2015 ford e-series and f-series
TRANSCRIPT
DIAGNOSTIC MANUALP-01B101-AF
2011-2014
Ford E-Series and F-Series ProductsLiquid Propane Autogas Fuel System (3rd Generation)Includes:E-150/E-250/E-350 Cargo Van/WagonE-150/E-250/E-350 Extended Range Cargo Van/WagonE-450 Custom BodyF-250/F-350/F-450/F-550/F-650F-53/F-59
Revision History
-AA Initial Release 2/2013
-AB Revised 5/2013
-AC Revised 7/2013
-AD Revised 11/2013
-AE Revised 3/2014
-AF Revised 8/2014
TABLE OF CONTENTS
Page iii
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Installation, Garaging and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Purging and Venting (Tanks and Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5About Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5System and Diagnostic Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Diagnostic Trouble Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Flow Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Bleed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Tank Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Fuel Rail Pressure Control Module Supply Solenoid and Wiring . . . . . . . . . . . . . . . . . . . . . .12SRM, CAN Bus Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Electronic Fuel Pump Relay (A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Integrated Pressure Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
DIAGNOSTIC TESTS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21No Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Slow Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Over Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Engine Cranks, No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Engine Stumble, Stall, Rough Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Excess Flow Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Maximum Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Supply Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Fuel System Fails to Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Fuel Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Fuel Level Indication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Tank Solenoid Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Fuel Rail Pressure Control Module Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Integrated Pressure Temperature Sensor Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Fuel Pump Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Fuel Pump Control Module Electrical Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Smart Relay Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Fuel Level Sender Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Fuel Level Interface Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Manual Solenoid Activation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .52E-150/250/350 Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .53E-150/250/350 Extended Range Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .54E-450 Custom Body Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . .55
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TABLE OF CONTENTS
F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .56F-650 Chassis Cab Wiring Harness and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . .57F-450/550 Roush Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58F-650 Chassis Cab, Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59F-53/59 Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness . . . . . . . .61E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness . . . . . . . . .62E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . .63E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness . . . . . . . . . .64E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness . . . . . . . . . .65E-450 Stripped Chassis CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . .67F-250/350 Pickup, F-450/550 and F-650, Tank Solenoid Harness Electrical Schematic . . . .68F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . .69F-250/350 Pickup, FTPT Jumper Harness Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . .70F-650 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71F-650 Fuel Tank Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72F-650 Underhood Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73F-53/59 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74F-53/59/250/350/450 Rear Frame Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .75F-53/59/250/350/450 Underhood Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . .76F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . .77
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INTRODUCTION
SAFETY INFORMATIONThe National Fire Protection Association (NFPA) publishes a code book of rules that apply to the storage, handling, transportation and use of liquefied petroleum gas (LP-Gas or LPG). The book is known as NFPA 58. It is revised as necessary and published every other year. This code is adopted as law in virtually every political subdivision in the United States. Check with your local authorities for regulations applicable to liquid propane.
Alert Messages
The following alert messages may appear from time to time in appropriate places in this manual. Ensure that all personnel read and adhere to these alert messages.
Although propane is nontoxic, nonpoisonous, has the lowest flammability range of any alternative fuel and dissipates quickly when released into the atmosphere, propane vapor is heavier than air and seeks the lowest point. When the ratio of propane to air is between 2.2% and 9.6%, propane will burn in the presence of an ignition source at 940°F (504°C) or hotter. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Failure to heed this danger may result in severe personal injury or death.
The fuel supply lines remain pressurized after engine shutdown. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Do NOT enter storage areas or confined space unless they are adequately ventilated. Failure to heed this danger may result in severe personal injury or death.
Do NOT carry lighted smoking materials or smoke while working on fuel system components. Failure to heed this danger could result in severe personal injury or death.
Disconnect the battery ground at the battery to ensure that the vehicle electrical system has no current. Failure to heed this danger could result in severe personal injury or death.
Propane is heavier than air and seeks the lowest available level when released to the atmosphere. Keep heat, sparks, flames, static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank. Failure to heed this danger can result in severe personal injury or property damage.
Technicians working with, or around, fuel systems should be properly trained to utilize extreme care and caution at all times. Failure to exercise extreme caution and care may lead to serious accidents which can result in property damage, personal injury and/or death.
Liquid propane is cold. The temperature of propane in its liquid state at atmospheric pressure is −44°F (−42°C). Wear eye and ear protection during venting and repair operations. Keep moisture away from the valves. Failure to heed this warning can result in personal injury.
INTRODUCTION
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Installation, Garaging and Training
Chapter 11 of NFPA 58 applies to engine fuel systems using LP-Gas in internal combustion engines, including containers, container appurtenances, carburetion equipment, piping, hose and fittings and their installation. Additionally, this chapter applies to garaging of vehicles and to the training of personnel.
Paragraph 11.2 specifies that each person engaged in installing, repairing, filling or otherwise servicing an LP-Gas engine fuel system shall be trained. Contact the Propane Education and Research Council to learn more about their CETP E-Learning computer-based training program: [email protected], or [email protected].
Purging and Venting (Tanks and Lines)
Venting of LP-Gas to the atmosphere is covered by paragraphs 7.3.1, General, and 7.3.2, Purging of NFPA 58, 2008 edition. Refer to NFPA 58, Local Codes and Proper Training for specific information relating to safe venting of LPG.
TROUBLESHOOTING
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DIAGNOSTIC TROUBLE CODES
About Diagnostic Trouble Codes
All diagnostic trouble codes (DTCs) known to be affected by the liquid propane autogas (LPA) system are covered in this manual. For all other
DTCs, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
System and Diagnostic Terminology
Acronym or Abbreviation Description
BS Bleed Solenoid
CAN Controller Area Network
DTC Diagnostic Trouble Code
EFPR Electronic Fuel Pump Relay
ERFS Electronic Returnless Fuel System
EVAP Evaporative
FCS Flow Control Solenoid
FLIM Fuel Level Interface Module
FLS Fuel Level Sender
FP Fuel Pump
FPCM Fuel Pump Control Module
FRP Fuel Rail Pressure
FRPCM Fuel Rail Pressure Control Module
FTS Fuel Temperature Sensor
GRD Ground
HEGO Heated Exhaust Gas Oxygen
IC Instrument Cluster
IPTS Integrated Pressure Temperature Sensor
KOEO Key On Engine Off
KOER Key On Engine Running
LPA Liquid Propane Autogas
MAF Mass Air Flow
OEM Original Equipment Manufacturer
OPD Overfill Protection Device
PCM Powertrain Control Module
PID Parameter Identification
PWR GND Power Ground
SIG RTN Signal Return
SRM Smart Relay Module
SS Supply Solenoid
TS Tank Solenoid
VMV Vapor Management Valve
VPWR Voltage Power
VREF Voltage Reference
WOT Wide Open Throttle
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TROUBLESHOOTING
Diagnostic Trouble Code List
Code Description
P0005 Fuel Shutoff Valve A Control Circuit Open
P0090 Fuel Pressure Regulator Circuit Open
P009B Fuel Pressure Relief Control Circuit Open
P009E Fuel Pressure Relief Control Performance Stuck Off
P009F Fuel Pressure Relief Control Stuck On
P0148 Fuel Delivery Error
P0171 System Too Lean (Bank 1)
P0172 System Too Rich (Bank 1)
P0174 System Too Lean (Bank 2)
P0175 System Too Rich (Bank 2)
P0182 Fuel Temperature Sensor (A) Circuit Low
P0183 Fuel Temperature Sensor (A) Circuit High
P0190 Fuel Pressure Sensor A Circuit
P0192 Fuel Pressure Sensor A Circuit Low
P0193 Fuel Pressure Sensor A Circuit High
P025A Fuel Pump Control Module Circuit Range/Performance A
P027A Fuel Pump Control Module Circuit Range/Performance B
P03xx Misfire
P0460 Fuel Level Sender A Circuit
P0461 Fuel Level Sender A Circuit Range/Performance
P0462 Fuel Level Sender A Circuit Low
P0463 Fuel Level Sender A Circuit High
P0627 Fuel Pump A Control Circuit Open
P116E Exceeded Maximum Pressure
P2067 Fuel Level Sensor B Circuit Low
P2068 Fuel Level Sensor B Circuit High
P2195 Heated Exhaust Gas Oxygen Sensor Stuck
P2197 Heated Exhaust Gas Oxygen Sensor Stuck
P25B1 Fuel Level Sensor B Stuck
P2632 Fuel Pump B Control Circuit Open
P2665 Supply Solenoid Circuit Fault
P26B3 Fuel Shutoff Valve A Control Circuit Performance/Stuck Off
P26B5 Fuel Shutoff Valve B Function Check
U0108 Lost Communication with Alternative Fuel Control Module
U0109 Lost Communication with Fuel Pump Control Module A
U016C Lost Communication with Fuel Pump Control Module B
U0309 Alt Fuel Module-Wrong SRM
TROUBLESHOOTING
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Calibration Release OBD Summary Chart
OEM MY HDE MY Cert Calibration OBD Class Detail Chart Comments
Vehicle (03P150)
E-Series 2011 N/A Fed Only PBGD-Ax & Bx OBD II E-Series 5.4L Group
FED OBD Identifier
2012 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group
2013 N/A Fed PBGD-Ax & Bx OBD II E-Series 5.4L Group
FED OBD Identifier
2013 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group
Fuel Pump Codes Added
F-250/F-350 2012 N/A 50S Only PCDH-Ax & Bx OBD II F-Series 6.2L Group
2013 N/A Fed PCDH-Cx & Dx OBD II F-Series 6.2L Group
Fuel Pump Codes Added
2013 N/A 50S PCDH-Ax & Bx OBD II F-Series 6.2L Group
Fuel Pump Codes Added
E-450 2011 2011 Fed PBJC-Bx & Dx Non-OBD (EMD)
E-Series 6.8L HDE
OBD I / EMD Level
2012 2012 50S PBJC-Ax & Cx Non-OBD (EMD)
E-Series 6.8L HDE
OBD I / EMD Level
2013 2013 50S PDJC-Ax & Bx EMD+ E-Series 6.8L HDE
Cat Monitor Added
F-450/F-550 2012 2011 Fed PCEB-Ax Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2012 2012 Fed PCEB-Ax Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2013 2012 Fed PCEB-Ax Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2013 2013 50S PDEB-Ax EMD+ F-Series 6.8L HDE
Cat Monitor Added
F-59 (Step Van)
2013 2012 Fed PCEB-Sx Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2013 2013 50S PDEB-Sx EMD+ F-Series 6.8L HDE
Cat Monitor Added
F-53 (Motorhome)
2013 2012 Fed PCEB-Mx Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2013 2013 50S PDEB-Mx EMD+ F-Series 6.8L HDE
Cat Monitor Added
F-650 2012 2012 Fed PCFB-Ax Non-OBD (EMD)
F-Series 6.8L HDE
OBD I / EMD Level
2013 2013 50S PDFB-Ax EMD+ F-Series 6.8L HDE
Cat Monitor Added
Note: HDE MY - Heavy Duty Engine Model Year (Some HD products have different engine certifications within the vehicle model year.)
