1994-2004 Ford Mustang

03 04 Mustang PCM Quick Test

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(Last Updated On: January 7, 2018)

03 04 Mustang PCM Quick Test

QT: Step 1: PCM Quick Test

QT1 PERFORM PCM QUICK TEST

Note:

    If the vehicle was brought in with an emission compliance failure symptom, GO directly to Section 5; GO to EM1 .

  • Complete preliminary checks looking for obvious concerns that may relate to the symptom. Check items such as those listed:
    • Related electrical connectors or fuses
    • Vacuum lines (leaks, routing)
    • Air intake system (leaks, restrictions)
    • Fuel quality (octane, contamination, winter/summer blend)
    • Cooling system (engine operating at proper temperature)
  • Access any related OASIS or TSB information (if available).
  • Complete PCM Quick Test to access any DTCs. Note any Key On Engine Off, Key On Engine Running (if engine runs) and Continuous Memory (MIL and non-MIL) DTCs.Note: If unable to access DTCs, or any scan tool communication concern exists, GO to QA1 in Section 5. For additional information on retrieving MIL and non-MIL DTCs, refer to Section 2, Diagnostic Methods (Continuous Memory Self-Test).
Were any DTCs present?
Yes No
If engine runs rough at idle and Key On Engine Running or Continuous Memory DTC(s) are present: GO to Quick Test QT2 to check injector fault PIDS.

All Others:

GO to Section 4 (Diagnostic Trouble Code (DTC) Charts) for direction to service DTC(s) after noting the following:

Service DTCs in the following order (for each mode, begin diagnosis with the first DTC output).

  1. Any KOEO DTC(s)
  2. Any KOER DTC(s)
  3. Any Continuous Memory DTC(s) (retrieve any available Freeze Frame Data)(disregard any identical/related Continuous DTC(s) of DTC(s) already serviced).
 GO to Step 2: NO DTC(s) PRESENT SYMPTOM CHART INDEX for direction to proper STEP 3 Chart.Note: If symptom is not listed, REFER to applicable Workshop Manual or GO to Z1 in Section 5 (for intermittent PCM system diagnostics).

QT2 ENGINE RUNS ROUGH AT IDLE WITH KEY ON ENGINE RUNNING OR CONTINUOUS MEMORY DTC(s): CHECK INJECTOR FAULT (INJxF) PID(s)

Note:

    An injector circuit fault could result in unrelated DTC(s) being received from the PCM.

  • Key on, engine off.
  • Access the INJxF PIDs (the “x” indicates the injector number). There will be one INJxF PID for each engine cylinder.
Do any of the INJxF PIDs indicate a fault (or Yes)?
Yes No
An injector circuit fault exists. KEY OFF. Disregard DTC(s).Natural Gas applications:

GO to HA60 .

All Others:

GO to H56 .

 No fault detected by injector fault PIDs. KEY OFF. GO to Quick Test QT1 and follow the YES Action To Take for all others.

Step 2: No DTC(s) Present Symptom Chart Index

Driveability
System/Symptom Oasis Number Chart Number
Starting Concerns Hard Start/Long Crank/Erratic Start/Erratic Crank 602300 Chart Number: 2
Stall After Start — Chart Number: 1
No Start/Normal Crank 603300 Chart Number: 3
Unique Idle Concerns Slow Return to Idle 617400 Chart Number: 4
Rolling Idle 618400 Chart Number: 1
Fast Idle 619400 Chart Number: 5
Low/Slow Idle — Chart Number: 6

 

Driveability – Performance While Driving Concerns
System/Symptom Oasis Number Chart Number
Stalls/Quits Idle, Acceleration, Cruise 607×00 Chart Number: 1
Deceleration 607700 Chart Number: 6
Runs Rough 608×00 Chart Number: 1
Misses 609×00 Chart Number: 1
Buck/Jerk 610×00 Chart Number: 1
Hesitation/Stumble 611×00 Chart Number: 1
Surge 612×00 Chart Number: 1
Backfires 613×00 Chart Number: 7
Lack/Loss of Power 614×00 Chart Number: 8
Spark Knock 615×00 Chart Number: 9

Note: OASIS identifiers (the “x” means any number (1-9) can be used) xxx4xx=during idle, xxx5xx=during acceleration, xxx6xx=during cruise, xxx7xx=during deceleration.

