESISTANCE AT THE 15-PIN INLINE CONNECTOR

15-Pin Inline Valve Cover Assembly connector disconnected.
Side Side
Fuel Injector, Fuel Injector,
Ground Power
Is the resistance between 150K - 250K ohms?
Yes No
GO to AR13. GO to AR12.
AR12 CHECK THE SUSPECT INJECTOR RESISTANCE AT THE FUEL INJECTOR

Suspect Fuel Injector connector disconnected.
( + ) Suspect ( - ) Suspect
Fuel Injector Fuel Injector
Component Component
Side Side
Ground Power
AR13 CHECK THE CYLINDER COMPRESSION TEST

Carry out a cylinder compression test on the suspect cylinder. Refer to ENGINE SYSTEM - GENERAL INFORMATION -- F-250-
550 (SUPER DUTY PICKUPS) .
AR14 CHECK ENGINE FOR MECHANICAL CONCERNS

Carry out a visual inspection for the following mechanical concerns:
push rods
rocker arms
valves
valve springs
Yes No
GO to AR15.
AR15 CHECK FOR CORRECT PCM OPERATION


pushed out pins
corrosion
PINPOINT TEST AT: ENGINE COOLANT TEMPERATURE AND ENGINE OIL TEMPERATURE
CORRELATION
INTRODUCTION

low engine coolant level
cooling system flow restriction
engine coolant temperature (ECT) sensor
engine oil temperature (EOT) sensor
TEST PROCEDURE
AT1 CHECK FOR AN ENGINE COOLANT LOSS OR AN ENGINE OVERHEATING CONCERN

Carry out a visual inspection. Refer to the ENGINE COOLING SYSTEM -- F250-F550 SUPER DUTY article.
Verify the pressure relief cap is capable of holding system pressure.
Verify that the coolant and cooling system maintenance has been carried out as recommended.
Is the engine overheating or losing coolant?
Yes No
REFER to the ENGINE COOLING SYSTEM -- F250-F550 GO to AT2.

SUPER DUTY article, Symptom Charts to continue diagnosis of
the engine overheats or loss of coolant symptoms.
AT2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTC)

Are there any other thermostat or cooling system DTCs present?
AT3 CHECK ECT OR EOT SENSOR FOR DAMAGE

Inspect the ECT and EOT sensor and circuits at the sensor and PCM for the following:
pinched, shorted, and corroded wiring and pins
oil or water contamination
crossed sensor wires
contaminated or damaged sensor
AT4 CHECK FOR CORRECT ECT AND EOT SENSOR OPERATION
NOTE: Verify that no accessories are in use (engine block or oil heaters).
Clear the PCM DTCs.

Cold soak the vehicle at ambient temperature for a minimum of 10 hours.
Ignition ON, engine OFF.
Access the PCM and monitor the ECT (temp) and EOT (temp) PIDs.
Access the PCM and monitor the RPM PID.
Access the PCM and monitor the MFDES (MASS) PID.

Record the ECT and EOT sensor temperature values at initial igintion ON.
Drive the vehicle at an engine speed greater than 1,800 RPM and 15mg/stroke MFDES for at least 15 minutes. Select the appropriate
gear to achieve the operating conditions.
Does the ECT PID and the EOT PID temperature values change by a minimum of 6C (10F) from when the ignition ON, engine OFF
values were recorded?
PINPOINT TEST AU: MANIFOLD ABSOLUTE PRESSURE (MAP)/BAROMETRIC PRESSURE (BARO)

CORRELATION
INTRODUCTION
BARO sensor
MAP sensor (12A697)
TEST PROCEDURE
AU1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P0069

Clear the DTCs.
Is DTC P0069 present along with other DTCs?
Yes No
GO to AU2.
(DTC) CHARTS AND
DESCRIPTIONS .
AU2 DIAGNOSTIC TROUBLE CODE (DTC) P0069
Key ON, engine OFF.

Access the PCM and monitor the BARO and MAP PIDs.
Record the BARO and MAP values.
Verify that the BARO PID reading is approximately the same as the barometric pressure reading for the location, day, and altitude where
the vehicle is being repaired.
Does the BARO PID reading compare with the daily barometric report for the local area?
AU3 COMPARE THE KOEO BARO AND MAP PID VALUES

Key ON, engine OFF.
Access the PCM and monitor the BARO and MAP PIDs.
Compare the BARO and MAP value with the KOEO value.
Is the MAP sensor reading within 10.35 kPa (1.5 psi) of the BARO reading?
AU4 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AV: MANIFOLD ABSOLUTE PRESSURE (MAP)/EXHAUST PRESSURE (EP)

CORRELATION
INTRODUCTION
MAP sensor (12A697)

EP sensor (9J460)
TEST PROCEDURE
AV1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P006B

Clear the DTCs.
Is DTC P006B present along with other DTCs?
(DTC) CHARTS AND

DESCRIPTIONS .
AV2 COMPARE THE KOEO EBP_A AND MAP PID VALUES

Key ON, engine OFF.
Access the PCM and monitor the BARO, EBP_A and MAP PIDs.
Are the EP and MAP sensor readings within 10.35 kPa (1.5 psi) of the BARO reading?
AV3 CHECK MAP SENSOR INLET FOR OBSTRUCTIONS

Remove the MAP sensor. Refer to ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES -- F-250-550 (SUPER DUTY
PICKUPS) .
Check for the following in the MAP sensor port and inlet:
contamination
restrictions
carbon build-up or deposits
AV4 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST AW: INTAKE AIR TEMPERATURE (IAT)/INTAKE AIR TEMPERATURE 2 (IAT2)
SENSOR CORRELATION
INTRODUCTION
harness circuits: IAT2, and SIGRTN

mass air flow/intake air temperature (MAF/IAT) sensor (12B579)
IAT2 sensor (12A697)
TEST PROCEDURE
AW1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P2199

AW2 DTC P2199

Cold soak the vehicle overnight.
Key ON, engine OFF.
Access the PCM and monitor the IAT and IAT2 PIDs.
Are both temperature readings within 20C (36F) of ambient temperature?
AW3 CHECK KOER IAT AND IAT 2 VALUES

Allow the engine to idle at the normal operating temperature.
Access the PCM and monitor the IAT and IAT2 PIDs.
Are the sensor values within 20C (36F) of each other?
AW4 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AX: INTAKE THROTTLE

INTRODUCTION
harness circuits: ITVF, ITVC, PWRGND and VPWR

intake throttle actuator
Fig. 21: Powertrain Control Module (PCM) (12A650)


Pin Circuit
2, 4, 6 PWRGND (Power Ground)

TEST PROCEDURE
AX1 CHECK THE VPWR CIRCUIT FOR VOLTAGE

Intake Throttle Actuator connector disconnected.
Key ON, engine OFF.
AX2 CHECK THE PWRGND CIRCUITS FOR AN OPEN

( - ) Intake
( + ) PCM-B Throttle
Connector, Actuator
Harness Side Connector,
Harness Side
PWRGND - Pin PWRGND - Pin
2, 4, 6 1
AX3 CHECK THE ITVC CIRCUIT AND ITVF CIRCUIT FOR A SHORT TO GROUND
AX4 CHECK THE ITVC CIRCUIT AND ITVF CIRCUIT FOR AN OPEN
Yes No
GO to AX5.
AX5 CHECK THE ITVC CIRCUIT AND ITVF CIRCUIT FOR A SHORT TO VOLTAGE
Key ON, engine OFF.
( + ) Intake
Throttle
Actuator (-)
Connector,
Harness Side
ITVC - Pin 3 Ground
ITVF - Pin 4 Ground
AX6 CHECK THE INTAKE THROTTLE ACTUATOR OPERATION WITH THE ENGINE OFF
Disconnect the charge air cooler (CAC) tube from the intake throttle actuator.
Intake Throttle Actuator connector connected.
Key ON, engine OFF.
Access the PCM and control the EGRTP PID.
Command the EGRTP PID to close and open the intake throttle actuator.
Visually inspect the intake throttle plate for correct operation.
Does the intake throttle actuator operate correctly?
AX7 CHECK THE INTAKE THROTTLE ACTUATOR OPERATION WITH THE ENGINE RUNNING
Connect the CAC tube to the intake throttle actuator.

Command the intake throttle actuator closed.
Does the engine stall or attempt to stall when the intake throttle is commanded closed?
AX8 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AY: BRAKE PRESSURE APPLIED (BPA) SWITCH

INTRODUCTION
BPA switch
BPA harness circuits BPS and B+
Fig. 24: Brake Pressure Applied (BPA) Switch Connector



TEST PROCEDURE
AY1 CHECK THE BPA SIGNAL
Key ON, engine OFF.

Access the PCM and monitor the BPA PID.
Monitor the BPA PID while applying and releasing the brake pedal.
Does the BPA PID state change when the brake pedal is fully applied and released?
AY2 CHECK THE BPA SWITCH

BPA Switch connector disconnected.
Point A BPA Point B BPA

Switch Switch
VBPWR - Pin 1 BPS - Pin 2
Key ON, engine OFF.

Access the PCM and monitor the BPA PID.
Record the BPA PID value.
Remove the jumper wire(s).
Does the PID change state?
AY3 CHECK THE VBPWR CIRCUIT FOR VOLTAGE

AY4 CHECK THE VBPWR CIRCUIT FOR AN OPEN

Yes No
GO to AY5.
AY5 CHECK THE VBPWR CIRCUIT FOR A SHORT TO GROUND

AY6 CHECK THE BPA SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
Key ON, engine OFF.
AY7 CHECK THE BPA SIGNAL FOR AN OPEN

Switch ( - ) PCM-B
BPS - Pin 2 BPS - Pin 9
Yes No
GO to AY8.
AY8 CHECK THE BPA SIGNAL FOR A SHORT TO GROUND

AY9 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST AZ: EXHAUST GAS RECIRCULATION (EGR) COOLER SYSTEM

INTRODUCTION
engine overheating condition

cooling system restriction
charge air cooler (CAC) system
restricted EGR cooler
TEST PROCEDURE
AZ1 PRELIMINARY DIAGNOSIS

Are any DTCs other than DTC P2457 retrieved?
AZ2 CHECK FOR ENGINE OVERHEATING CONDITION

Check for engine overheating condition or loss of coolant condition. Refer to ENGINE COOLING -- F-250-550 (SUPER DUTY
PICKUPS) .
Is the engine overheating or losing coolant?
AZ3 CHECK THE CAC SYSTEM FOR DAMAGE

Check the CAC system for:
air restrictions
debris
damaged clamps
damaged cooler fins
damaged hose
leaks
Is the CAC system operating correctly?
Yes No
REPAIR or INSTALL a new component
as necessary. REFER to ENGINE
GO to AZ4. COOLING -- F-250-550 (SUPER
DUTY PICKUPS) .
AZ4 RECREATE EGR COOLER PERFORMANCE CONDITIONS

Clear the PCM DTCs.
Road test the vehicle to recreate the EGR cooler performance condition DTC P2457 using the freeze frame data.
Retrieve and record the PCM continuous DTCs.
Is DTC P2457 retrieved?
AZ5 CHECK THE EGR COOLERS FOR RESTRICTIONS

Remove the EGR coolers. Refer to EXHAUST SYSTEM -- F-250-550 (SUPER DUTY PICKUPS) .
Check the EGR cooler exhaust ports, coolant ports and coolant hoses for restrictions.
Is either EGR cooler restricted?
Yes No
REPAIR the restricted EGR cooler or
INSTALL a new EGRT 2 sensor. REFER
coolant hose as necessary. INSTALL a
to ELECTRONIC ENGINE
new EGR cooler or coolant hose as
CONTROLS - GASOLINE ENGINES
necessary. REFER to the EXHAUST
-- F-250-550 (SUPER DUTY
SYSTEM -- F-250-550 (SUPER DUTY
PICKUPS) .
PICKUPS) .
PINPOINT TEST B: REFERENCE VOLTAGE (VREF)

INTRODUCTION
harness circuits: VREF and SIGRTN

accelerator pedal position (APP) sensor (9F836)
diesel particulate filter pressure sensor
exhaust gas recirculation (EGR) valve
exhaust pressure (EP) sensor
fuel rail pressure (FRP) sensor (6B288)
manifold absolute pressure (MAP) sensor (9F479)
power take-off (PTO) system or auxiliary idle control
Fig. 27: Accelerator Pedal Position (APP) Sensor Connector (1 Of 4)



Pin Circuit

Fig. 31: Manifold Absolute Pressure (MAP) Sensor C1087

Pin Circuit


Pin Circuit

TEST PROCEDURE
B1 DTCS P0642, P0643, P0652 AND P0653: PRELIMINARY DIAGNOSIS

Clear all the DTCs.
Are DTCs P0642, P0643, P0652, P0653 present, or were you directed here from another pinpoint test?
For symptoms without DTCs, GO to B2.

For all others, RETURN to the
GO to B2.
SYMPTOM CHARTS article, Symptom
Charts for further direction.
B2 CHECK FOR VOLTAGE BETWEEN THE VREF AND SIGRTN CIRCUITS

Suspect Sensor connector disconnected.
Key ON, engine OFF.
B3 CHECK THE VREF CIRCUIT FOR VOLTAGE

Yes No
GO to B15. GO to B4.
B4 CHECK THE VREF CIRCUIT VOLTAGE WITH ALL SENSORS DISCONNECTED
NOTE: For DTC P0642, the primary causes are concerns with the MAP sensor, EGR valve, EP sensor, FRP sensor
or VREF circuits in the PCM E connector.
NOTE: For DTC P0652, the primary causes are concerns with the APP sensor, diesel particulate filter pressure
sensor, PTO/auxiliary idle control or VREF circuits in the PCM B connector.
NOTE: When disconnecting the FRP sensor, disconnect the 15 pin inline connector.
NOTE: Leave all sensors disconnected until instructed in each step to connect each sensor leaving each sensor
connected until all sensors are connected to isolate the concern.