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TROUBLESHOOTING
Calibration Release OBD Summary Chart
E-Series 5.4L GroupE-150/E-250/E-350
F-Series 6.2L GroupF-250/F-350
Code Descriptions 2012 50S
2013 Fed
2013 50S
2012 50S
2013 Fed
2013 50S
P0005 Fuel Shutoff Valve A Control Circuit Open 1 1 1 1 1 1
P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1 1 1
P009B Fuel Pressure Relief Control Circuit Open 2 2 2 2 2 2
P009E Fuel Pressure Relief Control Performance Stuck Off 2 2 2 2 2 2
P009F Fuel Pressure Relief Control Stuck On 2 2 2 2 2 2
P0148 Fuel Delivery Error 1 1 1 1 1 1
P0171 System Too Lean (Bank 1) 2 2 2 2 2 2
P0172 System Too Rich (Bank 1) 2 2 2 2 2 2
P0174 System Too Lean (Bank 2) 2 2 2 2 2 2
P0175 System Too Rich (Bank 2) 2 2 2 2 2 2
P0182 Fuel Temperature Sensor (A) Circuit Low 2 2 2 2 2 2
P0183 Fuel Temperature Sensor (A) Circuit High 2 2 2 2 2 2
P0190 Fuel Pressure Sensor A Circuit 2 2 2 2 2 2
P0192 Fuel Pressure Sensor A Circuit Low 2 2 2 2 2 2
P0193 Fuel Pressure Sensor A Circuit High 2 2 2 2 2 2
P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 2 1 2 2
P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2
P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 2 1 2 2
P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2
P03xx Misfire 2 2 2 2 2 2
P0460 Fuel Level Sender A Circuit 2 2 2 2 2 2
P0461 Fuel Level Sender A Circuit Range/Performance 2 2 2 2 2 2
P0462 Fuel Level Sender A Circuit Low 2 2 2 2 2 2
P0463 Fuel Level Sender A Circuit High 2 2 2 2 2 2
P0627 Fuel Pump A Control Circuit Open 1 1 2 1 2 2
P116E Exceeded Maximum Pressure 1 1 1 1 1 1
P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2
P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2
P2632 Fuel Pump B Control Circuit Open 1 1 2 1 2 2
P2665 Supply Solenoid Circuit Fault 1 1 1 1 1 1
P26B3 Fuel Shutoff Valve A Control Circuit Performance/Stuck Off
1 1 1 1 1 1
P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1 1 1
U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2 2 2
U016C Lost Communication with Fuel Pump Control Module B 1 1 2 1 2 2
U0309 Alt Fuel Module-Wrong SRM 2 2 2 2 2 2
0 Code not present
1 DTC – non MIL
2 DTC – MIL (two trips)
TROUBLESHOOTING
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Calibration Release OBD Summary Chart
E-Series 6.8L HDE GroupE-450
F-Series 6.8L HDE GroupF-450/550/650/53/59
Code Descriptions 2012 50S 2013+ 50S 2012 50S 2013+ 50S
P0005 Fuel Shutoff Valve A Control Circuit Open 1 1 1 1
P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1
P009B Fuel Pressure Relief Control Circuit Open 1 2 2 2
P009E Fuel Pressure Relief Control Performance Stuck Off 1 2 2 2
P009F Fuel Pressure Relief Control Stuck On 0 0 0 0
P0148 Fuel Delivery Error 1 1 1 1
P0171 System Too Lean (Bank 1) 2 2 2 2
P0172 System Too Rich (Bank 1) 2 2 2 2
P0174 System Too Lean (Bank 2) 2 2 2 2
P0175 System Too Rich (Bank 2) 2 2 2 2
P0182 Fuel Temperature Sensor (A) Circuit Low 1 2 2 2
P0183 Fuel Temperature Sensor (A) Circuit High 1 2 2 2
P0190 Fuel Pressure Sensor A Circuit 1 2 2 2
P0192 Fuel Pressure Sensor A Circuit Low 1 2 2 2
P0193 Fuel Pressure Sensor A Circuit High 1 2 2 2
P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 1 1
P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1
P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 1 1
P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1
P03xx Misfire 1 1 1 1
P0460 Fuel Level Sender A Circuit 1 1 1 1
P0461 Fuel Level Sender A Circuit Range/Performance 0 0 0 0
P0462 Fuel Level Sender A Circuit Low 1 1 1 1
P0463 Fuel Level Sender A Circuit High 1 1 1 1
P0627 Fuel Pump A Control Circuit Open 1 1 1 1
P116E Exceeded Maximum Pressure 1 1 1 1
P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2
P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2
P2632 Fuel Pump B Control Circuit Open 1 1 1 1
P2665 Supply Solenoid Circuit Fault 1 1 1 1
P26B3 Fuel Shutoff Valve A Control Circuit Performance/Stuck Off
1 1 1 1
P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1
U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2
U016C Lost Communication with Fuel Pump Control Module B 1 1 1 1
U0309 Alt Fuel Module-Wrong SRM 2 2 2 2
0 Code not present
1 DTC – non MIL
2 DTC – MIL (two trips)
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TROUBLESHOOTING
Flow Control Solenoid
P0090 — Fuel Pressure Regulator Circuit Open
Bleed Solenoid
P009E/P26B3 — Fuel Pressure Relief Control Performance Stuck Off
P009F — Fuel Pressure Relief Control Stuck On
Description FCS circuit fault. SRM monitors FCS circuit for open and short circuit faults.
Possible Causes � Short to voltage
� Water in the harness connector
� Open power circuit
� GND circuit
� Low battery voltage
� Corrosion
� Incorrect connections
� Damaged FCS coil
� Blown fuse
Symptom Fuel pressure in the rail does not change when commanded. Extended fuel rail flush time.
Diagnostic Aid Check the FRPCM and SRM electrical connector for damage, corrosion and water intrusion.
Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures.
Description Fuel rail failed to bleed. The PCM measures fuel rail pressure on key-up to determine if fuel rail has been properly bled.
Possible Causes � BS did not open
� FRPCM check valve leaked (P26B3)
� FRPCM supply solenoid leaked (P26B3)
� Bleed port (bleed rate restrictor in outlet to VMV) clogged
� EVAP line kinked
� Blown fuse
Symptom Fuel pressure present in the fuel rail after bleed event should have occurred; this may result in hard starts.
Diagnostic Aid Check that FRPCM bleeds fuel from rail. Leaks to FRPCM can also trigger a fault.
Action Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures.
Description Bleed solenoid stuck open. While the engine is running, the PCM seals the EVAP system and checks for a rise in pressure. If pressure in the EVAP system exceeds the threshold, a fault is set.
Possible Causes � Short to GRD
� Armature stuck in post
� Solenoid seal compromised
Symptom There is a potential for fuel odor.
Diagnostic Aid —
Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures.
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P009B — Fuel Pressure Relief Control Circuit Open
Tank Solenoid
P0005 — Fuel Shutoff Valve A Control Circuit Open
Description Bleed solenoid circuit fault. The SRM monitors bleed solenoid circuit for open and short circuit faults.
Possible Causes � Short to voltage
� Water in the harness connector
� Open power circuit
� Open GND circuit
� Low battery voltage
� Corrosion
� Incorrect connections
� Damaged BS coil
Symptom Fuel rail bleed system does not operate correctly. There is a potential for fuel odor or hard start.
Diagnostic Aid Check the FRPCM and SRM electrical for damage, corrosion and water intrusion.
Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures.
Description TS circuit fault. The SRM monitors tank solenoid circuit for open and short circuit faults.
Possible Causes � Short to voltage
� Water in the harness connector
� Open power circuit
� Open GND circuit
� Low battery voltage
� Corrosion
� Incorrect connections
� Damaged TS coil
� Blown fuse
Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail.
Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action Refer to the Tank Solenoid Electrical Check procedure in Diagnostic Tests and Procedures.
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Fuel Rail Pressure Control Module Supply Solenoid and Wiring
P26B5 — Fuel Shutoff Valve B Function Check
P2665 — Supply Solenoid Circuit Fault
Description Fuel supply solenoid stuck. The SRM monitors fuel rail pressure before and after the solenoid was commanded open. If the pressure rise is below a threshold, the fault is set.
Possible Causes � Electrical fault
� Damaged SS coil
� Damaged SS armature
� Excess flow valve tripped
� Tank solenoid stuck closed
� Tank manual valve closed
� Fuel pumps not powering on
� Blown fuse
Symptom Vehicle does not start. The pumps run (or may not) but no pressure builds in the fuel rail.
Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.
Description FRPCM supply solenoid circuit fault. SRM monitors supply solenoid circuit for open and short circuit faults.
Possible Causes � Short to voltage
� Water in the harness connector
� Open power circuit
� Open GND circuit
� Low battery voltage
� Corrosion
� Incorrect connections
� Damaged SS coil
� Blown fuse
Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail.
Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.
Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures.