Additional Driveability Concerns
System/Symptom Oasis Number Chart Number
Diesels/Runs On 621000 Chart Number: 5
Poor Fuel Economy 622000 Chart Number: 10
Emissions Compliance 623000 Chart Number: 11
Malfunction Indicator Lamp (MIL) Concern 698298 Chart Number: 12

 

Electrical
System/Symptom Oasis Number Chart Number
Warning Indicators Malfunction Indicator Lamp (MIL) 698298 Chart Number: 12
Transmission Control Indicator Lamp (TCIL) 698298 Chart Number: 12
Temperature Warning Indicator Lamp or Gauge (applications with CHT sensor only) — Chart Number: 12
Shift Indicator Lamp (SIL) 698298 Chart Number: 12
Check Fuel Cap Indicator Lamp — Chart Number: 12
Climate Control Lack of A/C cooling, A/C not functioning 208200 Chart Number: 21
A/C always on and/or A/C compressor runs continuously — Chart Number: 21
A/C does not cut off under WOT conditions (Mustang only) — Chart Number: 21
Instrumentation Tachometer Inoperative — Chart Number: 14
Speedometer/odometer Inoperative — Chart Number: 14
Boost gauge indicates higher than normal boost (supercharger applications) — Chart Number: 14

 

Engine
System/Symptom Oasis Number Chart Number
Oil System Concerns High Oil Consumption — Chart Number: 15
Leaks — Chart Number: 15
Cooling System Concerns Electric cooling fan(s) does not operate (low, medium, high and/or variable speed) — Chart Number: 16
Electric cooling fan always runs — Chart Number: 17
Exhaust System Concerns Visible smoke — Chart Number: 18
Odor (sulfur or “rotten egg” smell) — Chart Number: 22
Fuel System Concerns Odor, engine compartment — Chart Number: 19
Engine Noise (under hood) 497000 Chart Number: 20

 

Driveline
System/Symptom Oasis Number Chart Number
Manual Transmission Concern Shift Indicator Lamp (SIL) 505000 Chart Number: 12
Automatic Transmission Shift Concerns A/T upshift concern 501000 Chart Number: 13
A/T downshift concern 502000 Chart Number: 13
Engagement concern 503000 Chart Number: 13

Step 3: No DTC(s) Present Symptom Charts

Chart 1

  • Starting Concerns: Stalls After Start
  • Stalls/Quits: Idle, Acceleration, Cruise
  • Runs Rough
  • Misses
  • Buck/Jerk
  • Hesitation/Stumble
  • Surge
  • Unique Idle concerns: Rolling Idle