Disconnect the following sensors connected to the VREF circuit:
MAP sensor
EGR valve
EP sensor
APP sensor
diesel particulate filter pressure sensor
FRP sensor
PTO or auxiliary idle control
Key ON, engine OFF.
Measure the voltage at the sensor disconnected in step B2.
Yes No
GO to B8. GO to B5.
B5 CHECK THE VREF CIRCUIT FOR A SHORT TO GROUND AND SIGRTN

( + ) Suspect
Sensor
(-)
Connector,
Harness Side
VREF Ground
B6 CHECK THE VREF CIRCUIT FOR AN OPEN



Harness Side
VREF - Pin 21,
VREF
22
Yes No
GO to B7.
B7 CHECK THE VREF CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
( + ) PCM-B
Connector, (-)
Harness Side
VREF - Pin 18,
Ground
20, 7
B8 CHECK THE VREF VOLTAGE WITH THE MAP SENSOR CONNECTED

MAP Sensor connector connected.
Key ON, engine OFF.
( + ) Suspect
Sensor
(-)
Connector,
Harness Side
VREF Ground
Yes No
INSTALL a new MAP sensor. REFER to
ELECTRONIC ENGINE CONTROLS
GO to B9. - GASOLINE ENGINES -- F-250-550
B9 CHECK THE VREF VOLTAGE WITH THE EGR VALVE CONNECTED

EGR Valve connector connected.
Key ON, engine OFF.
B10 CHECK THE VREF VOLTAGE WITH THE EP SENSOR CONNECTED

EP Sensor connector connected.
Key ON, engine OFF.
( + ) Suspect
Sensor
(-)
Connector,
Harness Side
VREF Ground
B11 CHECK THE VREF VOLTAGE WITH THE APP SENSOR CONNECTED

APP Sensor connector connected.
Key ON, engine OFF.
B12 CHECK THE VREF VOLTAGE WITH THE DIESEL PARTICULATE FILTER PRESSURE SENSOR CONNECTED
NOTE: If this sensor was used for the VREF measurement in Step B4, GO to B13.

Diesel Particulate Filter Pressure Sensor connector connected.
Key ON, engine OFF.
( + ) Suspect
Sensor
(-)
Connector,
Harness Side
VREF Ground
B13 CHECK THE VREF VOLTAGE WITH THE FRP SENSOR CONNECTED

FRP Sensor connector connected.
Key ON, engine OFF.
VREF Ground
Yes No
If equipped with a PTO system or an
auxiliary idle control, GO to B14.
For all others, Unable to duplicate the
condition. CHECK for a loose
INSTALL a new FRP sensor. REFER to
connection, and damaged or corroded
terminals. WIGGLE the harness
- GASOLINE ENGINES -- F-250-550
attempting to recreate the concern.
REPAIR as necessary. REFER toNO
DIAGNOSTIC TROUBLE CODES
(DTCS) PRESENT SYMPTOM
CHART INDEX , if a driveability
concern exists.
B14 CHECK THE VREF VOLTAGE WITH THE PTO SYSTEM OR AUXILIARY IDLE CONTROL CONNECTED
PTO connector connected.
Key ON, engine OFF.
B15 CHECK THE SIGRTN CIRCUIT FOR AN OPEN

( - ) Suspect
( + ) PCM-B
Sensor
Connector,
Connector,
Harness Side
Harness Side
SIGRTN - Pin
SIGRTN
21, 22, 50

B16 CHECK THE SUSPECT SENSOR FOR AN INTERNAL SHORT

Clear the KOEO, KOER, and continuous DTCs.
Suspect Sensor connector connected.
Key ON, engine OFF.

B17 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST C: CLUTCH PEDAL POSITION (CPP) SWITCH

INTRODUCTION
CPP switch (11A152/7C534)

harness circuits: CPP / CPP BT and SIGRTN / GND
Fig. 35: Clutch Pedal Position (CPP) Switch Connector

TEST PROCEDURE
C1 CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) P0704: CHECK THE CPP SWITCH
WARNING: Block all wheels, set the parking brake and firmly apply the service
brake to reduce the risk of vehicle movement during this procedure.
Failure to follow these instructions may result in serious personal
injury.
NOTE: During self-test, the clutch pedal must be down and gearshift lever in NEUTRAL.
Key ON, engine OFF.

Access the PCM and monitor the CPP PID.
Press and Release Clutch Pedal.
Does the CPP PID cycle when the clutch pedal is pressed and released?
Yes No
This may be an intermittent circuit
concern. INSPECT connectors for signs
GO to C2.
of damage, water intrusion, corrosion.
C2 CHECK THE CPP FOR A INTERNAL OPEN

Inspect the switches and brackets for damage. Repair as necessary.
CPP Switch connector disconnected.
C3 CHECK THE SWITCH CIRCUIT RESISTANCE

Press the clutch pedal.
Component Component
Side Side
CPP-BT - Pin 5 GND - Pin 6
Yes No
INSTALL a new CPP switch. CLEAR
GO to C4.
the DTCs. REPEAT the self-test.
C4 CHECK THE CPP FOR INTERNAL SHORTS
Release the clutch pedal.

Are the resistances less than 10K ohms?
C5 CHECK THE VPWR CIRCUIT

Key ON, engine OFF.
C6 CHECK THE CPP AND GROUND CIRCUITS FOR AN OPEN IN THE HARNESS
PCM Connector disconnected.
( + ) CPP
( - ) PCM-B
Switch
Connector,
Connector,
Harness Side
Harness Side
CPP-BT - Pin
CPP-BT - Pin 5
25
CPP-TT - Pin 4 CPP-TT - Pin 16
Yes No
GO to C7.
C7 CHECK THE GROUND CIRCUIT

C8 CHECK FOR CORRECT PCM OPERATION

pushed out pins.
corrosion.
Yes No
PINPOINT TEST D: CRANKSHAFT POSITION (CKP) SENSOR

INTRODUCTION
CKP sensor (6C315)

harness circuits: CKP(+) and CKP(-)
Fig. 37: Crankshaft Position (CKP) Sensor Connector

Pin Circuit
2 CKP- (Crankshaft Position Sensor Negative)

TEST PROCEDURE
D1 CHECK THE CKP SENSOR SIGNAL SENT TO THE PCM
Key ON, engine OFF.

Crank the engine.
Is the RPM greater than 150 RPM?
D2 CHECK FOR PROPER CKP BIAS VOLTAGES IN THE PCM

CKP Sensor connector disconnected.
Key ON, engine OFF.
( + ) CKP
Sensor
(-)
Connector,
Harness Side
CKP+ - Pin 1 Ground
CKP- - Pin 2 Ground
Are the voltages between 1 - 3 V?
D3 CHECK THE CKP SENSOR RESISTANCE

D4 CHECK THE CKP HARNESS SHIELD GROUND
(+)
CKP_SHLD
Assembly (-)
Connector,
Harness Side
CKP_SHLD Ground
Yes No
REPAIR the open circuit.
GO to D5. CHECK for a poor ground connection.
D5 CHECK FOR SHORT BETWEEN CKP(+) AND CKP(-) IN THE HARNESS

D6 CHECK THE CKP CIRCUIT(S) FOR AN OPEN IN THE HARNESS


GO to D7.
D7 CHECK THE CKP CIRCUIT(S) FOR A SHORT TO GROUND IN THE HARNESS

( + ) CKP
Sensor ( - ) Vehicle
Connector, Battery
Harness Side
Negative
CKP+ - Pin 1
terminal
Negative
CKP- - Pin 2
terminal
D8 CHECK THE CKP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS

Key ON, engine OFF.
D9 CHECK THE CKP AND CMP HARNESS FOR INTERMITTENT CONCERNS

Visually check for chafed CKP and CMP wires or other physical damage to the CKP or CMP harness.
Yes No
GO to D10.
D10 CHECK THE PHYSICAL CONDITION OF THE CRANKSHAFT PULSE WHEEL
INSPECT the crankshaft pulse wheel for damaged teeth.

Inspect the crankshaft pulse wheel for wobble.
Check for a loose crankshaft pulse wheel.
Check the CKP sensor for damage.
Are the CKP sensor and crankshaft pulse wheel OK?
D11 CHECK FOR CORRECT PCM OPERATION

pushed out pins.
corrosion.
PINPOINT TEST DF: VEHICLE SPEED SENSOR (VSS)

INTRODUCTION
anti-lock brake system (ABS) module

harness circuit: VSS
powertrain control module (PCM)
Fig. 39: Anti-lock Brake System (ABS) Module Connector


TEST PROCEDURE
DF1 DIAGNOSTIC TROUBLE CODE (DTC) P0500, P0503, P1501, P174E, P215A AND P215B
DF2 CHECK THE PCM VEHICLE SPEED SIGNAL INPUT

Access the PCM and monitor the VSS PID.
Road test the vehicle while monitoring the VSS PID.
Does the VSS PID increase as the vehicle speed is increased and decrease as the vehicle speed is decreased?
CHARTS article, Symptom Charts, if a

driveability concern exists.
DF3 CHECK THE VEHICLE SPEED SIGNAL CIRCUIT FOR AN OPEN

Anti-lock Brake System (ABS) Module connector disconnected.
( - ) Anti-lock
( + ) PCM-B Brake System
Connector, (ABS) Module
Harness Side
VSS - Pin 40 VSS - Pin 21
DF4 CHECK THE VEHICLE SPEED SIGNAL CIRCUIT FOR A SHORT TO GROUND
DF5 CHECK THE VEHICLE SPEED SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
Key ON, engine OFF.
VSS - Pin 40 Ground
Yes No
If the DTC is present again,
GO to DF9.
DF6 COMPARE THE PCM VSS VALUE TO THE ABS VSS VALUE
Road test the vehicle while monitoring the PCM VSS PID and the ABS VSS PID.
Do both VSS PIDs match?
DF7 COMPARE THE PCM VSS VALUE TO THE TCM VSS VALUE
Road test the vehicle while monitoring the PCM VSS PID and the TCM VSS PID.
Do both VSS PIDs match?
DF8 COMPARE THE TCM VSS TO THE ABS VSS VALUE

Road test the vehicle while monitoring the PCM VSS, TCM VSS and the ABS VSS PID.
Do all VSS PIDs match?
250-550 (SUPER DUTY PICKUPS) to

continue diagnostics.
DF9 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST E: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

INTRODUCTION
harness circuits: MAP, SIGRTN, and VREF

MAP sensor (12A697)
MAP SENSOR
1.93 250 36.26
2.32 300 43.51
2.72 350 50.76
3.11 400 58.02
3.51 450 65.27
3.90 500 72.52
4.30 550 79.77
4.69 600 87.02
4.82 616 89.34


Pin Circuit
54 MAP (Manifold Absolute Pressure)
TEST PROCEDURE
E1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P0106, P0107, OR P0108
Clear the DTCs.
Are DTCs P0106, P0107 or P0108 present?
E2 CHECK THE MAP SENSOR FOR BIAS
Access the PCM and monitor the MAP PID.

Key ON, engine OFF.
Is the PID voltage within 0.5 volts for the given pressure?
E3 MAP SENSOR CORRELATION TEST

Access the PCM and monitor the MAP, EBP_A and BARO PIDs.
Is the MAP sensor reading within 10.35 kPa (1.5 psi) of the BARO and EBP_A readings?
Yes No
INSTALL a new MAP sensor. REFER to
necessary. REFER to the SYMPTOM
CHARTS article, if a driveability
concern exists.
E4 CHECK FOR VREF VOLTAGE AT THE MAP SENSOR

MAP Sensor connector disconnected.
Key ON, engine OFF.
Is the voltage between 4.5 - 5.5 V?
E5 CHECK THE MAP SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

E6 CHECK THE MAP SIGNAL CIRCUIT FOR A SHORT TO GROUND

( + ) MAP ( - ) MAP
Sensor Sensor
MAP - Pin 3 SIGRTN - Pin 1
E7 CHECK THE MAP SIGNAL CIRCUIT FOR AN OPEN

E8 CHECK THE MAP SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

( + ) MAP
( - ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
SIGRTN - Pin
SIGRTN - Pin 1
55
Yes No
GO to E9.
E9 CHECK THE MAP SENSOR CIRCUIT

Key ON, engine OFF.
Access the PCM and monitor the MAP PID.
E10 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST F: INTAKE AIR TEMPERATURE (IAT) SENSOR

INTRODUCTION
harness circuits: IAT, and SIGRTN

IAT SENSOR SPECIFICATIONS
Fig. 43: Electronic Throttle Body Throttle Position Sensor (ETBTPS) Connector
Pin Circuit
1 IAT (Intake Air Temperature)

TEST PROCEDURE
F1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0112, P0113 OR P0114
Access the freeze frame data (if available) and record the DTC malfunction conditions.
Clear all the DTCs.
Carry out the on-demand self-test.
Yes No
For DTC P0112, GO to F2. WIGGLE the harness attempting to
For DTC P0113, GO to F4. recreate the concern. REPAIR as
For DTC P0114, GO to F8. necessary. REFER toNO DIAGNOSTIC
F2 DTC P0112 : INDUCING DTC P0113

MAF/IAT Sensor connector disconnected.
Key ON, engine OFF.
Is the DTC P0113 present?
F3 CHECK THE IAT SIGNAL CIRCUIT FOR A SHORT TO GROUND OR SIGNAL RETURN
IAT - Pin 1 Ground
( + ) MAF/IAT ( - ) MAF/IAT
Sensor Sensor
IAT - Pin 1 SIGRTN - Pin 2
F4 DTC P0113: INDUCING DTC P0112

Key ON, engine OFF.

F5 CHECK THE IAT SIGNAL CIRCUIT FOR AN OPEN

( - ) MAF/IAT
( + ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
IAT - Pin 59 IAT - Pin 1
F6 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN

F7 CHECK THE IAT SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
Yes No
GO to F9.
F8 DTC P0114: INTERMITTENT CHECK

Key ON, engine OFF.
Access the PCM and monitor the IAT PID.
While observing the PID, carry out the following:
Wiggle all accessible harness from the MAF/IAT sensor to the PCM and lightly tap on the sensor.
Wiggle the MAF/IAT sensor connector.
Look for sudden changes in the temperature or voltage when the harness and connector are wiggled or when the MAF/IAT sensor
is tapped.
F9 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST G: INTAKE AIR TEMPERATURE 2 (IAT2) SENSOR

INTRODUCTION
harness circuits: IAT2 and SIGRTN

IAT2 sensor (12A697)
IAT2 SENSOR SPECIFICATIONS
Fig. 45: Intake Air Temperature 2 (IAT2) Sensor

Pin Circuit
B SIGRTN (Signal Return)
A IAT2 (Intake Air Temperature 2)

Pin Circuit
87 IAT2 (Intake Air Temperature 2)
TEST PROCEDURE
G1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0096, P0097, OR P0098

Clear all the DTCs.
Yes No
For KOER and continuous memory DTC damaged or corroded terminals.
P0096, GO to G2. WIGGLE the harness attempting to
For DTC P0097, GO to G3. recreate the concern. REPAIR as
For DTC P0098, GO to G5. necessary. REFER to the SYMPTOM
G2 CHECK THE IAT2 SENSOR OPERATION

Clear the continuous DTCs.
Key ON, engine OFF.
Access the PCM and monitor the IAT2 and EOT PIDs.
Record the IAT2 PID value.
Verify the EOT PID is greater than 82C (180F).
Access the PCM and monitor the IAT2 PID.