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SRM, CAN Bus Circuit Wiring
U0108 — Lost Communication with Alternative Fuel Control Module
U0309 — Alternate Fuel Module-Wrong SRM
Fuel System
P0148 — Fuel Delivery Error
Description Lost communication with SRM. The PCM monitors CAN bus communication for missing messages from the SRM. If the messages are continuously missing, a fault is set.
Possible Causes � Wiring between the SRM and PCM
� SRM lacks power
� Blown fuse
Symptom Rough idle.
Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Check for power at the SRM.
Action Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures.
Description Alternate Fuel Module (SRM) is not broadcasting over vehicle communication link the expected SRM module identifier. A U0309 code should only be expected during initial build or during service replacement of the SRM module.
Possible Causes � Incorrect SRM was installed into the vehicle for initial build or during service of the SRM
� Loss of CAN communications between the SRM and PCM
Symptom � MIL light
� Fuel gage may not read full or empty correctly
Diagnostic Aid � Verify to latest calibration
� Verify SRM part number is correct for vehicle type and tank
� Verify that no other DTCs are set related to CAN communications
� Inspect CAN harness for connection issues and integrity
Action Replace SRM to correct type or fix any CAN communication DTCs or wiring/connection concerns.
Description LPA system is operating in vapor space. At least one bank is lean at WOT.
Possible Causes � Severely restricted fuel filter
� Severely restricted fuel supply line
� Damaged or worn fuel pump
� Damaged or contaminated MAF sensor
� Excess flow valve tripped
� TS or SS closed
� Tank manual shutoff valve not completely open
Symptom Vehicle hesitation or stall condition.
Diagnostic Aid —
Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.
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P116E — Maximum Pressure
P0171, P0174 — System Too Lean (Bank 1 and Bank 2 respectively)
P0172, P0175 — System Too Rich (Bank 1 and Bank 2 respectively)
P03xx — Misfire
Description Maximum injection pressure reached. The PCM monitors fuel rail pressure and battery voltage. Based on these measurements, the PCM adjusts fuel pump speed to stay below the maximum operating pressure of the injectors.
Possible Causes � Operating the vehicle in high ambient conditions
� Vehicle operated in a low voltage condition
Symptom Vehicle hesitation, stall, rough idle, misfire or no start.
Diagnostic Aid The P116E code is meant as an indication that the fuel system was operated at the limits of the system. The customer may have experienced drive issues although the system is performing as expected.
Action Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures.
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes � The LPA system was operated in the vapor region
� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom —
Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes � The LPA system was operated in the vapor region
� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom —
Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes � The LPA system was operated in the vapor region
� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom —
Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
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Heated Exhaust Gas Oxygen Sensor
P2195, P2197 — Heated Exhaust Gas Oxygen Sensor Stuck
Electronic Fuel Pump Relay (A/B)
U0109, U016C — Lost Communication with Fuel Pump Control Module A/B
P025A, P027A — Fuel Pump Control Module Circuit Range/Performance
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes � The LPA system was operated in the vapor region
� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom —
Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure.
Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.
Description The SRM repeats the signal from the second EFPR to the PCM over the CAN bus. The PCM monitors this communication. If there is a lack of communication for a long enough period of time, a fault is set.
Possible Causes � Wire fault between the EFPR and SRM
� Wire fault between SRM and PCM
� No power to the EFPR
� SRM fault
� CAN bus fault
� Blown fuse
� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom —
Diagnostic Aid —
Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure and also the Smart Relay Module Electrical Test procedure in Diagnostic Tests and Procedures.
Description The SRM receives the output of the second fuel pump monitor line and repeats the output over the CAN bus to the PCM. The PCM monitors the commanded output versus the monitor’s feedback. If the monitor is out-of-range, a fault is set.
Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.
Symptom Poor starts, rough idle, hesitation/surge.
Diagnostic Aid —
Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures.
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Integrated Pressure Temperature Sensor
P0182 — Fuel Temperature Sensor (A) Circuit Low
P0183 — Fuel Temperature Sensor (A) Circuit High
Description The SRM reads the IPTS and passes the voltage reading over the CAN to the PCM monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes � CAN bus fault between the SRM and PCM
� Wiring fault between IPTS and SRM
� Short in harness
� VREF open or short
� Low ambient temperature operation
� Incorrect harness connection
� Damaged IPTS (or FTS)
� IPTS failure
� SRM failure
Symptom —
Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short.
Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.
Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes � CAN bus fault between the SRM and PCM
� Wiring fault between IPTS and SRM
� Open circuit
� Open or short to voltage in harness
� Incorrect harness connection
� Damaged IPTS (FTS)
� IPTS failure
� SRM failure
Symptom —
Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short.
Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.
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P0190 — Fuel Pressure Sensor A Circuit
P0192 — Fuel Pressure Sensor A Circuit Low
P0193 — Fuel Pressure Sensor A Circuit High
Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes � CAN bus fault between the SRM and PCM
� Wiring fault between IPTS and SRM
� VREF open in harness
� VREF open in sensor
� Vacuum leaks
� IPTS failure
� SRM failure
Symptom —
Diagnostic Aid VREF should be between 4–6 volts.
Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.
Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes � CAN bus fault between the SRM and PCM
� Wiring fault between IPTS and SRM
� IPTS FRP signal short to SIG RTN or PWR GND
� Damaged IPTS (or FRP)
� IPTS failure
� SRM failure
Symptom —
Diagnostic Aid A FRP PID value during ignition ON, engine OFF, or ignition ON, engine running is less than 0.3 volt. This indicates a concern is present.
Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.
Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle.
Possible Causes � CAN bus fault between the SRM and PCM
� Wiring fault between IPTS and SRM
� IPTS FRP signal short to VREF or VPWR
� IPTS (or FRP) open signal
� Damaged IPTS (or FRP)
� IPTS failure
� SRM failure
Symptom —
Diagnostic Aid Verify the FRP PID value to determine open or short.
Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.
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Fuel Level Sender
P0460 — Fuel Level Sender A Circuit
P0461 — Fuel Level Sender A Circuit Range/Performance
P0462 (P2067) — Fuel Level Sender A (B) Circuit Low
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the FLS and the SRM and not the IC.
Symptom —
Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM.
Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.
Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.
Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the sender and the SRM and not the IC.
Symptom —
Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM.
Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.
Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value.
Possible Causes � Fuel level sender wiring shorted to ground
� Damaged Fuel Level Sender
� Smart Relay Module
Symptom P0462 — Fuel gauge may read empty all the timeP2067 — Fuel gauge will only show primary tank
Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster.
Action Refer to the following tests located later in this manual.� SRM Electrical Test
� Fuel Level Sender Test
� Fuel Level Interface Module
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P0463 (P2068) — Fuel Level Sender A (B) Circuit High
P25B1 — Fuel Level Sensor B Stuck
Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value.
Possible Causes � Fuel level sender wiring is disconnected or shorted to above 5 volts
� Damaged Fuel Level Sender
� Smart Relay Module
Symptom P0463 — Fuel gauge may read full all the time
P2068 — Fuel gauge will only show primary tank
Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster.
Action Refer to the following tests located later in this manual.
� SRM Electrical Test
� Fuel Level Sender Test
� Fuel Level Interface Module
Description Failed transfer of fuel from secondary tank B to primary tank A. Failure code sets if a transfer is not detected by sender movement in 3 transfer attempts.
Possible Causes Secondary tank transfer failure causes:� Tank supply solenoid did not open
� Manual valve closed
� Excess flow valve trips on transfer attempts
� Blown fuse
� Electrical fault or relay failure that supplies the tank solenoid or pumps
� SRM hardware failure
� Sender arm stuck
� Sender signal out of range
� Fuel transfer line between secondary and primary tank kinked or plugged
� High differential of pressure when the primary tank greater than ~60 psi over secondary tank (typically caused by higher temperatures in the primary tank)
Primary tank transfer failure causes:� Faulty transfer OPD connected to transfer line
Symptom � Fuel indication is only based on primary tank sender
� Customer does not achieve expected driving range
� Short fuel fills (only adds fuel to primary tank)
� Cluster fuel gauge may indicate inconsistent behavior
Diagnostic Aid Check all electrical connectors and voltage supply to the secondary tank valve and fuel pumps. Verify that the secondary tank sender voltages (or resistances) are in the expected range. Verify that no other primary or secondary tank out-of-range codes are set (P0462, P0463, P2067, P2068).
Action Refer to the Secondary Tank – Fuel Will Not Transfer Troubleshooting.
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Secondary Tank – Fuel Will Not Transfer
F-650 vehicles can be equipped with a unique ROUSH CleanTech liquid propane autogas storage system which includes two fuel tanks. The system operates as if it were just one large tank. A few key points about the system:
• The engine is always running from the driver's side tank. All fuel to the engine, and the excess fuel returning to the tank, is only connected to this tank.
• The passenger's side tank is used to store extra fuel only. When the driver's side tank fuel level drops, the system will activate fuel pumps in passenger's side tank to transfer fuel automatically.
• Both tanks are filled at the same time from the single fuel filler located on the driver's side. There is a ball valve on the fill line for the right-hand tank, which is used for periodic inspections only. It should always be open during normal operation in order to use the full system capacity.
The ROUSH CleanTech control system reads the usable fuel level in each tank and adds them together to provide a single reading for the instrument cluster. However, if the system detects a failure in the fuel transfer system which may interfere with the ability to transfer fuel, it will provide a reading based on the driver's side tank only. This ensures that the driver is warned before the vehicle runs out of fuel. If this occurs, the vehicle is fully usable, but should be serviced in order to restore full function and use of the full system fuel capacity.
The fuel transfer line from the passenger's side tank is connected to a dedicated overfill prevention device (OPD) on the driver's side tank. This is a safety device which ensures that even if there is a fault in the control system, it is not possible for the driver's side tank to overfill during transfers.
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DIAGNOSTIC TESTS AND PROCEDURESGeneral InformationMeasuring Fuel Rail and Fuel Tank PressureMeasuring Fuel Tank Pressure — Fuel tank pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information regarding the tools required.