Note: For stalls on passenger car applications, engine may stall if left running while refueling. Advise customer to turn engine off while refueling to avoid contamination or damage to the EVAP system.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Check The Following PIDs:
    • DPFEGR (if equipped) (hot idle value within 0.15V of KOEO value)
    • LONGFT1 / LONGFT2 (value between -20 and +20)
    • VPWR (value between 10.5 and 17.0 volts, and within 0.5 volts of battery voltage)
  • DPFEGR PID value not within 0.15V of KOEO value:
    • For vehicles equipped with ESM EGR: GO to HH100
    • All others: GO to HE100
  • LONGFT1 / LONGFT2 value low (-):
  • Continue diagnosis.
  • Concentrate checks in areas that would cause the engine to run rich.
  • LONGFT1 / LONGFT2 value high (+):
  • Continue diagnosis.
  • Concentrate checks in areas that would cause the engine to run lean.
  • VPWR not between 10.5 and 17.0 volts:
  • Go to the Workshop Manual, Charging System Section 414.
  • VPWR between 10.5 and 17.0 volts, but not within 0.5 of battery voltage:
  • CHECK B(+) supply to PCM power relay (or CCRM). CHECK VPWR circuit between PCM and PCM power relay or CCRM. CHECK PWR GND circuits.
  • For vehicles that run rough at idle:
  • With the key on, engine off, check the INJxF PIDs (the “x” indicates the injector number, there will be one INJxF PID for each engine cylinder). All INJxF PIDs must indicate no fault (or NO).
  • INJxF PID(s) indicate a fault (an injector circuit fault is indicated):
    • Natural Gas applications:
    • GO to HA60
    • All others:
    • GO to H56
  • Mass Air Flow (MAF) Sensor
  • GO to DC25
  • Secondary Ignition System
  • GO to JB1
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Exhaust System
  • GO to HF1
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • Natural Gas applications with rough idle:
  • Injector circuits between NG module and injectors.
  • GO to HA57
  • EVAP System
  • Check for EVAP system blockages (engine stalls) or leaks (other symptoms). REFER to Evaporative Emissions, Section 303 in the Workshop Manual (Section 310 for LS, Thunderbird, Explorer, Aviator and Blackwood).
  • Automatic Transmission
  • Automatic Transaxle/Transmission – Section 307 of the Workshop Manual
  • Base Engine
  • Engine System – General Information, Section 303 of the Workshop Manual
  • Intake Air System
  • GO to HU1
  • Applications with A/C Pressure Sensor (3 wire sensor):
  • A/C pressure (ACP) sensor input to PCM
  • GO to DS22
  • Additional Testing
  • GO to Z1
  • Additional Checks:Note: Some applications have a PID that will indicate whether the PCM is reducing torque (TQ_CNTL)(#095E b0), and if so, why the torque is being reduced (#095Eb1-13) (0 = No torque reduction requested; 1 = Torque Truncation. Cuts fuel to protect when line pressure fails to minimum limit; 2 = Traction Control Event. Cuts fuel and/or spark for traction control; 3 = Vehicle Speed Limit – Cuts fuel).
    • Correct PCM vehicle identification (VID) block information (refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
    • Be aware of engine RPM/speed limiting functions of the PCM (look for incorrect high vehicle speed signal from ABS, VSS or OSS)
    • Drivelines
    • Manual transmission/clutch
    • Charging System
    • Traction control system (if equipped)
    • A/C system (for surge with A/C on)
    • Speed control system (for surge with speed control on)
    • A/C compressor diode, if equipped (for rolling idle)
  • Applicable section in Workshop Manual.

Chart 2

  • Starting Concerns:
    • Hard Start/Long Crank
    • Erratic Start/Erratic Crank
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Battery Condition and Current Draw
  • Visual, Charging System – General Information Section 414 in the Workshop Manual.
  • Secondary Ignition System
  • GO to JB1
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Exhaust System
  • GO to HF1
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • EVAP System
  • Check for EVAP system blockages (engine stalls) or leaks (other symptoms). REFER to the Evaporative Emissions, Section 303 in the Workshop Manual (Section 310 for LS, Thunderbird, Explorer, Aviator and Blackwood).
  • Intake Air System
  • GO to HU1
  • Starting System
  • Starting System, Section 303 in the Workshop Manual.
  • Contaminated MAF Sensor
  • Visual Check
  • 5.4L SC F-Series only:
  • Check high speed fuel pump secondary circuits.
  • GO to KA70
  • Idle Air Control (IAC) System
  • GO to KE1
  • Additional Testing
  • GO to Z1

Chart 3

  • Starting Concerns:
    • No Start, Normal Crank

Note: Extended cranking because of a no start can load the exhaust system with raw fuel, damaging the catalytic converter after the engine starts. For applications with Secondary Air Injection (AIR) Systems, perform the following after the no start has been repaired: Disconnect the electric secondary air injection (AIR) solid state relay, run the engine until the surplus fuel is used up, and reconnect the relay (disconnecting the relay may set a Continuous Memory PCM DTC that will need to be cleared).