Does the IAT2 PID value change from the initial recorded value?
G3 DTC P0097: INDUCE DTC P0098

IAT2 Sensor connector disconnected.
INSTALL a new IAT2 sensor.

GO to G4.
G4 CHECK THE IAT2 SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND OR SIGNAL RETURN
( + ) IAT2
Sensor
(-)
Connector,
Harness Side
IAT2 - Pin A Ground
( + ) IAT2 ( - ) IAT2
Sensor Sensor
IAT2 - Pin A SIGRTN - Pin B
G5 DTC P0098: INDUCE DTC P0097

IAT2 Sensor connector disconnected.
Key ON, engine OFF.

Yes No
INSTALL a new IAT2 sensor.
GO to G6.
G6 CHECK THE SIGNAL CIRCUIT FOR AN OPEN

( - ) IAT2
( + ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
IAT2 - Pin 87 IAT2 - Pin A
G7 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN

G8 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
Sensor
Connector, (-)
Harness Side
IAT2 - Pin A Ground
Yes No
GO to G9.
G9 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST I: PARKING BRAKE APPLIED (PBA) SWITCH

INTRODUCTION
PBA switch
parking brake signal circuit short to ground
parking brake signal circuit open
Fig. 47: Parking Brake Applied (PBA) Switch Connector


TEST PROCEDURE
I1 DIAGNOSTIC TROUBLE CODE (DTC) P1536
NOTE: When performing the key on engine running (KOER) self-test, wait 5 seconds after beginning the test
before operating the parking brake.
Key ON, engine OFF.

Access the PCM and monitor the PARK_BRK PID.
Apply and release the parking brake.
Does the PARK_BRK PID indicate OFF with the parking brake released and ON with the parking brake applied?
I2 CHECK THE PBA SWITCH

PBA Switch connector disconnected.
Key ON, engine OFF.
Access the PCM and monitor the PARK_BRK PID.
Does the PARK_BRK PID indicate OFF?
I3 CHECK THE PARKING BRAKE SIGNAL CIRCUIT FOR A SHORT TO GROUND

I4 CHECK THE PARKING BRAKE SIGNAL CIRCUIT VOLTAGE

PBA Switch connector disconnected.

Key ON, engine OFF.
I5 CHECK THE PARKING BRAKE CIRCUIT FOR AN OPEN

I6 CHECK THE PARKING BRAKE GROUND CIRCUIT FOR AN OPEN

GND - Pin 2 Ground
Yes No
INSTALL a new PBA switch. REPAIR the open circuit. CLEAR the
CLEAR the DTCs. REPEAT the self-test. DTCs. REPEAT the self-test.
I7 CHECK FOR CORRECT PCM OPERATION


pushed out pins
corrosion
PINPOINT TEST J: MASS AIR FLOW (MAF) SENSOR

INTRODUCTION

harness circuits: MAF, MAF RTN, and vehicle power (VPWR)
Fig. 49: Electronic Throttle Body Throttle Position Sensor (ETBTPS) Connector

TEST PROCEDURE
J1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0101, P0102, P0103, P0104, P1102 AND P1103
Clear all the DTCs.
Carry out the KOEO on-demand self-test.
Carry out the KOER on-demand self-test.
Are DTCs P0101, P0102, P0103, P0104, P1102 or P1103 present?
J2 DTCS P1102 AND P1103
Check the air filter element and housing for contamination, blockage or water intrusion.
Disconnect the air inlet and check for restrictions and water intrusion.
Check the MAF/IAT sensor for contamination.
Charge air cooler (CAC) system leaks (hoses and cooler).
Charge air cooler (CAC) restriction.
Are any leaks, restrictions or contamination present?
J3 DTCS P0101 AND P0102

Inspect the air intake for restrictions.
Yes No
REMOVE the restriction. REPAIR the
system as necessary. GO to J4.
J4 CHECK THE VPWR CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
J5 CHECK THE MAF AND MAF RTN CIRCUITS FOR AN OPEN IN THE HARNESS
J6 CHECK THE MAF SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

( + ) MAF/IAT
Sensor
(-)
Connector,
Harness Side
MAF - Pin 3 Ground
Yes No
GO to J11.
J7 DTC P0103: SIMULATE THE OPPOSITE SIGNAL

Inspect the air inlet for restrictions or water intrusions.
The MAF/IAT sensor is disconnected to simulate the opposite DTC.
Key ON, engine OFF.
J8 CHECK THE MAF SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
Yes No
GO to J9.
J9 CHECK THE MAF RETURN CIRCUIT FOR AN OPEN

( + ) MAF/IAT
( - ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
MAF RTN - Pin MAF RTN - Pin
5 57
J10 CHECK FOR INTERMITTENT CIRCUIT FAULTS

Key ON, engine OFF.
Access the PCM and monitor the MAF_F PID.
Shake, wiggle, and bend the MAF/IAT sensor circuits.
Lightly tap on the MAF/IAT sensor to simulate road shock.
Does the MAF_F PID change in value?
J11 CHECK THE MAF SIGNAL TO THE PCM

Key ON, engine OFF.
Access the PCM and monitor the MAF_HZ PID.
Monitor the MAF_HZ PID at KOEO and record the value.
Monitor the MAF_HZ PID at idle and record the value.
Does the MAF_HZ PID change in value from greater than 13 kHz to less than 5 kHz at idle?
Yes No
INSTALL a new MAF/IAT sensor.
REFER to ELECTRONIC ENGINE
CONTROLS - GASOLINE ENGINES
GO to J12.
-- F-250-550 (SUPER DUTY
PICKUPS) .
J12 CHECK MAF SENSOR OPERATION

Access the PCM and monitor the MAF_HZ PID.
Access the PCM and monitor the EGRTP, EGRVPA and VGTDC PIDs.
Access the PCM and control the EGRVPA PID.
Decrease the EGRVPA PID to 0%.
Decrease the EGRTP PID to 5%.
Access the PCM and control the RPM PID.
Increase the commanded engine speed to 2,000 RPM.
Record the MAF_Hz PID value.
Record the MAF_Hz PID value.
Is the MAF_Hz PID between 2.75 - 2.9 Hz at 90% VGTDC duty cycle and 3.15 - 3.3 Hz at 0% VGTDC duty cycle?
J13 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST K: ENGINE COOLANT TEMPERATURE (ECT) SENSOR

INTRODUCTION
ECT sensor (12A648)

harness circuits: ECT and SIGRTN
TEMPERATURE VS. RESISTANCE VALUES (APPROXIMATE)

25 77 30,000
20 68 37,352
15 59 46,797
10 50 59,016
5 41 74,940
0 32 95,851
-5 23 123,485
-10 14 160,313
-15 5 209,816
-20 -4 276,959
Fig. 51: Engine Coolant Temperature (ECT) Sensor Circuit


TEST PROCEDURE
K1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0117, P0118 AND P0128

Clear all the DTCs.
Are DTCs P0117, P0118, or P0128 present?
K2 DTC P0117

ECT Sensor connector disconnected.
Key ON, engine OFF.
K3 CHECK THE ECT SIGNAL CIRCUIT FOR A SHORT TO GROUND

Harness Side
ECT - Pin 2 Ground
Is the resistance greater than 10,000 ohms?
Yes No
GO to K10.
K4 DTC P0118
Simulate the opposite DTC.
Key ON, engine OFF.

K5 CHECK THE ECT SIGNAL CIRCUIT FOR AN OPEN

Is the resistance less then 5 ohms?

GO to K6.
K6 CHECK THE ECT SIGNAL RETURN CIRCUIT FOR AN OPEN

( - ) ECT
( + ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
SIGRTN - Pin
SIGRTN - Pin 1
55
Is the resistance less then 5 ohms?
K7 CHECK THE ECT SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
K8 DTC P0128: CHECK THE ENGINE COOLANT LEVEL
Check the engine coolant level.

Is the engine coolant fill level correct?
Yes No
REFER to ENGINE COOLING -- F-
250-550 (SUPER DUTY PICKUPS) for
cooling system diagnosis.
GO to K9.
CLEAR the DTCs.
REPEAT the self-test.
K9 CHECK THE SENSOR OPERATION

Run the engine until the engine temperature stabilizes.
Verify the radiator hoses are hot and the cooling system is pressurized.
Access the PCM and monitor the ECT PID.
Is the temperature greater than 77C (170.6F) ?
Yes No
The test is complete.
DISREGARD the current diagnostic REFER to ENGINE COOLING -- F-
trouble code (DTC) at this time. 250-550 (SUPER DUTY PICKUPS) for
DIAGNOSE the next DTC. GO cooling system diagnosis.
toDIAGNOSTIC TROUBLE CODE REPAIR as necessary.
(DTC) CHARTS AND REPEAT the self-test.
DESCRIPTIONS .
K10 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST KA: TURBOCHARGER SYSTEM PERFORMANCE

INTRODUCTION
turbocharger system performance

turbocharger air leaks
TEST PROCEDURE
KA1 PRELIMINARY DIAGNOSIS

Clear the DTCs.
KA2 TURBOCHARGER ACTUATOR VISUAL INSPECTION

Inspect the turbocharger actuator linkage for damage.
Inspect for obstructions in the turbocharger actuator linkage travel.
Are there any concerns found during the visual inspection?
KA3 CHECK THE MECHANICAL OPERATION OF THE TURBOCHARGER ACTUATOR
Manually move the turbocharger actuator linkage toward the front of the vehicle.
Does the actuator linkage move and quickly return to the start position when released?
GO to KA4. GO to AK3.
KA4 CHECK FOR INPUT SENSOR BIAS

Key ON, engine OFF.
Refer to the REFERENCE VALUES article, Reference Values for normal operating values.
Are the BARO, EBP_A and MAP PIDs within specifications and is the EBP_A PID within 10.35 kPa (1.5 psi) of the MAP and
BARO PID values?
KA5 CHECK THE ELECTRICAL OPERATION OF THE TURBOCHARGER ACTUATOR

Access the PCM and monitor the VGT_MES PID.
Does the turbocharger actuator operate as commanded?
KA6 CHECK THE EGR VALVE OPERATION
Check the EGR valve operation. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES , Exhaust Gas Recirculation (EGR)
System Test.
KA7 CHECK THE TURBOCHARGER OPERATION BOOST
NOTE: Additional DTCs may set during the use of output state control (OSC).
Clear all PCM and transmission control module (TCM) DTCs after the
diagnostics have been completed. Repeat the self-test to verify all DTCs
have been cleared.


Access the PCM and monitor the MGP PID.
Access the PCM and monitor the EGRTP, EGRVPA and VCTDC PIDs.
Increase the commanded engine speed to 1,500 RPM using output state control.
Record the MGP PID value.
Record the MGP PID value.
Is the MGP PID below 1 kPa (0.15 PSI) at 0% VGTDC duty cycle and above 30 kPa (4.35 PSI) at 90% VGTDC duty cycle?
KA8 CHECK THE TURBOCHARGER OPERATION BACK PRESSURE

Access the PCM and monitor the EBP_A PID.
Access the PCM and monitor the EGRTP, EGRVPA and VCTDC PIDs.

Increase the commanded engine speed to 1,500 RPM using output state control.
Record the EBP_A PID value.
Record the EBP_A PID value.
Is the EBP_A PID below 120 kPa (17.4 PSI) at 0% VGTDC duty cycle and above 200 kPa (29 PSI) at 90% VGTDC duty cycle?
KA9 CHECK THE CHARGE AIR COOLER, AIR INTAKE AND EXHAUST SYSTEMS FOR LEAKS AND RESTRICTIONS

Remove the EP sensor.
Plug the exhaust pipe.
Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the exhaust system.
Fill the exhaust system with smoke.
Pressurize the exhaust system with 20 PSI regulated shop air.
Check the exhaust system for leaks and restrictions.
Remove the intake air temperature 2 (IAT2) sensor.
Plug the intake air system.
Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the intake air system.
Fill the intake air system with smoke.
Pressurize the intake air system with 20 PSI regulated shop air.
Check the intake air system for leaks and restrictions.
Are any leaks or restrictions present?
PINPOINT TEST L: ENGINE OIL TEMPERATURE (EOT) SENSOR

INTRODUCTION
EOT sensor (12A648)

harness circuits: EOT and SIGRTN

40 104 16,092
35 95 19,696
30 86 24,329
25 77 30,000
20 68 37,352
15 59 46,797
10 50 59,016
5 41 74,940
0 32 95,851
-5 23 123,485
-10 14 160,313
-15 5 209,816
-20 -4 276,959
Fig. 53: Engine Oil Temperature (EOT) Sensor Circuit


Pin Circuit
63 EOT (Engine Oil Temperature)
TEST PROCEDURE
L1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0196, P0197, P0198, P0298 OR P1184
Clear the DTCs.
Are DTCs P0196, P0197, P0198, P0298 or P1184 present?
L2 CHECK SENSOR CONNECTIONS

Inspect the EOT sensor circuitry at the sensor and PCM. Inspect for damaged, loose or pushed-out pins, and loose or poorly crimped
wires.
Are all connectors and terminals OK?
L3 CHECK THE EOT SENSOR OPERATION
Clear the DTCs.

Verify the engine temperature is at ambient room temperature before continuing with this test. A soak period of 6 hours may be required.
Key ON, engine OFF.
Access the PCM and monitor the EOT PID.
Access the PCM and monitor the MFDES PID.
Record the EOT sensor temperature value.
Drive the vehicle at an engine speed greater than 1,800 RPM and 15 mg/stroke MFDES for at least 15 minutes. Select the appropriate
gear to achieve the operating conditions.
Does the EOT sensor temperature value change by at least 6C (10F) off the key ON value recorded?
Yes No
INSTALL a new EOT sensor.
GO to L4.
L4 CHECK THE COOLING SYSTEM

Drive the vehicle an additional 15 minutes at an engine speed greater than 1,800 RPM and 15 mg/stroke MFDES.
Does the EOT sensor temperature reading increase above 50C (122F)?
L5 CHECK THE PCM FOR DTCS

Key ON, engine OFF.
L6 SIMULATE OPPOSITE DTC
NOTE: The EOT sensor is disconnected to simulate the opposite DTC.