Method 1 — Install a 0–500 psi (0–3447 kPa) fuel pressure gauge on the bleeder valve at the tank, or to the remote bleeder valve location. Open the valve to monitor the fuel tank pressure. Record the value.
Method 2 — If a 0–500 psi (0–3447 kPa) fuel pressure gauge is not available, fuel rail pressure can be used to infer fuel tank pressure. Refer to Method 1 of Measuring Fuel Rail Pressure. Monitor fuel rail pressure with the engine running. Turn the engine off and continue to monitor fuel rail pressure. When the pressure has stabilized, record the value as fuel tank pressure.
Measuring Fuel Rail Pressure — Fuel rail pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual for more information regarding the tools required.
Method 1 — Using the OBD-II scan tool, read the fuel rail pressure PID. If using the Ford IDS tool, it will be necessary to select the tool box tab, then select Powertrain near bottom of selection, OBD Test Modes, Mode 1 Powertrain Data. Then locate and select FRP (pressure) from PID selection table.
Method 2 — Empty the fuel rails and fuel lines. Refer to the Fuel Line Purging Procedure in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information. Using the Jiffy-Tite disconnect tool, disconnect the fuel supply line at the rear of the RH fuel rail. Install the ROUSH service port adapter between the fuel line and the fuel rail. Attach 0–500 psi (0–3447 kPa) fuel pressure gauge to the service port on the adapter. Record the value.
Expected Fuel Tank Pressure — On a tank at ambient temperature conditions, the following pressures can be expected:
On vehicles that have been operated for extended periods of time, the tank (fuel) can be much warmer and so higher pressures are to be expected.
Expected Fuel Rail Pressure — Under normal operating conditions, the fuel pump has two operating speeds. The pump operates in low speed mode at idle and during moderate fuel flow/part throttle driving. Once a fuel demand threshold is met, typically during wide open throttle (WOT) operation, the pump is switched to high speed. The pump is also operated at high speed during the pre-start flush sequence.
Temperature (°F)
Pressure (psi)
Min. Nominal Max.
0 15 25 35
5 19 29 39
10 23 33 43
15 28 38 48
20 33 43 53
25 38 48 58
30 43 53 63
35 49 59 69
40 55 65 75
45 62 72 82
50 69 79 89
55 77 87 97
60 84 94 104
65 93 103 113
70 102 112 122
75 111 121 131
80 121 131 141
85 131 141 151
90 142 152 162
95 153 163 173
100 165 175 185
105 178 188 198
110 191 201 211
115 205 215 225
120 219 229 239
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The fuel pressure controls are designed to keep the rails at a certain pressure over tank pressure, therefore, it is important to measure tank pressure prior to collecting fuel rail pressure data. For example, if the fuel tank is at 150 psi (1034 kPa) and pressure in the rail is measured at 200 psi (1379 kPa), the rail is running at 50 psi (345 kPa) over tank.
Under extreme operating conditions, there is a third pump mode. In the event that the fuel system has degraded and the sensor detects vapor, or if the fuel rail pressure is approaching the limit of the fuel system, the pump runs in a variable speed mode, controlling to a target pressure. In this mode there is no predicted rise over tank pressure. The fuel pump will adjust the pressure to maintain a required operating pressure. This condition will likely result in a P116E or P0148 code.
No Fill
Condition Pump SpeedPressure Over Tank
Engine Off Off <10
Idle Low >30
Part Throttle Low <25
Part Throttle High >25
WOT High >25
Step Procedure Action
1 Inspect vehicle to check for kinked fill lines.Are fill lines kinked?
Yes — Replaced kinked fill lines.
No — Go to Step 2.
2 Determine the location of the overflow protection device (OPD).Is the OPD located in the end cap of the fuel tank?
Yes — Go to Step 3.No — Go to Step 6.
3 Check the fuel gauge in the instrument cluster.Is the gauge indicating less than 1/4 full?
Yes — Go to Step 4.
No — Go to Step 6.
4 Check to see if the OPD is being activated.
Fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.
a. Loosen the fuel fill line at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line and release the OPD valve. Retighten the fill line.
b. Install a fuel fill pressure tester on the fill valve and close the ball valve.
c. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.
d. Did the tank fill?
Yes — Go to Step 5.No — Go to Step 6.
5 Remove the fuel fill pressure tester and attempt to fill the vehicle fuel tank to full 80% capacity.Does the vehicle fuel tank fill to capacity?
Yes — Diagnostic is complete.No — Go to Step 6.
6 Check the fuel gauge in the instrument cluster.Is the gauge indicating more than 1/2 full?
Yes — Go to Step 7.No — Go to Step 11.
7 Reverse direction of vehicle at the pump and try to fill the vehicle.Does the vehicle fuel tank fill?
Yes — Vehicle not on level ground. Diagnostic is complete.No — Drive vehicle until fuel gauge indicates less than 1/2 full and go to Step 8.
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8 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?
Yes — Go to Step 9.
No — Go to Step 11.
9 Open bleeder valve.Does liquid fuel vent?
Yes — Go to Step 10.No — Go to Step 12.
10 Check fuel gauge.Does fuel gauge read full?
Yes — Diagnostic complete.
No — Refer to Fuel Level Indication Check.
11 Check for sufficient fill station pressure.
a. Connect pressure gauge service tool to the fuel tank bleeder valve and record pressure.
b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle.
c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure.
d. Is fill station pump pressure at least 20 psi (138 kPa) greater than tank pressure?
Yes — Go to Step 12.No — Fill station may not be providing enough pressure to fill. Go to Step 19.
12 Check body side fuel fill valve; it may be stuck closed.
a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line.
b. Attempt to push open the piston in the fill valve to determine if it is stuck closed.
c. Is the fill valve piston stuck closed?
Yes — Replace body-side fill valve and go to Step 13.
No — Replace filter in the fuel fill line and go to Step 15.
13 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?
Yes — Diagnostic is complete.No — Go to Step 14.
14 Replace the filter in the fuel fill line and then attempt to fill the vehicle fuel tank.Does the vehicle fuel tank fill?
Yes — Diagnostic is complete.
No — Go to Step 16.
15 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?
Yes — Diagnostic is complete.
No — Go to Step 16.
16 Replace the OPD valve in the vehicle fuel tank.Is the OPD valve located in the end cap of the fuel tank?
Yes — Go to Step 17.No — Go to Step 18.
17 Attempt to fill the vehicle fuel tank as follows:
When filling a new tank that has the OPD valve mounted in the end cap of the fuel tank, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.
a. Install a fuel fill pressure tester on the fill valve and close the ball valve.
b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.
c. Remove the fuel fill pressure tester.
d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle.
e. Did the tank fill?
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer Service at 800-597-6874.
18 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?
Yes — Diagnostic is complete.No — Call ROUSH CleanTech Customer Service at 800-597-6874.
Step Procedure Action
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Slow Fill
19 Fill station is not providing enough pressure to fill.
a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature.
b. Is the vehicle fuel tank pressure greater than 20 psi (138 kPa) over the nominal expected pressure?
Yes — Go to Step 20.
No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 12.
20 Vehicle fuel tank is at a higher pressure.
a. Higher pressure is likely caused by heavy vehicle usage heating the fuel.
b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank.
When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 21.
21 Measure and compare vehicle fuel tank and fill station pressures.
a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure.
b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle.
c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure.
d. Is fill station pump pressure at least 20 psi (138 kPa) greater than fuel tank pressure?
Yes — Go to Step 22.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 22.
Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility).
22 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?
Yes — Diagnostic is complete.No — Go to Step 12.
Step Procedure Action
Step Procedure Action
1 Inspect vehicle to check for kinked fill lines.Are fill lines kinked?
Yes — Replaced kinked fill lines.No — Go to Step 2.
2 Determine flow rate at which the vehicle fuel system fills.
a. Time the fill station pump for 10 seconds and record the number of gallons dispensed.
b. Multiply the gallons dispensed by six to determine the flow rate in gallons per minute.
c. Is the fill station pump flow rate at least 6 gal (23 L) per minute?
Yes — System fill rate is OK; diagnostic is complete.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 3.
3 Measure and compare vehicle fuel tank and fill station pressures.
a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure.
b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle.
c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure.
d. Is fill station pump pressure at least 50 psi (345 kPa) greater than fuel tank pressure?
Yes — Go to Step 4.
No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 11.
4 Check fuel fill valve; it may not be opening completely.
a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line.
b. Attempt to push open the piston in the fill valve to determine if it is opening completely. Piston should travel 1/4 inch.
c. Is the fill valve piston opening completely?
Yes — Replace the filter in the fuel fill line and then go to Step 7.No — Replace the fuel fill valve and then go to Step 5.
5 Attempt to fill the vehicle fuel tank.Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Go to Step 6.
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6 Replace the filter in the fuel fill line.Does the vehicle fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.
No — Go to Step 7.
7 Attempt to fill the vehicle fuel tank.Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.No — Go to Step 8.
8 Replace the overfill protection device (OPD) valve in the vehicle fuel tank.Is the OPD valve located in the end cap of the fuel tank?
Yes — Go to Step 9.
No — Go to Step 10.
9 Attempt to fill the vehicle fuel tank as follows:
When filling a new tank that has the OPD valve mounted in the end cap, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.
a. Install a fuel fill pressure tester on the fill valve and close the ball valve.
b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.
c. Remove the fuel fill pressure tester.
d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle.
a. Did the tank fill?
Yes — Diagnostic is complete.
No — Call ROUSH CleanTech Customer Service at 800-597-6874.
10 Attempt to fill the vehicle fuel tank.Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.No — Call ROUSH CleanTech Customer Service at 800-597-6874.
11 Fill station is not providing enough pressure to fill.
a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature.
b. Is the vehicle fuel tank pressure greater than 20 psi (38 kPa) over the nominal expected pressure?
Yes — Go to Step 12.
No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 2.
12 Vehicle fuel tank is at a higher pressure.
a. Higher pressure is likely caused by heavy vehicle usage heating the fuel.
b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank.
When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 13.