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Add-on Anti-Theft Devices
  • Visual, check with customer.
  • Fuel/Ignition
  • Thunderbird and LS6/LS8:
  • GO to KB85 .
  • All others:
  • GO to A1 .
  • If engine will not start now:
  • If engine will not start at closed throttle, but will start and run normally at part throttle, check Idle Air Control (IAC) System.
  • Engine will now start and run normally at part throttle:
  • GO to KE2
  • Exhaust System (restrictions)
  • GO to HF1
  • Base Engine
  • Engine System – General Information Section 303 of the Workshop Manual.
  • Additional Testing
  • GO to Z1

Chart 4

  • Unique Idle Concerns:
    • Slow Return To Idle
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Vacuum Leaks, Throttle Body
 Visual
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • Intake Air System (air leaks)
  • GO to HU1
  • Idle Air Control (IAC) System
  • GO to KE1

Chart 5

  • Unique Idle Concerns:
    • Fast Idle
  • Additional Driveability Concerns:
    • Diesels/Runs On

Note: If vehicle runs normally after the ignition key is turned OFF, check for damaged ignition switch, IGN RUN circuit short to power, VPWR circuit short to power, etc. Refer to applicable Wiring Diagram and/or Workshop Manual.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Base engine air leaks, including proper sealing of intake manifold and components/vacuum lines attached to intake air (such as the PCV, EGR or IAC valve/vacuum lines).
  • Visual, Engine System – General Information Section 303 of the Workshop Manual.
  • Verify engine operates at normal temperature.
  • Visual (refer to Symptom Index, or Engine Cooling Section 303 of Workshop Manual, to diagnose any cooling system concerns that are present).
  • Fast idle concerns:
  • Key on, engine off, monitor TP MODE PID while wiggling TP sensor circuits. TP MODE PID can also be monitored during vehicle drive. With throttle closed, TP MODE PID must be C/T (closed throttle).
  • TP Mode PID is not C/T with throttle closed: Note: At vehicle start, the TPREL will begin at about 1.25 volts, and count down to the lowest TP V value seen since engine start. If the TP V value goes below the “normal” range, then increases again, TPREL will set to the lower voltage. If TP V is about 0.04 volts greater than the TPREL value at closed throttle, the PCM will go into part throttle mode.
  • Monitor TP V and TPREL PIDs for sudden changes while checking for intermittent TP circuit/connector concerns. Also check for loose/worn throttle plates. If no concern is found, GO to Z1 in Section 5.
  • Intake Air System (air leaks)
  • GO to HU1
  • Idle Air Control (IAC) System
  • GO to KE1
  • Additional Testing
  • GO to Z1

Chart 6

  • Unique Idle Concerns:
    • Low/Slow Idle
  • Stalls/Quits
    • Deceleration
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • For A/T with Stalls/Quits on deceleration:
  • Transmission
 Automatic Transaxle/Transmission, Section 307 of the Workshop Manual (Diagnosis By Symptom: Torque Converter Concerns)
  • For Low idle with A/C on (4.6/5.4L/6.8L E-Series):
  • Check ACCS PID with A/C on and engine running (PID should indicate ON when A/C clutch is engaged). (On applications where the PCM cannot control the A/C clutch on and off, the PCM uses the ACCS circuit to determine additional load on the engine.)
  • ACCS PID does not indicate ON with A/C clutch engaged:
  • GO to KM10
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Intake Air System
  • GO to HU1
  • Base Engine
  • Engine System – General Information, Section 303-00.
  • Additional Checks:
    • Verify fuel cap is properly tightened, and not physically damaged.
    • Check if the operation of certain systems are causing the low idle.
  • Visual

Chart 7

  • Backfires
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Secondary Ignition
  • GO to JB1
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Base Engine
  • Engine System – General Information, Section 303 of the Workshop Manual.
  • Exhaust System
  • GO to HF1
  • Additional Testing
  • GO to Z1

Chart 8

  • Lack/Loss of Power

Note: Verify symptom is reported under normal driving conditions without excessive engine/vehicle load. Also, be aware of the engine rpm/speed limiting functions of the PCM.