EOT Sensor connector disconnected.
Check for damaged, pushed-out, or corroded pins.
Key ON, engine OFF.
Yes No
GO to L7.
L7 CHECK THE EOT SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

L8 CHECK FOR A OPEN ON THE EOT CIRCUIT

Yes No
REPAIR the circuit.
GO to L9.
L9 SIMULATE THE OPPOSITE DTC

Key ON, engine OFF.
Point A EOT Point B EOT

Sensor Sensor
SIGRTN - Pin 1 EOT - Pin 2

L10 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
Is the voltage less than 0.2 V?
L11 CHECK THE SIGNAL CIRCUIT FOR AN OPEN

( - ) EOT
( + ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
EOT - Pin 63 EOT - Pin 2
Yes No
REPAIR the circuit.
GO to L22.
L12 CARRY OUT THE KEY ON ENGINE RUNNING (KOER) SELF-TEST

Verify no KOEO DTCs are present.
Drive the vehicle until the thermostat opens.
Carry out the KOER Cylinder Contribution self-test.
L13 EOT SENSOR CHECK

Key ON, engine OFF.
Monitor the EOT PID while tapping on the EOT sensor.
Does the EOT value fluctuate or decrease below 20C (68F) (3.82 volts)?
L14 CHECK THE VEHICLE HARNESS

Monitor the EOT PID while carrying out the following:
Grasp the vehicle harness close to the EOT sensor connector.
Wiggle and shake vehicle harness while working toward PCM.
Does the EOT PID value fluctuate?
Yes No
GO to L15.
L15 CHECK THE PCM AND VEHICLE HARNESS CONNECTORS

Inspect for damaged, loose, or pushed-out pins.
Are connectors and terminals OK?
L16 CHECK FOR A BIASED EOT SENSOR
Key ON, engine OFF.
Access the PCM and monitor the EOT and IAT PIDs.
Are the EOT and IAT PID values within 6C (11F)?
L17 INSPECT THE EOT SENSOR

Inspect the EOT sensor circuitry at the sensor and PCM.
Inspect for damaged, loose or pushed-out pins, and loose or poorly crimped wires.
Yes No
GO to L18.
L18 CHECK THE COOLING SYSTEM

Check the coolant system for correct level.
Check the radiator for correct performance. Verify there are no airflow obstructions across the radiator core and that the radiator core is
not plugged.
Verify the correct cooling fan/clutch operation.

Verify the correct thermostat operation.
Is the coolant system OK?
L19 CHECK FOR EOT SENSOR DTCS

Are other DTCs present?
L20 CHECK THE EOT SENSOR OPERATION

Key ON, engine OFF.
Is EOT sensor PID equal to ambient temperature?
Yes No
GO to L21.
L21 CONFIRM THE PCM CONCERN

Operate the engine for approximately 15 to 20 minutes.
Yes No
OPERATE the vehicle. VERIFY the
EOT PID does not increase above 110C
(230F) with an engine speed less than
GO to L22. 1,000 RPM. REFER toNO
CHART INDEX .
L22 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST M: FUEL SYSTEM

INTRODUCTION
NOTE: Regeneration may occur during normal operation. During regeneration,

diagnostic procedures may display biased values. If a regeneration occurs
during diagnostic procedures, allow the process to complete before continuing
diagnostics.
fuel injector
fuel pressure control valve
fuel rail pressure (FRP) sensor
fuel volume control valve
high pressure fuel injection pump
low pressure fuel system
Fig. 55: Fuel Rail Pressure (FRP) Sensor Circuit (1 Of 4)


Pin Circuit


4 Fuel Injector 4, Ground

3 Fuel Injector 2, Power
TEST PROCEDURE
M1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

Access the freeze frame data (if available) and record the DTC conditions.
Clear the DTCs.
M2 DTCS P000E, P0087, P0088, P0263 THROUGH P0284, P02CC THROUGH P02DB, P117F, P127A AND P2291: CHECK
ENGINE OIL LEVEL
Carry out the Check Engine Oil Level test. Refer toHARD START/NO START DIAGNOSTIC PROCEDURES .
M3 VERIFY FUEL QUALITY

Carry out the Sufficient Clean Fuel Test. Refer toHARD START/NO START DIAGNOSTIC PROCEDURES .
Yes No
GO to M4.
M4 CARRY OUT THE ELECTRIC FUEL PUMP PRESSURE TEST

Yes No
For DTCs P0087, P0088 and P2291, GO
to M11.
For all others, GO to M5.
M5 CYLINDER POWER BALANCE CHECK

Carry out the Power Balance Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
Are all cylinders contributing correctly during the power balance test?
M6 CHECK THE SUSPECT INJECTOR AND CIRCUIT RESISTANCE

( + ) 15-Pin ( - ) 15-Pin
Inline Valve Inline Valve
Cover Cover
Assembly Assembly
Component Component
Side Side
Ground Power
Yes No
For DTCs P000E and P117F, GO to M13.
GO to M7.
For all others, GO to M8.
M7 CHECK THE SUSPECT INJECTOR RESISTANCE AT THE FUEL INJECTOR

M8 CRANKCASE AND COMPRESSION TESTS

Carry out the Crankcase Pressure Test. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES .
Carry out a cylinder compression test on the suspect cylinder.
Yes No
GO to M9.
M9 CARRY OUT A VISUAL INSPECTION

Carry out a visual inspection for the following mechanical concerns:
push rods
rocker arms
valves
valve springs
Yes No
INSTALL a new Fuel Injector. REFER to
REPAIR as necessary. REFER to FUEL SYSTEM - GENERAL
ENGINE SYSTEM - GENERAL INFORMATION - GASOLINE AND
INFORMATION -- F-250-550 (SUPER DIESEL -- F-250-550 (SUPER DUTY
DUTY PICKUPS) . PICKUPS) .
M10 DTCS P0191, P120F AND P2289: CARRY OUT THE ELECTRIC FUEL PUMP PRESSURE TEST
M11 CHECK FOR A BIASED FRP SENSOR
Key ON, engine OFF.

Access the PCM and monitor the FRP PID.
Refer to the REFERENCE VALUES article Reference Values for normal operating values.
Are the FRP pressure and voltage within range?
VREF circuits for high resistance. If OK,

GO to M12.
INSTALL a new FRP sensor.
M12 CHECK THE FUNCTIONALITY OF THE FRP SENSOR
NOTE: If the engine does not start, answer YES to the question in this step.

Increase the engine speed to 1,500 RPM.

Access the PCM and control the FRP_DSD PID.
Increase the FRP_DSD PID pressure to 131 MPa (19,000 psi) and monitor the FRP voltage.
Decrease the FRP_DSD PID pressure to 48.3 MPa (7,000 psi) and monitor the FRP voltage.
Does the FRP voltage increase and decrease when the FRP_DSD PID pressure is increased and decreased during each step?
M13 CHECK FOR ANY FUEL PRESSURE CONTROL VALVE OR CIRCUIT DTCS
Are DTCs P0090, P0091 or P0092 present in the KOEO or KOER self-test?
M14 CHECK THE FUEL PRESSURE CONTROL VALVE AND FPCV CIRCUIT RESISTANCE

4-Pin Inline High Pressure Fuel Injection Pump Assembly connector disconnected.
Assembly Assembly
Component Component
Side Side
FVCV VPWR -
FVCV - Pin 2
Pin 4
Is the resistance between 1.5 - 15 ohms?
Yes No
GO to M17. GO to M15.
M15 CHECK THE FPCV CIRCUIT FOR AN OPEN IN THE HARNESS WITH THE HIGH PRESSURE FUEL INJECTION PUMP
DISCONNECTED
Fuel Pressure Control Valve Solenoid connector disconnected.

M16 CHECK THE HIGH PRESSURE FUEL INJECTION PUMP AND FRP SENSOR CIRCUITS FOR AN INTERMITTENT
CONCERN
WARNING: Be aware of moving vehicle components and heat. Failure to follow these instructions may result in
personal injury.

Access the PCM and monitor the F_PCV and F_VCV PIDs.
While observing the PIDs, wiggle, shake, and bend all accessible sections of the wiring harness while working from the high pressure
fuel injection pump and FRP sensor to the PCM.
Do the monitored PIDs indicate the intermittent concern?
Yes No
REPAIR the harness as necessary.
GO to M17.
M17 CHECK FOR CORRECT PCM OPERATION

pushed out pins

corrosion
PINPOINT TEST MA: FUEL PUMP CONTROL - LOW PRESSURE PUMP

INTRODUCTION
fuel pump relay

inertia fuel shutoff (IFS) switch
harness circuits: B+, FP, FPM, FPPWR, GND and VPWR
Fig. 59: Powertrain Control Module Power (PCM Power) Relay Connector
Pin Circuit
Fig. 60: Fuel Pump (FP) Connector (1 Of 2)

Fig. 61: Fuel Pump (FP) Connector (2 Of 2)


TEST PROCEDURE
MA1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0231, P0232, P0627, P0628 OR P0629
Clear the DTCs.
MA2 CHECK VPWR AT THE FUEL PUMP RELAY

FP Relay connector disconnected.
Key ON, engine OFF.
MA3 CHECK THE FUEL PUMP RELAY

Carry out the fuel pump relay component test. Refer to the Wiring Diagrams Cell 149 Component Testing.
MA4 CHECK THE FP CIRCUIT FOR AN OPEN IN THE HARNESS

Yes No
GO to MA5.
MA5 CHECK THE FP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.

MA6 CHECK THE FP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS

MA7 DTC P0231: CHECK THE INTERNAL RESISTANCE OF THE IFS SWITCH

IFS Switch connector disconnected.
( + ) IFS Switch ( - ) IFS Switch

Component Component
Side Side
B+ - Pin 2 IS - Pin 1
Yes No
INSTALL a new IFS switch. REFER to
FUEL TANK AND LINES -
GO to MA8. GASOLINE AND DIESEL -- F-250-
MA8 CHECK THE FUEL PUMP VOLTAGE

Key ON, engine OFF.
Is the voltage greater than 10 V for approximately 30 seconds?
MA9 CHECK THE FUEL PUMP VOLTAGE CIRCUIT FOR AN OPEN

Yes No
GO to MA10.
MA10 CHECK VPWR AT THE FUEL PUMP RELAY

Key ON, engine OFF.
( + ) FP Relay
Connector, (-)
Harness Side
VPWR - Pin 86 Ground
B+ - Pin 30 Ground

MA12 CHECK THE FP CIRCUIT FOR AN OPEN IN THE HARNESS

Yes No
GO to MA19.
MA13 DTC P0232: CHECK THE FUEL PUMP
NOTE: DTC P0232 may be set as a result of a FP circuit concern. Disregard a secondary fuel pump circuit DTC
P0232 at this time and diagnose fuel pump control circuit DTC P0628 (if present).

Key ON, engine OFF.
Is the fuel pump on?
MA14 CHECK THE FPM CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
FP connector disconnected.
Key ON, engine OFF.
MA15 CHECK THE FPM CIRCUIT FOR AN OPEN IN THE HARNESS

FP connector disconnected.
( + ) PCM-B ( - ) FP
FPM - Pin 15 FPPWR - Pin 1
Yes No
GO to MA16.
MA16 CHECK THE FUEL PUMP GROUND FOR AN OPEN IN HARNESS

MA17 CHECK THE FUEL PUMP RESISTANCE


Yes No
INSTALL a new FP relay. CLEAR the
GO to MA19.
MA19 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST MB: FUEL RAIL PRESSURE (FRP) SENSOR

INTRODUCTION
FRP sensor
harness circuits: FRP, FRP VREF, FRP SIGRTN

Pin Circuit
2 FRP SIGRTN (Fuel Rail Pressure Signal Return)
3 FRP VREF (Fuel Rail Pressure Reference Voltage)
1 FRP (Fuel Rail Pressure)


Pin Circuit
22 FRP VREF (Fuel Rail Pressure Reference Voltage)
9 FRP SIGRTN (Fuel Rail Pressure Signal Return)
39 FRP (Fuel Rail Pressure)
TEST PROCEDURE
MB1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0192, P0193 OR P0194
NOTE: If DTC P0642 is retrieved with other DTCs, diagnose DTC P0642 first.

Clear the DTCs.
MB2 DTC P0192: INDUCE THE OPPOSITE FRP SENSOR VOLTAGE TO SIMULATE A HIGH CONDITION

15-Pin Inline Bank 1 Valve Cover Assembly connector disconnected.
Key ON, engine OFF.
Is the FRP sensor voltage PID reading greater than 4.65 volts?
MB3 CHECK THE FRP CIRCUIT FOR A SHORT TO GROUND AND A SHORT TO SIGRTN IN THE HARNESS
NOTE: This step diagnoses the harness between the inline connector and the component.

FRP Sensor connector disconnected.
( + ) 15-Pin
Inline Bank 1
Valve Cover
Assembly (-)
Connector,
Component
Side
FRP - Pin 14 Ground
MB4 CHECK THE FRP CIRCUIT FOR A SHORT TO GROUND AND A SHORT TO SIGRTN WITH THE PCM
DISCONNECTED

( + ) PCM-E
Connector, (-)
Harness Side
FRP - Pin 39 Ground
( + ) PCM-E ( - ) PCM-E
FRP SIGRTN -
FRP - Pin 39
Pin 9
MB5 DTC P0193: CHECK THE VREF VOLTAGE TO THE FRP SENSOR

Key ON, engine OFF.
Yes No
GO to MB9. GO to MB6.
MB6 CHECK THE FRP VREF AND FRP SIGRTN CIRCUITS FOR AN OPEN IN THE HARNESS
NOTE: This step diagnoses the harness between the inline connector and the PCM.