13 Measure and compare vehicle fuel tank and fill station pressures.
a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure.
b. Using a fuel fill pressure tester installed on the fuel fill valve, attempt to fill the vehicle.
c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure.
d. Is fill station pump pressure at least 50 psi (345 kPa) greater than fuel tank pressure?
Yes — Go to Step 14.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 14.
Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility).
14 Attempt to fill the vehicle fuel tank.Does the fuel tank fill at greater than six gal (23 L) per minute?
Yes — Diagnostic is complete.No — Go to Step 4.
Step Procedure Action
Page 26
TROUBLESHOOTING
Over Fill
Step Procedure Action
1 Suspect overfill because fuel fill volumes achieved during refueling exceed the rated fuel capacity or excessive vehicle range between refueling.
a. Check the fuel gauge.b. Is the gauge reading below 1/2 tank?
Yes — Go to Step 2.No — Drive vehicle until gauge reads below 1/4 tank.
2 Open bleeder valve located on the tank or remotely mounted on the vehicle.
a. Listen at valve to verify propane vapor is venting.b. Is propane vapor venting?
Yes — Go to Step 3.
No — Bleeder valve is not functioning properly. Replace the valve.
3 Park the vehicle at the refueling station.
a. Check to determine if the vehicle is level using the vehicle frame as reference.
b. Does the vehicle sit level?
Yes — Go to Step 4.
No — Using a jack, raise the vehicle to obtain a level condition. Then, go to Step 4.
4 Locate the American Society of Mechanical Engineers (ASME) inspection plate on the fuel tank.
a. Note the tank water capacity listed on the plate.b. Multiply the listed capacity by 0.05 (5%) and record the value.
With the value recorded, go to Step 5.
5 Refuel the vehicle as follows:
If the key is on during refueling, it will take the fuel level gauge in the instrument cluster longer to register full.
a. Verify that the ignition is in the OFF position.b. Install the fuel fill pressure tester on the fill valve and close the ball
valve.
c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is open.
d. With the bleeder valve open, turn on the pump. Open the ball valve slightly to very slowly refuel the vehicle.
e. While refueling, observe the bleeder valve for fuel discharge.
f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically.
g. Did a solid stream of liquid flow from the bleeder valve?
Yes — Record the volume of fuel dispensed and then go to Step 6.No — Go to Step 7.
6 Resume filling until the dispensing pump stops automatically.
a. Record the total volume of fuel dispensed and subtract the amount from the volume recorded in Step 5.
b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4?
Yes — Tank does not overfill. Diagnostic is complete.No — Tank is overfilling. Replace the OPD fill valve in the fuel tank; then, go to Step 8.
7 The dispensing pump stopped automatically and a liquid fuel stream was not observed flowing from bleeder valve.
Tank does not overfill. Diagnostic is complete.
TROUBLESHOOTING
Page 27
Engine Does Not Crank
8 Refuel the vehicle as follows:
If the key is ON during refueling, it will take the fuel level gauge in the instrument cluster longer to register full.
a. Verify that the ignition is in the OFF position.
b. Install the fuel fill pressure tester on the fill valve and close the ball valve.
c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is OPEN.
d. With the bleeder valve open, turn ON the pump. Open the ball valve slightly to very slowly to refuel the vehicle.
e. While refueling, observe the bleeder valve for fuel discharge.
f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically.
g. Did a solid stream of liquid flow from the bleeder valve?
Yes — Record the volume of fuel dispensed and then go to Step 9.No — Go to Step 7.
9 Resume filling until the dispensing pump stops automatically.
a. Record the volume of fuel dispensed and subtract the amount from the volume recorded in Step 8.
b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4?
Yes — Tank does not overfill. Diagnostic is complete.No — Tank is overfilling. Replace the fuel tank assembly.
Step Procedure Action
Step Procedure Action
1 Is battery voltage above 10 volts? Yes — Go to Step 2.
No — Determine cause of low battery voltage.
2 Verify that the smart relay module (SRM) has communication.
Can fuel rail pressure and temperature be read with a scan tool?
Yes — Go to Step 3.
No — Go to the Smart Relay Module Electrical Test procedure.
3 Refer to the Ford Powertrain Control/Emission Diagnosis Service Manual.Is the problem corrected?
Yes — Diagnostic is complete.No — Call ROUSH CleanTech Customer Service at 800-597-6874.
Page 28
TROUBLESHOOTING
Engine Cranks, No Start
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
Step Procedure Action
1 Verify the following:
a. Is there fuel in the tank of at least 1/8 tank or more? (add fuel if necessary).
b. Is the tank supply manual shutoff valve fully open?
c. Is battery voltage above 10 volts?
Yes — Go to Step 2.
No — Correct fault and retry.
2 Check for diagnostic trouble codes (DTC).Are any codes present?
Yes — Go to Step 3.No — Go to Step 4.
3 Is the DTC identified on the ROUSH LPA DTC list? Yes— Refer to Diagnostic Trouble Code List.No — Refer to Ford service manual DTC chart.
4 Check fuel pressure.
a. Measure and record fuel rail and fuel tank pressure, Key ON Engine OFF (KOEO).
b. While monitoring fuel pressure, attempt to start engine.
c. Record the highest pressure observed.
d. Does fuel pressure rise 25 psi (172 kPa) before engine crank?
Yes — Go to Step 11.
No — Go to Step 5.
5 Check fuel pump operation.
a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank Harness for correct circuits.
b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of 2 amps should be recorded on both fuel pump circuits.
c. Do fuel pumps draw current?
Yes — Go to Step 6.No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 10.
6 Check excess flow valve (XFV).
a. Turn ignition key to the OFF position.
b. Close the manual shutoff valve on tank.
c. Wait 1 minute and then slowly open manual shutoff valve.
d. Measure and record fuel pressure, using a scan tool, at integrated pressure temperature sensor (IPTS).
e. Is problem resolved?
Yes — Go to Step 11.No — Go to Step 7.
7 Check ROUSH fuel pump (FP) fuse.Is fuse intact and OK?
Yes — Go to Step 8.
No — Determine the cause of the short and repair; replace the fuse. Diagnostic is complete.
8 Check the tank solenoid (TS) and supply solenoid (SS) fuses.
a. Locate the TS fuse (E3-E4) and check its condition.b. Locate the SS fuse (F1-F2) and check its condition.
c. Are the fuses blown?
Yes — Determine the cause of the short and repair; replace the fuse.No — Go to Step 9.
TROUBLESHOOTING
Page 29
9 Verify that there is power and proper grounding at the tank solenoid (TS) and supply solenoid (SS) wiring circuits.
a. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure.
b. Is +12 volts present at the TS connector?
c. Is +12 volts present at the SS connector?
Yes — Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly.No — Check for an open(s) in the wiring circuits and repair. Diagnostic is complete.
10 Verify that there is power and proper grounding in the wiring circuit to the tank.
a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Pump Electrical Check procedure.
b. Is +12 volts present at the FP1 connector?
c. Is +12 volts present at the FP2 connector?
Yes — Go to Step 12.
No — Check for an open(s) in the wiring circuits and repair.
11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification procedure?
Yes — Refer to the Integrated Pressure Temperature Sensor Electrical Check.
No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor.
12 Check wiring.
a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information.
b. Remove tank service cover.
c. Check for open or short circuits on tank pass-through harness.
d. Is a wiring problem present?
Yes — Replace harness.
No — Go to Step 13.
13 Check fuel hoses and quick-connect fittings.
� Are in-tank fuel hoses and quick-connect fittings connected and in good condition?
Yes — Replace fuel pump assembly.No — Replace hose assemblies as needed.
Step Procedure Action
Page 30
TROUBLESHOOTING
Engine Stumble, Stall, Rough Idle
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
Step Procedure Action
1 Verify the following:
a. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.)
b. Is the tank supply manual shutoff valve fully open?
c. Is battery voltage above 11 volts with engine running?
Yes — Go to Step 2.
No — Correct the fault and retry.
2 Check for diagnostic trouble codes (DTCs).Are any codes present?
Yes — Go to Step 3.No — Go to Step 4.
3 Identify the DTC.
a. Is the DTC covered in the ROUSH CleanTech DTC listing for LPA-fueled vehicles?
b. Correct all DTCs before continuing.
Yes — Refer to ROUSH CleanTech Diagnostic Trouble Code List.No — Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
4 Does the problem occur only after cold start? Yes — Go to Step 6.No — Go to Step 5.
5 Determine fuel pressure.
a. Measure tank pressure with Key ON Engine OFF (KOEO).b. Measure fuel rail pressure with Key ON Engine Running (KOER).
c. Subtract the KOEO pressure from the KOER pressure to obtain the difference. Compare to the chart in Expected Fuel Rail Pressure.
d. Is the resulting fuel pressure reading within the expected range?
Yes — Go to Step 7.
No — Go to Step 6.
6 Determine if the excess flow valve (XFV) is tripped.
a. Turn OFF the engine.
b. Wait one minute and then restart the engine.
c. Is the fault condition resolved?
Yes — Refer to the Excess Flow Valve Check procedure.
No — Go to Step 7.
7 Check fuel pump operation.
a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank Harness for correct circuits.
b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of 2 amps should be recorded on both fuel pump circuits.
c. Do fuel pumps draw current?
Yes — Go to Step 11.No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 8.
8 Verify that there is power and proper grounding in the wiring circuit to the tank.
a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure.
b. Is +12 volts present at the FP1 connector?
c. Is +12 volts present at the FP2 connector?
Yes — Go to Step 9.No — Check for an open/short in the wiring circuit and repair.
TROUBLESHOOTING
Page 31
Excess Flow Valve Check
The excess flow valve (XFV) is designed to restrict fuel exiting the tank if the pump is energized while the fuel lines are not connected to the fuel tank. Under normal circumstances, the XFV should not trip. The XFV will reset itself after the fuel pumps have been off for about one minute.
It is common to trip the XFV after the fuel lines have been serviced and contain no pressure. If the XFV trips, turn the vehicle off, wait one minute, and restart. This may take more than one attempt.