Note: For applications with knock sensor, a lack of power may result when the vehicle is operated with a breakout box installed at the PCM. The KS circuits are not shielded in the breakout box, and KS signal noise may be noticed by the PCM. If this happens, spark timing will be retarded and a lack of power may result.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
    • Automatic Transmission Fluid
    • Throttle Linkage
    • Air cleaner element
  • Visual
  • Check the Following PIDS:
    • DPFEGR (if equipped) (hot idle value within 0.15V of KOEO value)
    • LONGFT1 / LONGFT2 (value between -20 and +20)
    • For 4.6L E/F Series, 5.4L 4V Navigator/Blackwood: IMTVF with both Key On Engine Off, and with transmission in PARK/NEUTRAL and engine rpm greater than 3000 rpm (PID should indicate no fault (or NO) in both situations).
  • DPFEGR PID value not within 0.15V of KOEO value:
    • For vehicles equipped with ESM EGR: GO to HH100
    • All others: GO to HE100
  • LONGFT1 / LONGFT2 value low (-):
  • Continue diagnosis.
  • Concentrate checks in areas that would cause the engine to run rich.
  • LONGFT1 / LONGFT2 value high (+):
  • Continue diagnosis. Concentrate checks in areas that would cause the engine to run lean.
  • IMTVF PID indicates a fault:
  • GO to HU65
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All others:
  • GO to HC1
  • Secondary Ignition
  • GO to JB1
  • Mass Air Flow (MAF) Sensor
  • GO to DC25
  • Exhaust System
  • GO to HF1
  • Base Engine
  • Engine System – General Information, Section 303 of the Workshop Manual
  • Automatic Transmission
  • Automatic Transaxle/Transmission, Section 307 of the Workshop Manual (Diagnosis by Symptom – Poor Performance)
  • Brake System (brake drag or binding)
  • Brake System Section 206 of the Workshop Manual
  • Mustang only:
  • Check for lack of A/C cutoff under wide open throttle conditions.
  • Audible (listen for A/C clutch to disengage during a brief wide open throttle, then re-engage a few seconds after returning to idle). Follow Symptom Chart 21 if A/C does not cutoff.
  • Supercharged applications:
  • Supercharger bypass system
  • GO to KJ13
  • 5.4L SC F-Series:
  • Check high speed fuel pump secondary circuits
  • GO to KA70
  • Additional Testing
  • GO to Z1
  • Additional Checks:Note: Some applications have a PID that will indicate whether the PCM is reducing torque (095E b0), and if so, why the torque is being reduced (095E b1-13).
    • Customer driving habits
    • Correct PCM vehicle identification (VID) block information (refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
    • IMRC linkage (if equipped)
    • Clutch (M/T)
    • Charging System
    • Engine RPM/speed limiting functions of the PCM (look for incorrect high vehicle speed signal from ABS, VSS or OSS)
  • Visual. Appropriate Group of the Workshop Manual.

Chart 9

  • Spark Knock
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Verify engine operates at normal temperature
  • Visual (refer to Symptom Index, or Engine Cooling Section 303 of the Workshop Manual, to diagnose any cooling system concerns that are present).
  • Verify correct coolant level and coolant concentration
  • Refer to Engine Cooling Section 303-03 for proper fill concentrations and fill procedures.
  • Mass Air Flow (MAF) Sensor
  • GO to DC25
  • Base Engine
  • Engine System – General Information Section 303 of the Workshop Manual
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Secondary Ignition System
  • GO to JB1
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • Engine Oil Quality
  • Visual
  • Additional Testing
  • GO to Z1