( - ) 15-Pin
Inline Bank 1
( + ) PCM-E
Valve Cover
Connector,
Assembly
Harness Side
Connector,
Harness Side
FRP SIGRTN - FRP SIGRTN -
Pin 9 Pin 7
FRP VREF - FRP VREF -
Pin 22 Pin 15
MB7 CHECK THE FRP VREF CIRCUIT FOR A SHORT TO SIGRTN IN THE HARNESS

FRP SIGRTN - FRP VREF -
Pin 7 Pin 15
Yes No
GO to MB8.
MB8 CHECK THE FRP VREF CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
MB9 CHECK THE FRP CIRCUIT FOR AN OPEN IN THE HARNESS

Connector, Assembly
Harness Side
FRP - Pin 39 FRP - Pin 14
Yes No
GO to MB10.
MB10 CHECK THE FRP CIRCUIT FOR A SHORT TO VREF IN THE HARNESS
( + ) 15-Pin ( - ) 15-Pin
Inline Bank 1 Inline Bank 1
Valve Cover Valve Cover
Assembly Assembly
FRP VREF -
FRP - Pin 14
Pin 15
MB11 CHECK THE FRP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.

Assembly
Connector,
Harness Side
FRP - Pin 14 Ground
Yes No
GO to MB12.
MB12 INDUCE THE OPPOSITE FRP SENSOR VOLTAGE TO SIMULATE LOW CONDITION

Key ON, engine OFF.

Is the FRP sensor voltage PID reading 0 volts?
MB13 CHECK THE FRP, FRP VREF AND FRP SIGRTN CIRCUITS FOR AN OPEN IN THE HARNESS

FRP Sensor connector disconnected.
( + ) 15-Pin
Inline Bank 1
( - ) FRP
Valve Cover
Sensor
Assembly
Connector,
Connector,
Harness Side
Component
Side
FRP - Pin 14 FRP - Pin 1
FRP VREF - FRP VREF -
Pin 15 Pin 3
FRP SIGRTN - FRP SIGRTN -
Pin 7 Pin 2
Yes No
GO to MB14.
MB14 CHECK THE FRP VREF CIRCUIT FOR A SHORT TO SIGRTN IN THE HARNESS
MB15 CHECK THE FRP VREF CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
( + ) 15-Pin
Inline Bank 1
Valve Cover
Assembly (-)
Connector,
Component
Side
FRP VREF -
Ground
Pin 15
Yes No
GO to MB16.
MB16 CHECK THE FRP CIRCUIT FOR A SHORT TO VREF IN THE HARNESS
MB17 CHECK THE FRP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.

( + ) 15-Pin
Inline Bank 1
Valve Cover
Assembly (-)
Connector,
Component
Side
FRP - Pin 14 Ground
Yes No
INSTALL a new FRP sensor. REFER to
MB18 DTC P0194: INTERMITTENT CHECK

Key ON, engine OFF.
While observing the PIDs, carry out the following:
Wiggle all accessible harness from the 15-pin inline bank 1 valve cover connector to the PCM connector.
Look for sudden changes in the pressure or voltage when the harness is wiggled.
MB19 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST MC: FUEL RAIL TEMPERATURE (FRT) SENSOR

INTRODUCTION
FRT sensor
harness circuits: FRT and SIGRTN

25 77 30,000
20 68 37,352
15 59 46,797
10 50 59,016
5 41 74,940
0 32 95,851
-5 23 123,485
-10 14 160,313
-15 5 209,816
-20 -4 276,959
-30 -22 496,051
-40 -40 925,021
Fig. 66: Fuel Rail Temperature (FRT) Sensor Circuit


TEST PROCEDURE
MC1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P008F, P0168, P0181, P0182 OR P0183
NOTE: Diagnose DTCs P0181, P0182 and P0183 before diagnosing DTC P008F.
Clear the DTCs.
Are DTCs P008F, P0168, P0181, P0182 or P0183 present?
MC2 DTC P008F: CHECK THE ECT SENSOR TEMPERATURE PID
Key ON, engine OFF.
Access the PCM and monitor the ECT PID.
Is the ECT within 20C (36F) of the ambient temperature?
and CHECK for biased ECT sensor.

refer to PINPOINT TEST K.
MC3 CHECK THE FRT SENSOR TEMPERATURE PID

Access the PCM and monitor the FRT PID.
Is the FRT within 20C (36F) of the ambient temperature?
Yes No
INSTALL a new FRT sensor. REFER to
GO to MC13. - GASOLINE ENGINES -- F-250-550
MC4 DTCS P0168 OR P0181: VISUAL INSPECTION OF FUEL COOLER AND ENGINE COOLING SYSTEMS
Visually inspect the fuel cooler system for the following:

leaks
pinched hoses
restricted radiator air flow
correct coolant level
coolant flow at the fuel cooler reservoir
loose electrical connections at the fuel cooler pump
MC5 CHECK THE FRT SENSOR OPERATION

Key ON, engine OFF.
Does the PID temperature match ambient temperature?
Yes No
INSTALL a new FRT sensor. REFER to
GO to MC13. - GASOLINE ENGINES -- F-250-550
MC6 KOEO AND KOER DTC P0182: SIMULATE THE OPPOSITE DTC
FRT Sensor connector disconnected.
Key ON, engine OFF.

MC7 CHECK THE FRT CIRCUIT FOR A SHORT TO SIGRTN IN THE HARNESS
MC8 CHECK THE FRT CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
( + ) PCM-E
Connector, (-)
Harness Side
FRT - Pin 64 Ground
Yes No
GO to MC13.
MC9 KOEO AND KOER DTC P0183: SIMULATE THE OPPOSITE DTC
FRT Sensor connector disconnected.

Key ON, engine OFF.

MC10 CHECK THE FRT AND SIGRTN CIRCUITS FOR AN OPEN IN THE HARNESS
Remove the jumper wire(s).
( + ) FRT
( - ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
FRT - Pin 2 FRT - Pin 64
SIGRTN - Pin
SIGRTN - Pin 1
55
Yes No
GO to MC11.
MC11 CHECK THE FRT CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
MC12 CONTINUOUS DTCS P0182, P0183 OR P0184: INTERMITTENT CHECK

Key ON, engine OFF.
Wiggle all accessible harness from the FRT sensor to the PCM and lightly tap on the sensor.
Wiggle the FRT sensor connector.
Look for sudden changes in the voltage when the harness and connector are wiggled or when the FRT sensor is tapped.
as necessary. REFER toNO

CHART INDEX , if a driveability
concern exists.
MC13 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST MD: FUEL COOLING PUMP SYSTEM

INTRODUCTION
fuel cooling pump

harness circuits: FCP, VPWR
Fig. 68: Positive Crankcase Ventilation (PCV) Connector

TEST PROCEDURE
MD1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P008C, P008D OR P008E
Clear the DTCs.
Are DTCs P008C, P008D or P008E present?
Yes No
GO to MD2.
INDEX , if the driveability concern
exists.
MD2 CHECK VPWR AT THE FUEL COOLING PUMP

Fuel Cooling Pump Motor connector disconnected.
Key ON, engine OFF.
MD3 CHECK THE FCP CIRCUIT FOR AN OPEN IN THE HARNESS

Yes No
GO to MD4.
MD4 CHECK THE FCP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
Key ON, engine OFF.
MD5 CHECK THE FCP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS
MD6 CHECK THE FUNCTIONALITY OF THE FCP CIRCUIT AT THE PUMP

Connect a non-powered test lamp between:
Motor Motor
FCP - Pin 1 VPWR - Pin 2
Does the test lamp illuminate?
Yes No
INSTALL a new Fuel Cooling Pump
motor. REFER to FUEL SYSTEM -
GENERAL INFORMATION -
GO to MD7.
GASOLINE AND DIESEL -- F-250-
MD7 CHECK FOR CORRECT PCM OPERATION

pushed out pins.
corrosion.
PINPOINT TEST ME: FUEL PUMP CONTROL - HIGH PRESSURE FUEL INJECTION PUMP
INTRODUCTION
fuel volume control valve

fuel pressure control valve
harness circuits: FPCV, FVCV, VPWR
Fig. 70: Fuel Pump Control - High Pressure Fuel Injection Pump Circuit (1 Of 3)

TEST PROCEDURE
ME1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0001, P0003, P0004, P0090, P0091 OR P0092

Clear the DTCs.

Are DTCs P0001, P0003, P0004, P0090, P0091 or P0092 present?
ME2 CHECK THE FUEL VOLUME CONTROL VALVE AND FUEL PRESSURE CONTROL VALVE RESISTANCE

4-Pin Inline High Pressure Fuel Injection Pump Assembly connector disconnected.
Are the resistances between 1.5 - 15 ohms?
ME3 CHECK THE FPCV AND FVCV CIRCUITS FOR A SHORT TO GROUND IN THE HARNESS

( + ) 4-Pin
Inline High
Pressure Fuel
Injection Pump
(-)
Assembly
Connector,
Component
Side
FPCV - Pin 1 Ground
FVCV - Pin 2 Ground
ME4 CHECK THE FPCV AND FVCV CIRCUITS FOR AN OPEN IN THE HARNESS

Fuel Volume Control Valve Solenoid connector disconnected.
( + ) 4-Pin
Inline High ( - ) Fuel
Pressure Fuel Volume
Injection Pump Control Valve
Assembly Solenoid
Component Harness Side
Side
FVCV - Pin 2 FVCV - Pin 2
FVCV VPWR - FVCV VPWR -
Pin 4 Pin 1

Fuel Volume Control Valve Solenoid connector disconnected.
Yes No
INSTALL a new High Pressure Fuel
Injection Pump. REFER to FUEL
SYSTEM - GENERAL
INFORMATION - GASOLINE AND
DIESEL -- F-250-550 (SUPER DUTY
PICKUPS) .
ME6 CHECK FOR VPWR AT THE 4-PIN INLINE CONNECTOR
Key ON, engine OFF.

ME7 CHECK THE FPCV AND FVCV CIRCUITS FOR A SHORT TO VOLTAGE IN THE HARNESS

Key ON, engine OFF.
( + ) 4-Pin
Inline High
Pressure Fuel
Injection Pump (-)
Assembly
Connector,
Harness Side
FPCV - Pin 1 Ground
FVCV - Pin 2 Ground
Yes No
GO to ME8.

ME9 CHECK THE FPCV AND FVCV CIRCUITS FOR AN OPEN IN THE HARNESS
( + ) 4-Pin
Inline High
Pressure Fuel ( - ) PCM-E
Injection Pump Connector,
Assembly Harness Side
Connector,
Harness Side
FPCV - Pin 1 FPCV - Pin 48
FVCV - Pin 2 FVCV - Pin 24
Yes No
CONNECT the 4-pin inline connector.
For DTCs P0087 or P2291 with overfull
engine oil level, REFER toHARD
START/NO START DIAGNOSTIC
PROCEDURES and CARRY OUT the
Fuel System Leak Test Alternate
Procedure.
For DTCs P0087 or P2291 with correct REPAIR the open circuit. CLEAR the
engine oil level, INSTALL a new High DTCs. REPEAT the self-test.
Pressure Fuel Injection Pump. REFER to
FUEL SYSTEM - GENERAL
INFORMATION - GASOLINE AND
DIESEL -- F-250-550 (SUPER DUTY
PICKUPS) .
For all others, GO to ME10.
ME10 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST O: WATER IN FUEL (WIF) SENSOR

INTRODUCTION
fuel system contamination

circuitry
WIF sensor
Fig. 74: Water In Fuel (WIF) Sensor Connector

TEST PROCEDURE
O1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P2269
NOTE: The PCM must detect water in fuel during engine idle at least 6 consecutive times to set DTC P2269 and to
light the WIF indicator. The PCM monitors the WIF sensor for 30 seconds at idle. Each time the PCM
checks for water in fuel it must detect a change in the vehicle speed before it will check for water in fuel
again.

Clear the DTCs.
Idle the engine for 30 seconds and then drive the vehicle. Repeat this 8 times.
Is DTC P2269 present or is the water in fuel indicator illuminated?
O2 CHECK FOR WATER OR CONTAMINANTS IN THE FUEL
sample is cloudy, the fuel is aerated or emulsified with water. If the fuel
sample is aerated, refer toPERFORMANCE DIAGNOSTIC PROCEDURES
and carry out the Fuel Aeration Test. If the fuel sample is emulsified,
replace the fuel filters.
Open the fuel conditioning module drain valve and fill the clear container until it is half full.
Close the drain valve.
Inspect the fuel sample for water or contaminants.
Is water or contaminants present in the fuel sample in the clear container?
Yes No
GO to O3. GO to O4.
O3 CHECK 2 ADDITIONAL FUEL SAMPLES FOR WATER IN THE FUEL
Start the engine.

Start the engine.
Inspect the fuel sample for water.
Is water present in the final fuel sample in the clear container?
O4 CHECK THE WIF SENSOR

WIF Sensor connector disconnected.
Side Side
WIF - Pin 1 SIGRTN - Pin 2
Yes No
GO to O5. GO to O6.
O5 CHECK FOR A SHORT TO GROUND IN THE SIGNAL CIRCUIT

O6 CHECK THE WIF SENSOR FOR CONTAMINATION
Remove the fuel conditioning module manifold.

Remove the WIF sensor.
Check the WIF sensor pins and the fuel conditioning module manifold and reservoir for contamination.
Clean the WIF sensor pins and the fuel conditioning module manifold and reservoir as necessary.
Yes No
INSTALL a new WIF sensor. REFER to
INSTALL the fuel conditioning module FUEL TANK AND LINES -
manifold. GASOLINE AND DIESEL -- F-250-
GO to O7. 550 (SUPER DUTY PICKUPS) .
GO to O7.
O7 CHECK THE WATER IN FUEL INDICATOR FOR CORRECT OPERATION
NOTE: The PCM must detect water in fuel during engine idle at least 6 consecutive times to set DTC P2269 and to
light the WIF indicator. The PCM monitors the WIF sensor for 30 seconds at idle. Each time the PCM
checks for water in fuel it must detect a change in the vehicle speed before it will check for water in fuel
again.
NOTE: In this step the vehicle needs to be driven enough so the PCM can detect a change to the vehicle speed.

WIF Sensor connector connected.
Clear the DTCs.
Idle the engine for 30 seconds and then drive the vehicle. Repeat this 8 times.
Does the Water In Fuel indicator illuminate briefly at key ON and then remain off?
PINPOINT TEST P: FUEL INJECTOR

INTRODUCTION
fuel injector wiring can result in electric shock. Failure to follow this
instruction may result in serious personal injury.
fuel injector
harness circuits: fuel injector, ground and fuel injector, power
Fig. 75: Fuel Injector Circuit (1 Of 3)






TEST PROCEDURE
P1 PRELIMINARY DIAGNOSIS
Retrieve and record all diagnostic trouble codes (DTCs).