If the fuel lines have not been serviced recently and the problem persists, there may be a leak in the supply side fuel line. If the problem is only present after the vehicle has been sitting for a length of time, but not present during a short soak, or there is a propane odor when the vehicle is running, refer to the Fuel Line Leak Detection procedure.
9 Check wiring.
a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information.
b. Remove tank service cover.
c. Check for open or short circuits on tank pass-through harness.
d. Is a wiring problem present?
Yes — Replace harness.
No — Go to Step 10.
10 Check fuel hoses and quick-connect fittings.
� Are in-tank fuel hoses and quick-connect fittings connected and in good condition?
Yes — Replace fuel pump assembly.No — Replace hose assemblies as needed.
11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification? Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure.
Yes — Go to Step 12.
No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor.
12 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
—
Step Procedure Action
Step Procedure Action
1 Verify fuel supply line pressure prior to cranking engine.
a. Read fuel rail pressure and tank pressure.b. Energize bleed solenoid until rail pressure is at least 50 psi
(345 kPa) below tank pressure. If rail is bled, skip to Step D.
c. Let pressure stabilize for 1 minute.
d. Open the supply solenoid.
e. Read fuel rail pressure and tank pressure.
f. Does fuel rail pressure jump to tank pressure?
Yes — Check is OK.No — Repair the leak in the fuel supply line.
Page 32
TROUBLESHOOTING
Maximum Pressure Check
The LPA system operates over a wide range of pressures depending on ambient temperature, driving mode, etc. When the vehicle is subjected to a severe drive cycle in high ambient temperatures, the fuel rail pressure can rise to the limit of the injectors capabilities. This limit is a function of injector voltage and fuel rail pressure. The PCM protects for this condition by reducing the fuel pump speed when the condition is sensed, however, there still may be drive concerns. When the PCM starts controlling the fuel pump a P116E code is set. While this
condition can occur in a normally functioning vehicle, it can also be exacerbated by several factors. If the fuel tank was not properly bled during the first fill, trapped air in the vapor space can increase tank pressure. In this condition there is often only a faint smell of propane when the bleeder valve is opened. The tank should be vented until there is a strong propane odor coming from the bleeder valve. The tank pressure should be confirmed against the expected pressure.
Allow the fuel tank to cool to ambient temperature before performing the following procedure.
Supply Solenoid Check
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
Step Procedure Action
1 Measure tank pressure and tank surface temperature.Is tank pressure more than 15 psi (103 kPa) over expected tank pressure?
Yes — Vent the tank until pressure is within the expected range.
No — Vehicle is working properly; inform and explain operating characteristics to customer.
Step Procedure Action
1 Verify the following:
a. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.)
b. Is the tank supply manual shutoff valve fully OPEN?
c. Is battery voltage above 10 volts?
Yes — Go to Step 2.No — Correct fault and retry.
2 Check for diagnostic trouble codes (DTC).Are any codes present?
Yes — Go to Step 3.No — Go to Step 4.
3 Is the DTC identified on the ROUSH liquid propane autogas DTC list?
Yes — Refer to Diagnostic Trouble Code List.No — Refer to the Ford service manual DTC chart.
4 Check fuel pressure.
a. Measure and record fuel rail pressure and fuel tank pressure at Key ON Engine OFF (KOEO).
b. While monitoring fuel pressure, attempt to start engine.
c. Record the highest pressure observed.
d. Does fuel pressure rise 20 psi (138 kPa) before engine crank?
Yes — Go to Step 11.No — Go to Step 5.
TROUBLESHOOTING
Page 33
5 Check fuel pump operation.
a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank Harness for correct circuits.
b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of 2 amps should be recorded on both fuel pump circuits.
a. Do fuel pumps draw current?
Yes — Go to Step 6.
No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)
If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 10.
6 Check XFV.
a. Turn OFF engine.b. Wait 1 minute and then restart engine.
c. Measure and record fuel rail pressure and fuel tank pressure.
d. Is problem resolved?
Yes — Go to Step 11.No — Go to Step 7.
7 Check ROUSH FP fuse.Is fuse intact and OK?
Yes — Go to Step 8.No — Determine the cause of the short and repair; replace the fuse.
8 Check the TS and SS fuses.
a. Locate the TS fuse (E3-E4) and check its condition.b. Locate the SS fuse (F1-F2) and check its condition.
c. Are the fuses blown?
Yes — Determine the cause of the short and repair; replace the fuse.No — Go to Step 9.
9 Verify that there is power and grounding in the TS and SS wiring circuits.
a. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure.
b. Is +12 volts present at the TS connector?
c. Is +12 volts present at the SS connector?
Yes — Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly.No — Check for an open/short in the wiring circuit and repair.
10 Verify that there is power and grounding in the wiring circuit to the tank.
a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure.
b. Is +12 volts present at the FP1 connector?
c. Is +12 volts present at the FP2 connector?
Yes — Refer to Engine Stumble, Stall, Rough Idle Step 12.
No — Check for an open/short in the wiring circuit and repair.
11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification?
Yes — Go to Step 12.No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor.
12 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
—
Step Procedure Action
Page 34
TROUBLESHOOTING
Fuel System Fails to Bleed
Step Procedure Action
1 Check for diagnostic trouble codes (DTC).
a. Are both DTC 26B3 and P009E present?
Yes — Go to Step 8.No — Go to Step 2.
2 Check for oil contamination at vapor port/EVAP line.
a. Disconnect EVAP line from vapor port.
b. Is oil present in EVAP line or vapor port?
Yes — Replace vapor port and perform Step 3.No — Go to Step 3.
3 Determine if fault condition repeats.
a. START the engine and allow it to run for a few minutes.b. Turn OFF the engine and wait one minute.
c. Measure and record the fuel rail pressure, fuel rail temperature and fuel tank pressure with the Key ON Engine OFF (KOEO).
d. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.
e. With the engine OFF, monitor fuel rail pressure for 15 minutes.
f. Does fuel rail pressure drop more than 20 psi (138 kPa)?
Yes — Potential intermittent fault. Return vehicle to customer and see if problem persists.
No — Go to Step 4.
4 Verify vapor port function.
a. Disconnect the EVAP line from the FRPCM port.
b. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.
c. Is there propane flowing from the port?
Yes — Go to Step 7.No — Go to Step 5.
5 Verify bleed solenoid function.
a. Disconnect the EVAP line from the FRPCM port.
b. Remove the vapor port.
c. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.
d. Is there propane flowing from the port?
Yes — Replace vapor port and repeat Step 3.No — Go to Step 6.
6 Verify that wiring is in good condition and functioning.
a. Perform wiring checks of the FRPCM harness.
b. Is the wiring OK?
Yes — Bleed solenoid stuck closed. Replace the FRPCM.
No — Repair wiring and repeat Step 3.
7 Check for a kinked EVAP line.
a. Inspect the EVAP line between the FRPCM and EVAP canister.
b. Are there kinks in the line?
Yes — Replace the kinked EVAP line and then repeat Step 3.
No — Go to Step 8.
8 Check for leaks to the FRPCM.
a. START the engine and allow it to run for a few minutes.b. Turn OFF the engine.
c. Measure and record fuel rail pressure.
d. Activate bleed solenoid to bleed pressure from fuel rail until fuel pressure drops more than 50 psi (345 kPa). Refer to the Manual Solenoid Activation Procedure.
e. De-energize bleed solenoid.
f. Disconnect the FRPCM and wait 120 minutes.
g. Measure fuel rail pressure and fuel tank pressure.
h. Does fuel rail pressure rise more than 10 psi (69 kPa)?
Yes — FRPCM leaks at either supply solenoid or return check valve. Replace FRPCM.
No — Potential intermittent fault. Return vehicle to customer and see if problem persists.
TROUBLESHOOTING
Page 35
Fuel Pressure Drop
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
Step Procedure Action
1 Verify the following:
a. Is there fuel in the tank of at least 1/8 tank?b. Is the tank supply manual shutoff valve fully open?
c. Is battery voltage above 10 volts?
Yes — Go to Step 2.
No — Correct the fault condition and retry.
2 Determine fuel pressure.
a. Measure and record fuel tank pressure.b. Measure and record fuel rail pressure with Key ON Engine
Running (KOER).
c. Subtract the tank measurement from the KOER measurement.
d. Is the resulting fuel pressure in the expected range?
Yes — Go to Step 4.No — Go to Step 3.
3 Determine if the excess flow valve is tripped.
a. Turn OFF the engine.b. Wait one minute and then restart the engine.
c. Is the problem resolved?
Yes — Refer to the Excess Flow Valve Check procedure.No — Go to Step 4.
4 Check fuel pump operation.
a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank Harness for correct circuits.
b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of 2 amps should be recorded on both fuel pump circuits.
c. Do fuel pumps draw current?
Yes — Go to Step 5.No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 6.
5 Check tank solenoid (TS) and supply solenoid (SS) fuses.
a. Locate the TS (E3-E4) and SS (F1-F2) fuses.b. Are the fuses blown?
Yes — Find and repair the short; replace the fuse.No — Go to Step 8.
6 Verify that there is power and ground in the wiring circuit to the tank.
a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure.
b. Is +12 volts present at the FP1 connector?
c. Is +12 volts present at the FP2 connector?
Yes — Refer to Engine Stumble, Stall, Rough Idle Step 9.
No — Check for an open/short in the wiring circuit and repair.
7 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification? See the Integrated Pressure Temperature Sensor Electrical Check procedure.
Yes — Go to Step 8.No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor.
8 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
—
Page 36
TROUBLESHOOTING
Fuel Level Indication Check
The ROUSH CleanTech fuel level indication system differs from the gasoline system as the fuel level sender is not wired directly to the instrument cluster. Instead, the fuel level sender is wired to the SRM, which reads the fuel level and transmits the signal to the PCM via the CAN bus, and to the FLIM, which in turn simulates the resistance the instrument cluster expects to see for a given fuel level.