Chart 10

  • Poor Fuel Economy

Note: Since driving styles can have a significant influence on fuel economy, verify the concern before starting an in-depth diagnosis. Also, the following external factors could contribute to “poor fuel economy” conditions:

  • Stop/go driving
  • Improper tire pressure/size
  • Vehicle loads (such as trailer towing)
  • Extended winter warm-up conditions
  • High speed driving
  • Improper axle ratio
  • Road/weather conditions
  • Aftermarket add-ons
  • Short run operations
  • Customer expectations
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Transmission Fluid Level
  • Visual
  • Check The Following PIDs:
    • DPFEGR (if equipped) (hot idle value within 0.15V of KOEO value)
    • LONGFT1 / LONGFT2 (value between -20 and +20)
    • VPWR (value between 10.5 and 17.0 volts, and within 0.5 volts of battery voltage)
  • DPFEGR PID value not within 0.15V of KOEO value:
    • For vehicles equipped with ESM EGR: GO to HH100
    • All others: GO to HE100
  • LONGFT1 / LONGFT2 value low (-):
  • Continue diagnosis. Concentrate checks in areas that would cause the engine to run rich.
  • LONGFT1 / LONGFT2 value high (+):
  • Continue diagnosis. Concentrate checks in areas that would cause the engine to run lean.
  • VPWR not between 10.5 and 17.0 volts:
  • Go to the Charging System – General Information Section 414 of the Workshop Manual.
  • VPWR between 10.5 and 17.0 volts, but not within 0.5 of battery voltage:
  • CHECK B(+) supply to PCM power relay (or CCRM). CHECK VPWR circuit between PCM and PCM power relay or CCRM. CHECK PWR GND circuits.
  • Verify engine operates at normal temperature
  • Visual (refer to Symptom Index, or Engine Cooling Section 303 of the Workshop Manual, to diagnose any cooling system concerns that are present).
  • Secondary Ignition System
  • GO to JB1
  • Fuel System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Exhaust System
  • GO to HF1
  • Automatic Transmission
  • Automatic Transaxle/Transmission Section 307 of the Workshop Manual (Diagnosis by Symptom – Poor Performance)
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • Additional Checks:
    • Correct PCM vehicle identification (VID) block information (refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
    • Brake drag
    • Base engine concerns
    • Incorrect PCV valve
    • Contaminated MAF sensor
    • Intake air system
  • Appropriate section in Workshop Manual
  • Additional Testing
  • GO to Z1

Chart 11

  • Emissions Compliance
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Emissions Related Systems
  • GO to EM1

Chart 12

  • Warning Indicators:
    • MIL
    • TCIL
    • SIL
    • Temperature Warning Indicator Lamp or Gauge (applications with CHT sensor)
    • Check Fuel Cap Indicator Lamp

Note:

  • If the symptom is both “MIL on” AND “exhaust emission test failure”, GO directly to Chart 11.
  • If engine is a no start, GO directly to Chart 3.
  • If engine runs rough at idle, GO directly to Chart 1.
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Verify fuel filler cap is properly tightened
  • Visual
  • Trucks with Power Takeoff (PTO) and MIL concern:
  • PTO input to PCM
  • GO to FB3
  • MIL always on when engine is running (no DTCs):
  • MIL circuits
  • Focus, Mustang, Town Car, Thunderbird, LS6/LS8, Escape, Windstar, F-150, Expedition, Aviator, Navigator and Blackwood:
  • Instrument Cluster, Section 413 of the Workshop Manual.
  • All Others:
  • GO to NB1
  • TCIL always on when engine is running (no DTCs):
  • TCIL circuits
  • Focus, Mustang, Town Car, Thunderbird, LS6/LS8, Windstar , Expedition, Aviator and Navigator:
  • Instrument Cluster, Section 413 of the Workshop Manual.
  • All Others:
  • GO to TB6
  • MIL never on (including the bulb check when the engine is first started):
  • MIL circuits
  • Focus, Mustang, Town Car, Thunderbird, LS6/LS8, Escape, Windstar, F-150, Expedition, Aviator, Navigator and Blackwood:
  • Instrument Cluster, Section 413 of the Workshop Manual.
  • All others:
  • GO to NB2
  • TCIL never on:
  • TCIL circuits
  • Focus, Mustang, Town Car, Thunderbird, LS6/LS8, Windstar, Expedition, Aviator and Navigator:
  • Instrument Cluster, Section 413 of the Workshop Manual.
  • All others:
  • GO to TB8
  • Temperature Warning Indicator Lamp or Gauge concerns (applications with CHT sensor only):
  • Engine cooling system or lamp circuits
  • If engine is overheating:
  • Engine Cooling, Section 303 of the Workshop Manual. Be aware that since a PCM DTC was not received, the PCM has not attempted to turn the lamp on.
  • If engine operates at normal temperature:
  • GO to DL40
  • SIL always on or off:
  • SIL circuits
  • GO to KL1
  • Check Fuel Cap Indicator Lamp Always on or off:
  • Check fuel indicator lamp circuits
  • Escort, Focus, Taurus/Sable, Crown Victoria/Grand Marquis, Ranger, Explorer Sport/Sport Trac and F-150 (except Lightning):
  • Indicator Lamp Always On:
  • GO to HX88
  • Indicator Lamp Always Off:
  • GO to HX89
  • All others:
  • Instrument Cluster, Section 413 of the Workshop Manual.
  • Additional Testing
  • GO to Z1

Chart 13

  • Automatic Transmission Concerns:
    • Upshift
    • Downshift
    • Engagement
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Transmission
  • Automatic Transaxle/Transmission Section 307 of the Workshop Manual
  • Additional Tests
  • GO to Z1

Chart 14

  • Instrumentation:
    • Tachometer Inoperative
    • Speedometer Inoperative
    • Boost Gauge indicates higher than normal boost (supercharger applications)
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Tachometer Inoperative
  • Applications with CTO circuit from PCM pin 48:
  • CTO circuit from PCM
  • GO to JH1
  • Speedometer/odometer Inoperative
  • Applications with Manual Shift On The Fly (MSOF) transfer case using a Transfer Case Speed Sensor (TCSS):
  • GO to DP30
  • Boost Gauge indicates higher than normal boost
  • Supercharger bypass control
  • Intercooler system
  • Supercharger bypass control: GO to KJ1
  • Intercooler system: GO to KP7
  • Instrumentation
  • Instrument Cluster, Section 413 of the Workshop Manual

Chart 15

  • Oil System Concerns:
    • High Oil Consumption
    • Leaks
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4
  • Base Engine
  • Engine System – General Information Section 303 of the Workshop Manual
  • Additional Checks
    • External leaks
    • Proper dipstick
    • Proper oil viscosity
  • Visual

Chart 16

  • Cooling System Concerns:
    • Electric Cooling Fan(s) Does Not Operate (Low, Medium, High or Variable speed))
    • Visctronic Cooling Fan Does Not Operate
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Electric or Visctronic Cooling Fan Components
  • Escort and Mustang:
  • GO to X40
  • Crown Victoria/Grand Marquis, LS6/LS8, Thunderbird and Town Car:
  • GO to KN15
  • F-Series, Expedition and Navigator:
  • GO to KG4
  • All Others:
  • GO to KF25
  • Cooling System
  • Engine Cooling, Section 303 of the Workshop Manual

Chart 17

  • Cooling System Concerns:
    • Electric or Visctronic Cooling Fan(s) Always Runs