Clear the DTCs.
Carry out the injector electrical self-test.
Carry out the key on engine off (KOEO) self-test.
Carry out the key on engine running (KOER) self-test.
Are any DTCs retrieved?
P2 DTCS P0201 THROUGH P0208: CHECK THE SUSPECT INJECTOR AND CIRCUIT RESISTANCE
NOTE: Verify the engine temperature is at ambient room temperature before continuing with this test. A soak
period of 6 hours may be required.
NOTE: Only the suspect injector indicated by the DTC needs to be diagnosed.
NOTE: Disregard any FRP sensor related DTCs that may set during this test.

P3 CHECK THE SUSPECT INJECTOR RESISTANCE AT THE FUEL INJECTOR

Yes No
REPAIR the open circuit. CLEAR the INFORMATION - GASOLINE AND
DTCs. REPEAT the self-test. DIESEL -- F-250-550 (SUPER DUTY
PICKUPS) .
P4 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR AN OPEN IN THE HARNESS

( + ) 15-Pin
Inline Valve
( - ) PCM-E
Cover
Connector,
Assembly
Harness Side
Connector,
Harness Side
Ground Ground
Power Power
P5 DTC P062D: MONITOR INJECTOR FAULT PIDS

Key ON, engine OFF.
Access the PCM and monitor the INJ1_F, INJ4_F, INJ6_F, INJ7_F and INJ_F PIDs.
Does any PID indicate a concern with any of the injectors?
P6 DTC P062E: MONITOR INJECTOR FAULT PIDS

Key ON, engine OFF.
Access the PCM and monitor the INJ2_F, INJ3_F, INJ5_F, INJ8_F and INJ_F PIDs.
Does any PID indicate a concern with any of the injectors?
Yes No
GO to P7. GO to P13.
P7 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO VOLTAGE IN
THE HARNESS
NOTE: Only injectors identified by the fault PIDs need to be diagnosed.

Key ON, engine OFF.
P8 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO VOLTAGE
WITH THE SUSPECT FUEL INJECTOR(S) DISCONNECTED

Key ON, engine OFF.
( + ) 15-Pin
Inline Valve
Cover
Assembly (-)
Connector,
Component
Side
Fuel Injector,
Ground
Ground
Fuel Injector,
Ground
Power
P9 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO GROUND

Ground
Yes No
P10 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO GROUND
WITH THE SUSPECT FUEL INJECTOR(S) DISCONNECTED

THE HARNESS WITH THE PCM DISCONNECTED

Key ON, engine OFF.
( + ) 15-Pin
Inline Valve
Cover
(-)
Assembly
Connector,
Harness Side
Fuel Injector,
Ground
Ground
Fuel Injector,
Ground
Power
Yes No
GO to P12.
P12 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO GROUND IN
THE HARNESS WITH THE PCM DISCONNECTED

THE HARNESS

Key ON, engine OFF.
( + ) 15-Pin
Inline Bank 1
Valve Cover
Assembly (-)
Connector,
Component
Side
Fuel Injector 1,
Ground
Ground - Pin 2
Fuel Injector 3,
Ground
Ground - Pin 4
Fuel Injector 5,
Ground
Ground - Pin 9
Fuel Injector 7,
Ground
Ground - Pin 11
Ground - Pin 4
Fuel Injector 6,
Ground
Ground - Pin 9
Fuel Injector 8,
Ground
Ground - Pin 11
Yes No
P14 CHECK THE BANK 1 FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO
VOLTAGE WITH THE FUEL INJECTORS DISCONNECTED

Fuel Injector 1 Assembly connector disconnected.
Key ON, engine OFF.
Power - Pin 10
Fuel Injector 7,
Ground
Ground - Pin 11
Fuel Injector 7,
Ground
Power - Pin 12
Yes No
GO to P15.
VOLTAGE WITH THE FUEL INJECTORS DISCONNECTED


Key ON, engine OFF.
Fuel Injector 6,
Ground
Power - Pin 10
Fuel Injector 8,
Ground
Ground - Pin 11
Fuel Injector 8,
Ground
Power - Pin 12
Yes No
INSTALL a new suspect fuel injector.
REPAIR the short circuit. CLEAR the GENERAL INFORMATION -
DTCs. REPEAT the self-test. GASOLINE AND DIESEL -- F-250-
P16 CHECK THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS FOR A SHORT TO GROUND IN
THE HARNESS

( + ) 15-Pin
Inline Bank 1
Valve Cover
Assembly (-)
Connector,
Component
Side
Fuel Injector 1,
Ground
Ground - Pin 2
Fuel Injector 3,
Ground
Ground - Pin 4
Fuel Injector 5,
Ground
Ground - Pin 9
Fuel Injector 7,
Ground
Ground - Pin 11
Inline Bank 2
Valve Cover
Assembly
(-)
Connector,
Component
Side
Fuel Injector 2,
Ground
Ground - Pin 2
Fuel Injector 4,
Ground
Ground - Pin 4
Fuel Injector 6,
Ground
Ground - Pin 9
Fuel Injector 8,
Ground
Ground - Pin 11
GROUND WITH THE FUEL INJECTORS DISCONNECTED

Ground - Pin 4
Fuel Injector 3,
Ground
Power - Pin 5
Fuel Injector 5,
Ground
Ground - Pin 9
Fuel Injector 5,
Ground
Power - Pin 10
Fuel Injector 7,
Ground
Ground - Pin 11
Fuel Injector 7,
Ground
Power - Pin 12
Yes No
GO to P18.
GROUND WITH FUEL INJECTORS DISCONNECTED

Power - Pin 5 Ground

Fuel Injector 6,
Ground
Ground - Pin 9
Fuel Injector 6,
Ground
Power - Pin 10
Fuel Injector 8,
Ground
Ground - Pin 11
Fuel Injector 8,
Ground
Power - Pin 12
Yes No
INSTALL a new suspect fuel injector.
GENERAL INFORMATION - REPAIR the short circuit. CLEAR the
GASOLINE AND DIESEL -- F-250- DTCs. REPEAT the self-test.
VOLTAGE IN THE HARNESS WITH THE PCM DISCONNECTED

Key ON, engine OFF.
Power - Pin 5
Fuel Injector 5,
Ground
Ground - Pin 9
Fuel Injector 5,
Ground
Power - Pin 10
Fuel Injector 7,
Ground
Ground - Pin 11
Fuel Injector 7,
Ground
Power - Pin 12
Yes No
GO to P20.
( + ) 15-Pin
Inline Bank 2
Valve Cover
Fuel Injector 8,
Ground
Power - Pin 12
Yes No
GO to P21.
This step diagnoses the harness between the inline connector and the PCM.
( + ) 15-Pin
Inline Bank 1
Valve Cover
(-)
Assembly
Connector,
Harness Side
Fuel Injector 1,
Ground
Ground - Pin 2
Fuel Injector 1,
Ground
Power - Pin 3
Fuel Injector 3,
Ground
Ground - Pin 4
Fuel Injector 3,
Ground
Power - Pin 5
Fuel Injector 5,
Ground
Ground - Pin 9
Fuel Injector 5,
Ground
Power - Pin 10
Fuel Injector 7,
Ground
Ground - Pin 11
Fuel Injector 7,
Ground
Power - Pin 12
GROUND IN THE HARNESS WITH THE PCM DISCONNECTED
( + ) 15-Pin
Inline Bank 2
Valve Cover
(-)
Assembly
Connector,
Harness Side
Fuel Injector 2,
Ground
Ground - Pin 2
Fuel Injector 2,
Ground
Power - Pin 3
Fuel Injector 4,
Ground
Ground - Pin 4
Fuel Injector 4,
Ground
Power - Pin 5
Fuel Injector 6,
Ground
Ground - Pin 9
Fuel Injector 6,
Ground
Power - Pin 10
Fuel Injector 8,
Ground
Ground - Pin 11
Fuel Injector 8,
Ground
Power - Pin 12
P23 DTCS P1551 THROUGH P1558: CHECK THE SUSPECT INJECTOR AND CIRCUIT RESISTANCE
NOTE: Only the suspect injector indicated by the DTC needs to be diagnosed.

P24 CHECK FOR THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS SHORTED TOGETHER IN
THE HARNESS

Yes No
INFORMATION - GASOLINE AND REPAIR the short circuit. CLEAR the
DIESEL -- F-250-550 (SUPER DUTY DTCs. REPEAT the self-test.
PICKUPS) .
P25 CHECK FOR THE FUEL INJECTOR, GROUND AND FUEL INJECTOR, POWER CIRCUITS SHORTED TOGETHER
HARNESS

P26 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST QH: FUEL LEVEL INPUT (FLI)

INTRODUCTION
fuel tank control module

fuel tank control module circuitry
instrument cluster
TEST PROCEDURE
QH1 PRELIMINARY DIAGNOSIS
Key ON, engine OFF.

Carry out the instrument cluster self-test.
For additional PCM DTCs, REFER

(DTC) CHARTS AND
DESCRIPTIONS .
QH2 CHECK THE INSTRUMENT CLUSTER FUEL LVL PID

Access the IC and monitor the FUEL LVL PID.
Record the FUEL LVL PID value.
Compare the instrument cluster FUEL LVL PID recorded value to the instrument cluster fuel gauge.
Does the instrument cluster FUEL LVL PID correspond to the fuel gauge level?
Yes No
REFER to INSTRUMENT CLUSTER
AND PANEL ILLUMINATION -- F-
GO to QH3.
250-550 (SUPER DUTY PICKUPS) to
continue diagnosis of the fuel level.
QH3 CHECK THE PCM FLI PID

Access the PCM and monitor the FLI PID.
Record the FLI PID value.
Compare the PCM FLI PID recorded value to the instrument cluster FLI PID recorded value.
Does the PCM FLI PID correspond to the instrument cluster FLI PID?
QH4 CHECK IF A DTC IS STILL PRESENT

Clear the DTCs.
Is DTC P115A present?
QH5 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST RA: CATALYST SYSTEM

INTRODUCTION
This pinpoint test is intended to diagnose the oxidation catalytic converter (OC).
TEST PROCEDURE
RA1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODE (DTC) P0420

Clear the DTCs.
Attempt to recreate the concern.
Yes No
GO to RA2. recreate the concern. REPAIR as
RA2 CHECK FOR OTHER DTCS

Check for self-test DTCs.
Are any other DTCs present?
RA3 CHECK FOR LEAKS IN THE EXHAUST SYSTEM

Visually inspect the OC, EGT11, and EGT12 for the following:
correct connection at the exhaust tube fittings
correct connection at the sensors exhaust ports
leaks, cracks, or punctures
RA4 CHECK THE FUEL QUALITY

Verify the fuel level, grade, and quality is sufficient to support normal operation of the engine. Refer toPERFORMANCE
DIAGNOSTIC PROCEDURES and carry out the Sufficient Clean Fuel Test.
Check with the customer to verify the use of ultra low sulfur diesel fuel.
Yes No
REPAIR as necessary. ADVISE the
customer of the correct fuel type required
GO to RA5.
for this vehicle.
RA5 IDENTIFY THE CUSTOMER'S DRIVING HABITS

Check with the customer for the following conditions:
excessive trailer weight
steep uphill grade operation
high engine load operation
high ambient temperature operation
Is the vehicle consistently operated under high load or high temperature conditions?
RA6 CHECK FOR EXCESSIVE ENGINE OIL CONSUMPTION

Carry out the oil consumption test. Refer to ENGINE SYSTEM - GENERAL INFORMATION -- F-250-550 (SUPER DUTY
PICKUPS) for additional information on excessive engine oil consumption.
PINPOINT TEST RB: DIESEL PARTICULATE FILTER SYSTEM

INTRODUCTION
WARNING: While conducting tests on a hot engine take all safety precautions to
prevent skin contact with hot engine components. Failure to follow these
instructions may result in personal injury.
WARNING: Initiate a manual regeneration of the diesel particulate filter only when the vehicle is on the ground with
the area around the tailpipe free of people, obstructions, foreign material or other items. Manual
regeneration causes the exhaust gas to quickly get VERY HOT. Failure to follow these instructions may
result in serious personal injury.
diesel particulate filter (5H221)

diesel particulate filter pressure sensor (9G824)
harness circuits: DPF, SIGRTN, and VREF
Fig. 79: Diesel Particulate Filter Pressure Sensor (9G824)


TEST PROCEDURE
RB1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P2002, P242F, P244A, P244C, P244D, P2452,
P2453, P2454, P2455, P2456, P2459, P246C
Clear the DTCs.
Are DTCs P2002, P242F, P244A, P244C, P244D, P2452, P2453, P2454, P2455, P2456, P2459 or P246C present?
RB2 DTC P2452: CHECK FOR A RESTRICTED DIESEL PARTICULATE FILTER DTC
Key ON, engine OFF.
Yes No
INSTALL a new Diesel Particulate Filter.
REFER to EXHAUST SYSTEM -- F-
250-550 (SUPER DUTY PICKUPS) .
CARRY OUT the diesel particulate filter
parameter reset function on the scan tool. GO to RB4.
REFER toRESETTING THE DIESEL
PARTICULATE FILTER
PARAMETER .
RB3 DTCS P2453 AND P2456: CHECK FOR HIGH AND LOW CIRCUIT DTCS
Key ON, engine OFF.
Check for KOEO and KOER DTCs.
Are DTCs P2454 or P2455 present?
RB4 CHECK THE DIESEL PARTICULATE FILTER PRESSURE SENSOR HOSE FOR LEAKS
Visually inspect the hose between the exhaust port and the diesel particulate filter pressure sensor for the following:
correct hose connection at the exhaust port and sensor
RB5 CHECK THE DIESEL PARTICULATE FILTER PRESSURE SENSOR CONNECTOR FOR DAMAGE OR CORROSION
Diesel Particulate Filter Pressure Sensor connector disconnected.
pushed out pins
corrosion
RB6 DTCS P2454 AND P2455: CHECK THE VREF AND SIGRTN CIRCUITS FOR AN OPEN IN THE HARNESS
Key ON, engine OFF.
RB7 SIMULATE THE OPPOSITE SIGNAL

Key ON, engine OFF.
Access the PCM and monitor the DPF_V PID.
RB8 CHECK THE DPF CIRCUIT(S) FOR A SHORT TO SIGRTN OR GND IN THE HARNESS
( + ) Diesel ( - ) Diesel
Particulate Particulate
Filter Pressure Filter Pressure
Sensor Sensor
DPF - Pin 3 SIGRTN - Pin 2
RB9 CHECK THE DPF CIRCUIT FOR AN OPEN IN THE HARNESS

RB10 CHECK THE DPF CIRCUIT FOR A SHORT TO VREF

( + ) Diesel ( - ) Diesel
Particulate Particulate
Filter Pressure Filter Pressure
Sensor Sensor
VREF - Pin 1 DPF - Pin 3
Yes No
GO to RB11.
RB11 CHECK THE DPF CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
RB12 INDUCE A LOW VOLTAGE ON THE DPF CIRCUIT

Sensor Sensor
DPF - Pin 3 SIGRTN - Pin 2
Key ON, engine OFF.