The gauge on the sending unit must not be used for any diagnostics. The gauge is not accurate. Only resistance or voltage outputs should be used for diagnostic purposes.
Symptom Cause/Action to be taken
Fuel gauge does not move on a partial fill This behavior is not uncommon. The fuel level sender may not move far enough to trigger movement on the gauge if only a small amount of fuel is added to the tank. Once driven, the gauge may move to reflect the fill.
Malfunction Indicator Lamp (MIL) There is a circuit fault that has been identified by the PCM. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is called for, refer to the Fuel Level Interface Module Electrical Test procedure.
Gauge points below E This is an indication of an error state. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is called for, refer to the Fuel Level Interface Module Electrical Test procedure.
Doesn’t read full after a fill This could be the result of either a fuel level sender fault or an OPD valve triggering prematurely. Refer to fill issues and the Fuel Level Sender Electrical Check procedure for more information.
TROUBLESHOOTING
Page 37
Tank Solenoid Electrical Check
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS
1
Figure 1 — Underhood Harness Connectors2
Figure 2 — Rear Frame Harness Connectors3
Figure 3 — Solenoid Harness Connectors
100070a
FUSE BOX
F E D C B A
4 5 3
5 53 332
14
2
A B
1
42
2
11E
F
55
36
44
21
1 15
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
44
100071aA
A B C D E F
B C D
21 30
100072aD C B A A B
1 9
Page 38
TROUBLESHOOTING
PROCEDURE
Step Procedure Action
1 Unplug the solenoid harness connector 9 from the tank solenoid. Go to Step 2.
2 Using a multimeter, measure resistance of the solenoid.Is the measured resistance within 6–35 ohms?
Yes — Go to Step 3.No — Replace the tank solenoid.
3 Using a multimeter, measure voltage at the tank solenoid as follows:
a. With the ignition key ON, check for voltage present at pin-A, connector 9 (solenoid harness). Use the body as the reference ground.
b. Is battery (B+) voltage present?
Yes — Supply circuit OK.No — Go to Step 4.
4 Check fuse (E3-E4, 20A) in auxiliary fuse box.Is fuse blown?
Yes — Replace fuse.
No — Fuse OK; go to Step 5.
5 Check relay.Is relay functioning properly?
Yes — Go to Step 6.No — Replace relay.
6 Check supply circuit continuity from solenoid harness to fuse box.
a. Check continuity between:� Pin-A, connector 9 and pin-A, connector 1 (solenoid harness)
� Pin-A, connector 21 and pin-A, connector 30 (rear wiring harness)
� Pin-A, connector 15 and cavity A5, fuse box (underhood harness)
b. Is there good continuity in the circuit?
Yes — Go to Step 7.
No — Repair supply circuit wiring.
7 Check ground circuit continuity from solenoid harness to smart relay module (SRM) connector.
a. Check continuity between:
� Pin-B, connector 9 and pin-B, connector 1 (solenoid harness)� Pin-B, connector 21 and pin-E, connector 30 (rear wiring
harness)� Pin-E, connector 15 and pin-44, connector 1 (underhood
harness)
b. Is there good continuity in the circuit?
Yes — Refer to the Smart Relay Module Electrical Test procedure.No — Repair ground circuit wiring.
TROUBLESHOOTING
Page 39
Fuel Rail Pressure Control Module Electrical Check
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS
4
Figure 4 — Underhood Harness Connectors
PROCEDURE
100073a
FUSE BOX
4 5 3
5 53 332
14
2
A B
1
42
2
11E
F
55
36
44
21
1 11
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
46
F1-F2
33
17 F E D C B A
Step Procedure Action
1 Unplug the fuel rail pressure control module (FRPCM) connector from connector 11 of underhood harness.
Go to Step 2.
2 Using a multimeter, check the resistance of each solenoid.
a. Check resistance across the terminals of the FRPCM connector in sequence as follows:
� Supply Solenoid — Pin-A and pin-F� Flow Control Solenoid — Pin-B and pin-E� Bleed Solenoid — Pin-C and pin-D
b. Is the measured resistance for each solenoid within 6–35 ohms?
Yes — Go to Step 3.No — Replace the FRPCM if resistance for any one of the solenoids is not within the specified range.
3 Check supply voltage to FRPCM solenoids.Using a multimeter, measure voltage between the terminal for each solenoid at the harness side connector 11 and ground as follows:
Go to Steps 4–6.
Page 40
TROUBLESHOOTING
4 Supply Solenoid — Pin-A and body ground B+ Voltage — Go to Step 5.
No Voltage — Go to Step 5.
5 Flow Control Solenoid — Pin-B and body ground B+ Voltage — Go to Step 6.No Voltage — Go to Step 6 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7.
6 Bleed Solenoid — Pin-C and body ground B+ Voltage — Continue with Step 9.No Voltage — Go to Step 8 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7.
7 Check fuses (F1-F2, 10A) in auxiliary fuse box.Is a fuse blown?
Yes — Replace fuse.No — Go to Step 8.
8 Check solenoid supply circuit continuity.
a. Check continuity between:� Supply Solenoid — Pin-A, connector 11 (underhood harness)
and cavity F2 (auxiliary fuse box)
� Flow Control Solenoid — Pin-B, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box)
� Bleed Solenoid — Pin-C, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box)
b. Is there good continuity in all three circuits?
Yes — Go to Step 9.No — Repair wiring circuit.
9 Check solenoid ground circuit continuity.
a. Check continuity in the underhood harness between:� Supply Solenoid — Pin-F, connector 11 and pin-46, connector
1 at SRM� Flow Control Solenoid — Pin-E, connector 11 and pin-33,
connector 1 at SRM� Bleed Solenoid — Pin-D, connector 11 and pin-17, connector 1
at SRMb. Is there good continuity in all three circuits?
Yes — Refer to the Smart Relay Module Electrical Test procedure.No — Repair wiring circuit.
TROUBLESHOOTING
Page 41
Integrated Pressure Temperature Sensor Electrical Check
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS
Figure 5 — Underhood Harness Connectors
PROCEDURE
Step Procedure Action
1 Unplug the connector 8 (underhood harness) to the IPTS. Go to Step 2.
2 Check resistance of the integrated pressure temperature sensor (IPTS).
a. With vehicle at ambient room temperature (20–30°C, 68–86°F) and using a multimeter, measure resistance across the IPTS terminals (between pin-1 and pin-3).
b. Is the resistance value between 8K–12K ohms?
Yes — Go to Step 3.No — Replace the IPTS.
3 Check circuit continuity between the IPTS and the smart relay module (SRM).
a. Using a multimeter, check continuity in the underhood harness between:� Pin-1, connector 8 and pin-40, connector 1
� Pin-2, connector 8 and pin-7, connector 1� Pin-3, connector 8 and pin-5, connector 1� Pin-4, connector 8 and pin-25, connector 1
b. Is there good continuity in the circuits?
Yes — Refer to the Smart Relay Module Electrical Test procedure.
No — Repair circuit wiring.
Page 42
TROUBLESHOOTING
Fuel Pump Electrical Test
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS5
Figure 6 — Rear Frame Harness Connectors6
Figure 7 — In-Tank Harness Connectors
PROCEDURE
100075a
4 1B A
B A8 5
12 13 24 27
100076a
A B
B
A
1 2 4A 4B
Step Procedure Action
1 Check fuel pump circuit continuity.
a. Unplug the FPCM connector 12 for fuel pump 1. Check fuel pump circuit continuity.
b. Using a multimeter, measure resistance between pin-5 and pin-8.
c. Is resistance between 0.4–1.0 ohm?
Yes — Go to Step 2.No — Go to Step 3.
2 Check fuel pump circuit continuity.
a. Unplug the FPCM connector 13 for fuel pump 2.b. Using a multimeter, measure resistance between pin-5 and pin-8.
c. Is resistance between 0.4–1.0 ohm?
Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure.
No — Go to Step 3.
3 Check resistance of each fuel pump.
a. Unplug the fuel pump connectors (in-tank harness) at the fuel pump assembly.
b. Using a multimeter, measure resistance for fuel pump 1 across the terminals of the fuel pump.
c. Is resistance between 0.4–1.0 ohm?
Yes — Go to Step 4.No — Replace fuel pump assembly.
TROUBLESHOOTING
Page 43
4 Check resistance continued.
a. Using a multimeter, measure resistance for fuel pump 2 across the terminals of the fuel pump.
b. Is resistance between 0.4–1.0 ohm?
Yes — Go to Step 5.
No — Replace fuel pump assembly.
5 Check harness circuit continuity from fuel pumps to FPCM.
a. Check continuity for pump 1, wire FPPWR, V+ across:� Pin-A, connector 4A (in-tank harness) to pin-A, connector 1
(in-tank harness)� Pin-A, connector 24 (rear frame harness) and pin-5, connector
12 (rear frame harness)
b. Check continuity for pump 1, wire FPRTN, V– across:
� Pin-B, connector 4A (in-tank harness) to pin-B, connector 1 (in-tank harness)
� Pin-B, connector 24 (rear frame harness) and pin-8, connector 12 (rear frame harness)
c. Check continuity for pump 2, wire FPPWR, V+ across:
� Pin-A, connector 4B (in-tank harness) to pin-A, connector 2 (in-tank harness)
� Pin-A, connector 27 (rear harness) and pin-5, connector 13 (rear harness)
d. Check continuity for pump 2, wire FPRTN, V– across:
� Pin-B, connector 4B (in-tank harness) to pin-B, connector 2 (in-tank harness)
� Pin-B, connector 27 (rear frame harness) and pin-8, connector 13 (rear frame harness)
e. Is there good continuity in all circuits?
Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure.No — Repair circuit wiring.
Step Procedure Action
Page 44
TROUBLESHOOTING
Fuel Pump Control Module Electrical Continuity Test
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS7
Figure 8 — Underhood Harness Connectors8
Figure 9 — Rear Frame Harness Connectors
100077a
4 5 3
5 53 332
14
2
AD
B
1
42
2
11E
F
55
36
44
21
A5 A3
FUSE BOX E4
15
F E D C B AC
100078a
1 4
5 8
A B C D E F B
4 1
8 5
B A
A
1
30 41
1312 27
TROUBLESHOOTING
Page 45
PROCEDURE
Step Procedure Action
For fuel pump control module (FPCM) functional testing and diagnostic trouble codes, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.