Note: This chart is intended to only diagnose an electric or Visctronic cooling fan that always runs with a “cool” engine and the A/C and defroster off.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Cooling fan circuits and ACPSW or ACP circuits
  • Escort and 4.6L Mustang:
  • GO to X80
  • 3.8L Mustang:
  • GO to X82
  • Crown Victoria/Grand Marquis, Thunderbird, LS6/LS8 and Town Car:
  • VERIFY results of Quick Test. Visually inspect cooling fan for concerns.
  • Windstar:
  • GO to KF63
  • F-Series, Expedition and Navigator:
  • GO to KG10
  • Aviator:
  • Go to Cooling System check below
  • Ranger:
  • GO to KF65
  • All Others:
  • GO to KF60
  • Cooling System
  • Engine Cooling, Section 303 of the Workshop Manual

Chart 18

  • Exhaust System Concerns:
    • Smoke

Note: Black smoke indicates a rich fuel mixture, blue smoke indicates burning oil, and white smoke indicates water in the combustion chamber.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Base Engine
  • Engine System – General Information Section 303 of the Workshop Manual
  • Black Smoke:
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All Others:
  • GO to HC1
  • Black Smoke:
  • Ignition System
  • GO to JB1
  • Blue Smoke:
  • PCV System
  • For 4.6L Mustang, Aviator:
  • GO to HG1
  • All Others:
  • GO to HG4

Chart 19

  • Fuel System Concerns:
    • Odor, Engine Compartment
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Natural Gas Applications:
  • Fuel Delivery System
  • GO to HB16
  • EVAP System
  • Check for EVAP system leaks. REFER to Evaporative Emissions, Section 303 in the Workshop Manual (Section 310 for LS, Thunderbird, Explorer, Aviator and Blackwood).
  • Fuel System
  • Visual (refer to Fuel Tank and Lines, Section 310 of the Workshop Manual for system description)

Chart 20

  • Engine Noise (under hood)

Note: Attempt to identify source of noise. If noise is from source other than those listed below, refer to Symptom Index (for noise such as spark knock) or applicable Workshop Manual section.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Snap noise that may be due to secondary ignition arcing:
  • Secondary Ignition System
  • Coil On Plug Ignition Systems:
  • Check condition of spark plug boots.
  • All Others:
  • GO to JB1

Chart 21

  • Climate Control:
    • Lack of Cooling (A/C)/ A/C Not Functioning
    • A/C Always On
    • A/C Compressor Runs Continuously
    • A/C Does Not CUT-OFF Under WOT Conditions (Mustang only)
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Mustang only:
  • A/C electrical circuits
  • For lack of A/C cooling or A/C not functioning:
  • GO to X98 (Mustang)
  • For A/C always on:
  • GO to X140 (Mustang)
  • For A/C does not CUT-OFF under WOT conditions:
  • GO to X130 (Mustang)
  • A/C System
  • If sent here from Workshop Manual with WACF PID indicating a fault (or YES):
  • GO to Section 4 , Powertrain Diagnostic Trouble Code (DTC) Charts and follow direction for KOEO DTC P0645.
  • All others:
  • Climate Control System, Section 412 of the Workshop Manual

Chart 22

  • Exhaust System Concerns
    • Odor (Sulfur, Rotten Egg Smell)

Note: A slight sulfur smell may be normal. Catalysts with less than 8,000-16,000 kilometers (5,000-10,000 miles)(new vehicle or replaced catalyst) are likely to have a sulfur smell due to the highly active state of new catalysts. Replacing the catalyst can actually make the symptom worse.

SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
  • Check for any driveability or exhaust smoke symptoms
  • Refer to STEP 2: NO DTC(s) PRESENT SYMPTOM Chart INDEX for direction to repair other symptoms.
  • Fuel Delivery System
  • Natural Gas Applications:
  • GO to HB1
  • All others:
  • GO to HC1
  • EVAP System
  • Check for EVAP system leaks. REFER to Evaporative Emissions, Section 303 in the Workshop Manual (Section 310 for LS, Thunderbird, Explorer, Aviator and Blackwood).
  • Fuel Source
  • Talk with customer. Since sulfur content can vary in different fuels, suggest trying a different fuel source.

 

 

 

 

 

 

 

 

 

 

 

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