Access the PCM and monitor the DPF_V PID.
Is the voltage less than 0.1 V?
Yes No
INSTALL a new Diesel Particulate Filter
Pressure sensor. REFER to
GO to RB26.
RB13 DTC P2456: DETERMINE THE CAUSE OF THE INTERMITTENT CONCERN
Key ON, engine OFF.

Access the PCM and monitor the DPF PID.
Observe the DPF PID for an indication of a concern while carrying out the following:
shake, wiggle, and bend the DPF, SIGRTN, and VREF circuits
lightly tap on the diesel particulate filter pressure sensor to simulate road shock
pushed out pins
corrosion
RB14 DTCS P2002 AND P244A: CHECK THE VEHICLE REPAIR HISTORY
manual regeneration or operating conditions that allowed a thorough

regeneration to occur.
NOTE: When a new diesel particulate filter is installed, the parameters that determine the level of ash content in
the filter must be reset.

Check the vehicle repair history to determine if a new diesel particulate filter was installed within the last 4,828 - 6,437 km (3,000 -
4,000 miles).
Was a new diesel particulate filter installed within the last 4,828 - 6,437 km (3,000 - 4,000 miles)?
Yes No
parameter reset function on the scan tool.
GO to RB15.
PARTICULATE FILTER
PARAMETER .
RB15 CHECK THE EXHAUST SYSTEM FOR LEAKS AND AFTERMARKET ACCESSORIES
Visually inspect the exhaust system for the following:
leaks in the diesel particulate filter pressure sensor connecting hose
aftermarket accessories and performance modifications
tailpipe modifications that decrease the exhaust restriction
RB16 CHECK THE DIESEL PARTICULATE FILTER PRESSURE AT IDLE

Is the pressure less than 150 Pa (0.0 psi)?
Yes No
INSTALL a new Diesel Particulate Filter
Pressure sensor. REFER to
The concern is not present at this time.
RETURN the vehicle to the customer.
CLEAR the DTCs.
GO to RB17.
RB17 RECHECK THE DIESEL PARTICULATE FILTER PRESSURE AT IDLE

Is the pressure less than 150 Pa (0.0 psi)?
RB18 DTC P242F: CHECK FOR SENSOR AND CIRCUIT RELATED DTCS
Key ON, engine OFF.
Are any diesel particulate filter pressure, EGT, or MAF/IAT sensor DTCs present?
RB19 DTC P246C: CARRY OUT A DIESEL PARTICULATE FILTER MANUAL REGENERATION
Carry out the diesel particulate filter manual regeneration with the scan tool. Refer toSCAN TOOL SETUP AND
FUNCTIONALITY .
Does the diesel particulate filter manual regeneration successfully complete?

parameter reset function on the scan tool.
The test is complete and no concerns are
present.
PARTICULATE FILTER
PARAMETER .
RB20 DTCS P244C, P244D AND P2459: CHECK FOR ANY OTHER DTCS
Yes No
For DTCs P244C or P244D, GO to
RB21.
For all others, GO to RB23.
(DTC) CHARTS AND
DESCRIPTIONS .
RB21 CHECK FOR PERFORMANCE CONCERNS OR MODIFICATIONS AND AFTERMARKET ACCESSORIES

Check for aftermarket exhaust accessories and performance modifications.
Check the fuel and turbocharger systems for performance concerns. Refer toPERFORMANCE DIAGNOSTIC PROCEDURES and
carry out the High Pressure Fuel and Boost Pressure tests.
RB22 CHECK FOR LEAKS IN THE EXHAUST SYSTEM

Inspect the exhaust system, including the oxidation catalytic converter (OC) for leaks, cracks, loose connections, or punctures before the
diesel particulate filter.
INSTALL a new OC. REFER to

REPAIR as necessary. EXHAUST SYSTEM -- F-250-550
CLEAR the DTCs. REPEAT the self-test. (SUPER DUTY PICKUPS) .
RB23 IDENTIFY THE CUSTOMER'S DRIVING HABITS
NOTE: Some vehicle operating conditions may cause a high temperature condition at the diesel particulate filter.
The temperature conditions that cause this DTC to set are cumulative.
Check with the customer for the following conditions:

excessive trailer weight
steep uphill grade operation
high engine load operation
high ambient temperature operation
Is the vehicle consistently operated under high load or high temperature conditions?
RB24 IDENTIFY THE VEHICLE MILEAGE

Verify the vehicle has followed the maintenance schedule. The diesel particulate filter should have been repaired or a new one installed
at 193,000 km (120,000 miles).
Is the vehicle mileage greater than 193,000 km (120,000 miles)?
RB25 CHECK THE VEHICLE REPAIR HISTORY

Check the vehicle repair history to determine if a stand alone DTC P244D or P2459 is a repeat concern.
Is the stand alone DTC P244D or P2459 a repeat concern?
Yes No
INSTALL a new Diesel Particulate Filter.
REFER to EXHAUST SYSTEM -- F- RETURN the vehicle to the customer.
250-550 (SUPER DUTY PICKUPS) . CLEAR the DTCs. REPEAT the self-test.
RB26 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST RC: EXHAUST GAS TEMPERATURE (EGT) SENSOR

INTRODUCTION
EGT sensor (12B591)

harness circuits: EGT11, EGT12, EGT13, and SIGRTN
EGT SENSOR TEMPERATURE AND RESISTANCE SPECIFICATIONS

Temperature Temperature Sensor Value
C F Resistance (ohms)
850 1,562 766.31
800 1,472 737.68
750 1,382 708.46
700 1,292 678.66
650 1,202 648.27
600 1,112 617.30
550 1,022 585.74
500 932 553.60
450 842 520.87
400 752 487.56
350 662 453.66
Fig. 81: Exhaust Gas Temperature (EGT) Sensor


TEST PROCEDURE
RC1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0544, P0545, P0546, P117B, P2031, P2032,
P2033, P2080, P2081, P2084, P2085, P20E2, P20E3, P20E4, P242A, P242B, P242C, P242D, OR P242E

Clear the DTCs.
Are DTCs P0544, P0545, P0546, P117B, P2031, P2032, P2033, P2080, P2081, P2084, P2085, P20E2, P20E3, P20E4, P242A,
P242B, P242C, P242D or P242E present?

RC2 DTCS P0544, P117B, P2031, P2080, P2081, P2084, P2085, P20E2, P20E3, P20E4, P242A, P242B AND P242E: CHECK FOR
HIGH AND LOW CIRCUIT DTCS
Key ON, engine OFF.
Check for KOEO and KOER DTCs.
Are DTCs P0545, P0546, P2032, P2033, P242C or P242D present?
Yes No
For DTCs P0544, P2031 or P242A, GO
to RC3.
For DTC P117B, GO to RC9.
For DTCs P2080, P2084 or P242B, GO
GO to RC5. to RC10.
For DTCs P2081, P2085 or P242E, GO to
RC13.
For DTCs P20E2, P20E3 or P20E4, GO
to RC12.
RC3 CHECK FOR LEAKS IN THE EXHAUST SYSTEM

Visually inspect the exhaust system for the following:
exhaust leaks at flanges and gaskets
punctures or cracks in the catalyst
punctures or cracks in the diesel particulate filter
RC4 CHECK THE EGT CIRCUIT FOR CORRECT RESPONSE
Key ON, engine OFF.

Access the PCM and monitor the EGT11_V, EGT12_V and EGT13_V PIDs.
EGT Sensor connector disconnected.
Does the suspect PID value change when the sensor is disconnected?
Yes No
INSTALL a new EGT sensor. REFER to
- GASOLINE ENGINES -- F-250-550 GO to RC14.
RC5 DTCS P0545, P0546, P2032, P2033, P242C AND P242D: CHECK THE EGT SENSOR FOR CORRECT RESISTANCE

RC6 CHECK THE EGT SIGNAL CIRCUIT FOR A SHORT TO GROUND AND SIGRTN
( + ) EGT ( - ) EGT
Sensor Sensor
EGT - Pin 1 SIGRTN - Pin 2
Yes No
GO to RC14.
RC7 CHECK THE EGT SIGNAL AND SIGRTN CIRCUITS FOR AN OPEN
RC8 CHECK THE EGT SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.

GO to RC14.
RC9 DTC P117B: DETERMINE THE SUSPECT EGT SENSOR

Allow the exhaust system temperature to stabilize. A soak period of 8 hours may be required.
Key ON, engine OFF.
Access the PCM and monitor the EGT11, EGT12 and EGT13 PIDs.
Are the differences in the PID values less than 25C (45F)?
Yes No
GO to RC14. GO to RC12.
RC10 DTCS P2080, P2084 AND P242B: DETERMINE VEHICLE STORAGE CONDITIONS

Check with the customer to determine vehicle storage conditions.
Did the vehicle recently experience an extreme temperature change during the first 5 minutes of driving, either hot to cold or
cold to hot?
RC11 COMPARE THE EGT AND IAT PID VALUES
Allow the vehicle temperature to stabilize.

Key ON, engine OFF.
Access the PCM and monitor the EGT11, EGT12, EGT13 and IAT PIDs.
Is the suspect EGT sensor PID value within 40C (72F) of the IAT PID value?
RC12 CHECK THE SUSPECT EGT SENSOR CONNECTOR FOR CORROSION
NOTE: Disconnect the suspect EGT sensor harness connector. Only diagnose the suspect EGT sensor indicated
by the DTC or PID value.

pushed out pins
corrosion
RC13 DTCS P2081, P2085 AND P242E: DETERMINE THE CAUSE OF THE INTERMITTENT CONCERN
Key ON, engine OFF.

Access the PCM and monitor the EGT11_V, EGT12_V and EGT13_V PIDs.
Observe the suspect EGT PID for an indication of a concern while carrying out the following:
Shake, wiggle, and bend the EGT and SIGRTN circuits
Lightly tap on the EGT sensor to simulate road shock
pushed out pins
corrosion
RC14 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST V: CAMSHAFT POSITION (CMP) SENSOR

INTRODUCTION
CMP sensor (12K073)

harness circuits: CMP+ and CMP-
Fig. 83: Camshaft Position (CMP) Sensor

TEST PROCEDURE
V1 CHECK THE CMP SENSOR

Inspect the CMP sensor for misalignment and improper installation.
CMP Sensor connector disconnected.
Remove the CMP sensor.
Inspect the CMP sensor for damage.
Inspect the CMP sensor connector for damaged or corroded pins.
Yes No
GO to V2.
V2 CHECK THE RESISTANCE OF THE CMP SENSOR
Is the resistance between 616 - 1.275K ohms?
V3 CHECK THE CMP CIRCUITS FOR AN OPEN IN THE HARNESS

V4 CHECK THE CMP CIRCUITS FOR A SHORT TO VOLTAGE IN THE HARNESS

Key ON, engine OFF.
( + ) CMP
Sensor
(-)
Connector,
Harness Side
CMP- - Pin 2 Ground
CMP+ - Pin 1 Ground
Yes No
GO to V5.
V5 CHECK THE CMP CIRCUITS FOR A SHORT TO GROUND IN THE HARNESS

V6 CHECK THE CMP CIRCUITS FOR AN INTERMITTENT CONCERN

Key ON, engine OFF.
Access the PCM and monitor the CMP_F PID.
Wiggle all accessible harness from the CMP sensor to the PCM and lightly tap on the sensor.
Wiggle the CMP sensor connector.
Look for sudden changes in the reading when the harness is wiggled or the sensor is tapped.
Yes No
For DTCs P0341 and P0342, GO to V7.
For all others, the CMP sensor and wiring
REPAIR as necessary. is not a cause of the no start condition.
CLEAR the DTCs. REPEAT the self-test. RETURN to the SYMPTOM CHARTS
article, Symptom Charts for further
direction.
V7 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST W: EXHAUST GAS RECIRCULATION (EGR) SYSTEM

INTRODUCTION
harness circuits: VREF, EGRVCH, EGRVCL, EGR and SIGRTN

EGR valve
EGR VALVE POSITION SENSOR (APPROXIMATE)

10% 1.39 V
20% 1.66 V
30% 1.98 V
40% 2.27 V
50% 2.53 V
60% 2.78 V
70% 3.07 V
80% 3.4 V
90% 3.72 V
100% 3.99 V
Fig. 85: Exhaust Gas Recirculation (EGR) System Circuit


79 EGR (Exhaust Gas Recirculation)

19, 43 EGRVCH (Exhaust Gas Recirculation Valve Control High)
20, 44 EGRVCL (Exhaust Gas Recirculation Valve Control Low)
TEST PROCEDURE
W1 DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P0403, P0404, P0405, P0406, P042E, P042F, P1335 OR P1408:
PRELIMINARY DIAGNOSIS
NOTE: Diagnose any intake air system component, exhaust system component or VREF circuit DTCs before
diagnosing EGR DTCs.

Clear the DTCs.
Are any DTCs retrieved?
W2 DTCS P0401, P0402, P0404, P042E, P042F OR P1408: CHECK FOR OTHER DTCS

Are other DTCs present?
DESCRIPTIONS .
W3 CHECK THE EGR VALVE OPERATION
NOTE: Additional DTCs may set during the use of output state control (OSC). Clear all PCM and transmission
control module (TCM) DTCs after the diagnostics are completed. Repeat the self-test to verify all DTCs are
cleared.
Access the PCM and monitor the EBP_A and MAP PIDs.
Access the PCM and monitor the EGRVPA PID.
Access the PCM and monitor the EGRVP PID.
Record the PID values.
Access the PCM and control the EGRVPDES PID.

Monitor the EGRVP PID, EGRVPA PID, EBP_A PID and MAP PID while increasing and decreasing the EGRVPDES PID.
Do the EGRVP PID, EGRVPA PID, EBP_A or MAP reading indicate any EGR valve movement?
W4 CHECK FOR INPUT SENSOR BIAS

Key ON, engine OFF.
Are the BARO, EBP_A and MAP PIDs within specifications and is the EBP_A PID within 10.35 kPa (1.5 psi) of the MAP and
BARO PID values?
W5 DTC P0403: CHECK THE EGRVCL AND EGRVCH CIRCUITS FOR A SHORT TO VOLTAGE
Key ON, engine OFF.
( + ) EGR
Valve
(-)
Connector,
Harness Side
EGRVCL - Pin
Ground
2
EGRVCH - Pin
Ground
6
Yes No
GO to W6.
W6 CHECK THE EGRVCL AND EGRVCH CIRCUITS FOR A SHORT TO GROUND

W7 CHECK THE EGRVCL AND EGRVCH CIRCUITS FOR AN OPEN

( + ) PCM-E ( - ) EGR Valve

EGRVCL - Pin EGRVCL - Pin
20, 44 2
EGRVCH - Pin EGRVCH - Pin
19, 43 6
Yes No
GO to W8.
W8 CHECK THE EGR VALVE

( + ) EGR
( - ) EGR Valve
Valve
Connector,
Connector,
Component
Component
Side
Side
EGRVCH - Pin EGRVCL - Pin
6 2
Is the resistance between 0.5 - 50 ohms?
W9 DTC P0405: CHECK THE VREF CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
( + ) EGR
( - ) EGR Valve
Valve
Connector,
Connector,
Harness Side
Harness Side
VREF - Pin 1 SIGRTN - Pin 3
Yes No
GO to W10. refer to PINPOINT TEST B.
W10 CHECK THE EGR CIRCUIT FOR A SHORT TO GROUND

W11 CHECK THE EGR CIRCUIT FOR AN OPEN

W12 CHECK THE EGR VALVE POSITION VALUES

Access the PCM and control the EGRVPDES PID.
Monitor the EGRVP PID and compare the values to the EGR valve position sensor table at the beginning of this pinpoint test while
increasing and decreasing the EGRVPDES PID.
Does the EGRVP PID value and the EGRVPDES value match (approximately) with the EGR valve position sensor table?
Yes No
INSTALL a new EGR valve. REFER to
ENGINE EMISSION CONTROL -- F-
250-550 (SUPER DUTY PICKUPS) .
GO to W17. RESET the KAM, REFER
toRESETTING THE KEEP ALIVE
MEMORY (KAM) .
W13 DTC P0406: CHECK FOR DTC P0405


The EGR valve is disconnected to simulate the opposite DTC.
Key ON, engine OFF.
W14 CHECK THE EGR CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
EGR - Pin 5 Ground
Yes No
GO to W15.
W15 CHECK THE SIGRTN CIRCUIT FOR AN OPEN

( + ) PCM-E ( - ) EGR Valve

SIGRTN - Pin
SIGRTN - Pin 3
55
W16 DTC P1335: CHECK THE EGRVP PID VOLTAGE
Key ON, engine OFF.

Is the EGRVP PID voltage under 1.50 volts?
W17 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
Yes No
PINPOINT TEST WA: EXHAUST GAS RECIRCULATION TEMPERATURE (EGRT) SENSORS

INTRODUCTION
harness circuits: EGRT, EGRT2 and SIGRTN

EGRT sensor
EGRT2 sensor
EGRT SENSOR
360 680 2,447 3,087
380 716 1,967 2,447
400 752 1,601 1,967
420 788 1,319 1,601
440 824 1,098 1,319
460 860 924 1,098
480 896 784 924
500 932 671 784
520 968 578 671
540 1,004 502 578
560 1,040 439 502
580 1,076 386 439
600 1,112 341 386
620 1,148 302 342
640 1,184 268 305
660 1,220 240 273
680 1,256 215 246
700 1,292 194 222
720 1,328 176 201
EGRT2 SENSOR
50 122 29.12 41.46
60 140 20.19 28.06
70 158 14.26 19.38
80 176 10.25 13.63
90 194 7.784 9.757
100 212 5.547 7.096
110 230 4.169 5.238
120 248 3.174 3.92
130 266 2.446 2.972
140 284 1.906 2.281
150 302 1.502 1.77
160 320 1.195 1.388
170 338 0.9592 1.1
180 356 0.777 0.8797
190 374 0.6347 0.7098
200 392 0.5225 0.5775
210 410 0.4285 0.479
220 428 0.354 0.4
230 446 0.2945 0.3363
240 464 0.2467 0.2845
Fig. 87: Exhaust Gas Recirculation Temperature (EGRT) Sensor (1 Of 2)

Fig. 88: Exhaust Gas Recirculation Temperature (EGRT) Sensor (2 Of 2)

Pin Circuit

TEST PROCEDURE
WA1 DIAGNOSTIC TROUBLE CODES (DTCS) P040B, P040C, P040D, P041B, P041C AND P041D: PRELIMINARY DIAGNOSIS

Clear all the DTCs.
Are DTCs P040B, P040C, P040D, P041B, P041C or P041D present?
Yes No
For DTCs P040B or P041B, GO to WA2. WIGGLE the harness attempting to
For DTCs P040C or P041C, GO to WA5. recreate the concern. REPAIR as
For DTCs P040D or P041D, GO to WA7. necessary. REFER toNO DIAGNOSTIC
WA2 DTCS P040B OR P041B: CHECK SUSPECT EGRT SENSOR RELATED CONNECTORS AND TERMINALS
Inspect the EGRT sensor (P040B) or EGRT2 sensor (P041B) circuitry at the sensor and PCM.
WA3 CHECK FOR OTHER DTCS

WA4 CHECK THE SUSPECT EGRT SENSOR OPERATION

Key ON, engine OFF.
Access and monitor the EGRT_A or EGRT_B PID.
Record the EGRT_A or EGRT_B PID value.
Drive the vehicle while monitoring the EGRT_A or EGRT_B PID.
Does the EGRT_A or EGRT_B PID value change from the initial recorded value?
Yes No
INSTALL a new EGRT sensor or
EGRT2 sensor as necessary. REFER to
WA5 DTCS P040C OR P041C: SIMULATE THE OPPOSITE DTC

For DTC P040C.
EGRT Sensor connector disconnected.
For DTC P041C.
EGRT 2 Sensor connector disconnected.
Is the opposite DTC present?
WA6 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO GROUND

For DTC P040C.
( + ) EGRT
Sensor
(-)
Connector,
Harness Side
EGRT - Pin 2 Ground
For DTC P041C.

WA7 DTCS P040D OR P041D: CONNECT FUSED JUMPER TO SIMULATE OPPOSITE DTC
For DTC P040D.
EGRT Sensor connector disconnected.
For DTC P041D.

EGRT 2 Sensor connector disconnected.

EGRT 2 - Pin 2 SIGRTN - Pin 1
Key ON, engine OFF.

Is DTC P040C or DTC P041C present?
Yes No
INSTALL a new EGRT sensor or
EGRT2 sensor as necessary. REFER to
GO to WA8.
WA8 CHECK THE SIGNAL CIRCUIT FOR AN OPEN

For DTC P040D.
For DTC P041D.

WA9 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN

For DTC P040D.
( - ) EGRT
( + ) PCM-E
Sensor
Connector,
Connector,
Harness Side
Harness Side
SIGRTN - Pin
SIGRTN - Pin 1
55
For DTC P041D.

WA10 CHECK THE SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
For DTC P040D.
For DTC P041D.

Connector,
Harness Side
EGRT 2 - Pin 2 Ground
Yes No
GO to WA11.
WA11 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST X: EXHAUST PRESSURE (EP) SENSOR

INTRODUCTION
harness circuits: EP, SIGRTN, VREF

EP sensor (9J460)
EP SENSOR
Volts kPa psi
0.18 29 4.21
0.34 50 7.25
0.74 100 14.5


TEST PROCEDURE
X1 PRELIMINARY DIAGNOSIS FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0472 OR P0473

Clear the DTCs.
X2 DIAGNOSTIC TROUBLE CODE (DTC) P0472: CHECK THE VREF CIRCUIT FOR VOLTAGE
EP Sensor connector disconnected.
Key ON, engine OFF.
X3 CHECK THE EP SENSOR SIGNAL

Access the PCM and monitor the EBP PID.
Is the EBP PID voltage approximately 4.5 to 5.5 volts?
X4 CHECK THE SIGNAL CIRCUIT FOR AN OPEN


GO to X5.
X5 CHECK THE EP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND OR SIGNAL RETURN
( + ) EP Sensor
Connector, (-)
Harness Side
EP - Pin 3 Ground
X6 CHECK THE EP SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

EP Sensor connector disconnected.
X7 CHECK THE EP SENSOR SIGNAL CIRCUIT FOR A SHORT TO VREF

( + ) EP Sensor ( - ) EP Sensor
EP - Pin 3 VREF - Pin 2
Yes No
GO to X8.
X8 CHECK THE EP SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Key ON, engine OFF.
X9 DTC P0473: SETTING DTC P0472

Key ON, engine OFF.
X10 CHECK THE EP SENSOR FOR BIAS

Key ON, engine OFF.
Is the EBP PID value within 10.35 kPa (1.5 psi) of the MAP and BARO PID values?
Yes No
CHECK the EP sensor and tube for
blockage or restrictions. REPAIR as
INSTALL a new EP sensor.
necessary. REFER to the SYMPTOM
X11 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion
PINPOINT TEST Z: KEEP ALIVE POWER (KAPWR)

INTRODUCTION
battery cables loose or intermittent connections

harness circuit: KAPWR
engine cooling system concerns

TEST PROCEDURE
Z1 DIAGNOSTIC TROUBLE CODES (DTCS) P0603 AND P2610: PRELIMINARY DIAGNOSIS

Clear all the DTCs.
Z2 CHECK THE CHARGING SYSTEM

Check the battery and charging system. Refer to BATTERY, MOUNTING AND CABLES -- F-250-550 (SUPER DUTY
PICKUPS) .
Yes No
REPAIR as necessary. REFER to
BATTERY, MOUNTING AND
GO to Z3.
CABLES -- F-250-550 (SUPER DUTY
PICKUPS) .
Z3 CHECK THE KAPWR CIRCUIT FOR VOLTAGE

Key ON, engine OFF.
Z4 CHECK THE ENGINE COOLING SYSTEM

Check the engine cooling system for a low coolant condition or other cooling system concern. Refer to ENGINE COOLING -- F-250-
Is the engine cooling system OK?
Z5 CHECK FOR CORRECT PCM OPERATION

pushed out pins
corrosion

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2008

2008 ENGINE PERFORMANCE

Pinpoint Tests - F-250-550 6.4L Diesel Engines

PINPOINT TEST A: POWERTRAIN CONTROL MODULE (PCM) POWER RELAY

This pinpoint test is intended to diagnose the following:

harness circuits: B+, ISP-R, PCMRC, VPWR and PWRGND

Fig. 1: Fuel Injector Control Module (FICM) Relay Connector (1 Of 2)

lunes, 21 de agosto lunes,

2 PCMRC (PCM Relay Control)

Fig. 2: 58-Pin Body Connector

A1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

A3 CHECK THE PCM POWER RELAY

A4 CHECK THE B+ CIRCUITS FOR VOLTAGE

Are the voltages greater than 10 V?

A5 CHECK THE PCMRC CIRCUIT FOR AN OPEN

Is the resistance less than 5 ohms?

A6 CHECK THE PCMRC CIRCUIT FOR A SHORT TO VOLTAGE

Is any voltage present?

A7 CHECK THE PCMRC CIRCUIT FOR A SHORT TO GROUND

Is the resistance greater than 10K ohms?

A8 CHECK THE ISP-R CIRCUIT FOR VOLTAGE

Is the voltage greater than 10 V?

REPAIR the open circuit. CLEAR the

A9 CHECK THE ISP-R CIRCUIT FOR A SHORT TO VOLTAGE

Is any voltage present?

A10 CHECK THE VPWR CIRCUIT FOR AN OPEN

Are the resistances less than 5 ohms?

A11 CHECK THE PWRGND CIRCUITS FOR AN OPEN

Is the resistance less than 5 ohms?

A12 CHECK FOR CORRECT PCM OPERATION

This pinpoint test is intended to diagnose the following:

incorrect PCM calibration

AA1 DIAGNOSTIC TROUBLE CODE (DTC) P0605: PRELIMINARY DIAGNOSIS

AA2 PROGRAM THE PCM

Clear the DTCs.

AA3 CHECK FOR CORRECT PCM OPERATION

This pinpoint test is intended to diagnose the following:

drive conditions not satisfied

AC1 DIAGNOSTIC TROUBLE CODE (DTC) P1000: PRELIMINARY DIAGNOSIS

monitors have run and cleared.

AC2 CARRY OUT THE DIESEL DRIVE CYCLE TEST

AC3 CHECK FOR CORRECT PCM OPERATION

Visually inspect for:

PINPOINT TEST AD: POWERTRAIN CONTROL MODULE (PCM) RESET

This pinpoint test is intended to diagnose the following:

loose, damaged or corroded connections

Fig. 3: 58-Pin Body Connector

AD1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

AD2 CHECK THE VPWR CIRCUITS FOR VOLTAGE

AD3 CHECK THE PWRGND CIRCUITS FOR AN OPEN

Are the resistances less than 5 ohms?

PINPOINT TEST AE: UNABLE TO ACTIVATE SELF-TEST/NETWORK COMMUNICATION ERROR

This pinpoint test is intended to diagnose the following:

unable to communicate with the powertrain control module (PCM)

Fig. 4: Powertrain Control Module (PCM) (1 Of 2)

Fig. 5: 58-Pin Body Connector

AE1 DIAGNOSTIC TROUBLE CODE (DTC) P2545: PRELIMINARY DIAGNOSIS

AE3 CARRY OUT THE NETWORK TEST

AE4 CHECK THE VREF CIRCUIT FOR VOLTAGE

Key in OFF position.

Is the voltage between 4 - 6 V?

AE5 CHECK THE ISP-R CIRCUIT FOR VOLTAGE

Is the voltage greater than 10 V?

AE6 CHECK THE PCM VPWR CIRCUITS FOR VOLTAGE