1 Check Ford FPCM circuit continuity to Ford harness.
a. Disconnect rear frame harness connectors 1 and 12.
b. Check for continuity in the rear frame harness across:
� Pin-1, connector 1 and pin-1, connector 12
� Pin-3, connector 1 and pin-3, connector 12� Pin-4, connector 1 and pin-4, connector 12� Pin-5, connector 1 and pin-5, connector 12
� Pin-6, connector 1 and pin-6, connector 12� Pin-7, connector 1 and pin-7, connector 12
c. Is there good continuity in each circuit?
Yes — Go to Step 2.No — Repair circuit wiring.
2 Check FPCM circuit continuity to Ford harness.
a. Disconnect rear frame harness connector 13.b. Check wire VPWR (V+) for continuity across:
� Pin-1, connector 13 (rear frame harness) and pin-A, connector 30 (rear frame harness)
� Pin-A, connector 15 (underhood harness) and cavity-A5, fuse box (underhood harness)
� Cavity-A3, fuse box (underhood harness) and cavity-E4, fuse box (underhood harness)
c. Is there good continuity in each circuit?
Yes — Go to Step 3.
No — Repair circuit wiring.
3 Check fuse condition (E3-E4).Is the fuse blown?
Yes — Replace the fuse.No — Go to Step 4.
4 Check Roush CleanTech FPCM circuit continuity to Ford harness.
a. Check for continuity in the rear frame harness across:� Pin-A, connector 30 and pin-1, connector 13
� Pin-4, connector 1 and pin-4, connector 13� Pin-A, connector 27 and pin-5, connector 13� Pin-6, connector 1 and pin-6, connector 13
� Pin-B, connector 27 and pin-8, connector 13� Pin-A, connector 41 and pin-7, connector 13
b. Is there good continuity in each circuit?
Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the FPCM.
No — Repair circuit wiring.
Page 46
TROUBLESHOOTING
Smart Relay Module Electrical Test
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS9
Figure 10 — Underhood Harness Connectors10
Figure 11 — CAN Harness Connectors
PROCEDURE
100079a
FUSE BOX
4 5 3
5 53 332
14
2
A B
1
42
2
11E
F
55
36
44
21
1
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
31
2
E1-E2
100080a
7
14 8
1 C
D F
5 9A
Step Procedure Action
1 Disconnect the smart relay module (SRM) connector 1 (underhood harness).
Go to Step 2.
2 Check for battery voltage (B+) to the SRM.
a. Using a multimeter, check for B+ voltage at cavity 2, connector 1. Use a body ground for reference.
b. Is there voltage (B+)?
Yes — Go to Step 5.
No — Go to Step 3.
3 Check for battery voltage (B+) to the SRM.
a. Check circuit continuity between cavity 2, connector 1 and cavity E2, auxiliary fuse box.
b. Is there good continuity in the circuit?
Yes — Go to Step 4.
No — Repair circuit wiring.
TROUBLESHOOTING
Page 47
4 Check for battery voltage (B+) to the SRM.
a. Check condition of SRM power fuse (E1-E2, 25A) in the auxiliary fuse box.
b. Is fuse blown?
Yes — Replace fuse.
No — Go to Step 5.
5 Check the SRM ground circuit for continuity.
a. Using a multimeter, check ground at cavity 31, connector 1 (underhood harness). Use a body ground for reference.
b. Is there good continuity?
Yes — Go to Step 6.
No — Repair circuit wiring.
6 Check for active signal to SRM.
a. Using a multimeter, check the underhood harness for continuity in the E-Series system between pin-26, connector 1 and pin-A, connector 23 and in F-Series system between pin-26, connector 1 and pin-1, connector 51/55.
b. Is there good continuity in the circuit?
Yes — E-Series: Go to Step 8, F-Series: Go to Step 9.
No — Go to Step 7.
7 Check fuse.
a. Check condition of fuse (F5-F6, 5A) in auxiliary fuse box.
b. Is fuse blown?
Yes — Replace fuse.No — Repair circuit wiring
8 E-Series Only: Check CAN harness for SRM circuit continuity.
a. Check continuity between pin-A, connector 9 and pin-12, connector 5.
b. Is there good continuity in the circuit?
Yes — Go to Step 9.No — Repair circuit wiring.
9 Check CAN and underhood harness continuity.
a. Check CAN-H(+) continuity across:� Pin-28, SRM connector 1 (underhood harness) and pin-C,
connector 23 (underhood harness)
� Pin-C, connector 9 (CAN harness) and pin-2, connector 5 (CAN harness)
b. Is there good continuity in the circuits?
Yes — Go to Step 10.No — Repair circuit wiring.
10 Check CAN and underhood harness continuity.
a. Check CAN-H(−) continuity across:� Pin-43, SRM connector 1 (underhood harness) and pin-B,
connector 23 (underhood harness)
� Pin-B, connector 9 (CAN harness) and pin-3, connector 5 (CAN harness)
b. Is there good continuity in the circuits?
Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the CAN bus.No — Repair circuit wiring.
Step Procedure Action
Page 48
TROUBLESHOOTING
Fuel Level Sender Electrical Check
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS11
Figure 12 — Underhood Harness Connectors12
Figure 13 — Rear Frame Harness Connectors13
Figure 14 — Solenoid Harness Connectors
100081a
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
151
F E D C B A3
100082aA B C D
A B C D E F21 30
100083aD C BB
A
A
1 6
TROUBLESHOOTING
Page 49
PROCEDURE
Step Procedure Action
For fuel level sender (FLS) functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes.
1 Check resistance in FLS circuit wiring.
a. Disconnect the SRM connector 1 (underhood harness).
b. Using a multimeter, measure the resistance between pin-3 and pin-40 of the harness connector.
c. Is resistance between 24–260 ohms?
Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure.No — Go to Step 2.
2 Check resistance of the FLS.
a. Disconnect the FLS connector 6 (solenoid harness).b. Using a multimeter, measure the resistance across the FLS
connector pins.
c. Is resistance between 24–260 ohms?
Yes — Go to Step 3.No — Replace the FLS.
3 Check circuit wiring continuity between FLS connector and SRM connector.
a. Disconnect connector 1 of the solenoid harness.
b. Check continuity between pin-B, connector 6 (solenoid harness) and pin-C, connector 1 (solenoid harness).
c. Is there good continuity in the circuit?
Yes — Go to Step 4.No — Repair circuit wiring.
4 Check circuit wiring continuity between FLS connector and SRM connector.
a. Disconnect connector 30 of the rear frame harness.
b. Check continuity between pin-C, connector 21 (rear frame harness) and pin-D, connector 30 (rear frame harness).
c. Is there good continuity in the circuit?
Yes — Go to Step 5.No — Repair circuit wiring.
5 Check circuit wiring continuity between FLS connector and SRM connector.
a. With SRM connector 1 and connector 15 of the underhood harness disconnected, check continuity between pin-C, connector 15 and pin-3, SRM connector 1.
b. Is there good continuity in the circuit?
Yes — Go to Step 6.No — Repair circuit wiring.
6 Check circuit wiring continuity between FLS connector and SRM connector.
a. Check continuity between pin-A, connector 6 (solenoid harness) and pin-D, connector 1 (solenoid harness).
b. Is there good continuity in the circuit?
Yes — Go to 7.
No — Repair circuit wiring.
7 Check circuit wiring continuity between FLS connector and SRM connector.
a. Check continuity between pin-D, connector 21 (rear frame harness) and pin-C, connector 30 (rear frame harness).
b. Is there good continuity in the circuit?
Yes — Go to Step 8.
No — Repair circuit wiring.
8 Check circuit wiring continuity between FLS connector and SRM connector.
a. Check continuity between pin-D, connector 15 (rear frame harness) and pin-40, SRM connector (underhood harness).
b. Is there good continuity in the circuit?
Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure.
No — Repair circuit wiring.
Page 50
TROUBLESHOOTING
Fuel Level Interface Module Electrical Test
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTORS14
Figure 15 — Underhood Harness Connectors
15
Figure 16 — Rear Frame Harness Connectors
PROCEDURE
100084a
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
1 3537
B A
C D
2
A
100085a
B C D E F9 30
Step Procedure Action
For FLIM functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes.
1 Check FLIM circuit wiring for continuity to SRM.
a. Disconnect underhood harness connector 1 to SRM.b. Check underhood harness continuity between pin-A, connector 35 and pin-26,
connector 1.
c. Is there good continuity in the circuit?
Yes — Go to Step 2.
No — Repair circuit wiring.
2 Check FLIM circuit wiring for continuity to SRM.
a. Check underhood harness continuity between pin-B, connector 35 and pin-37, connector 1.
b. Is there good continuity in the circuit?
Yes — Go to Step 3.
No — Repair circuit wiring.
3 Check FLIM circuit wiring for continuity to SRM.
a. Check underhood harness continuity between pin-C, connector 35 and body ground.
b. Is there good continuity in the circuit?
Yes — Go to Step 4.No — Repair circuit wiring.
4 Check FLIM circuit wiring for continuity to SRM.
a. Disconnect underhood harness connector 15 to rear frame harness.
b. Check underhood harness continuity between pin-D, connector 35 and pin-F, connector 15.
c. Is there good continuity in the circuit?
Yes — Go to Step 5.No — Repair circuit wiring.
5 Check FLIM circuit wiring for continuity to SRM.
a. Disconnect rear frame harness connector 9 to Ford harness.b. Check rear frame harness continuity between pin-F, connector 30 and pin-2,
connector 9.
c. Is there good continuity in the circuit?
Yes — Refer to the Smart Relay Module Electrical Test procedure.
No — Repair circuit wiring.
TROUBLESHOOTING
Page 51
Manual Solenoid Activation Procedure
For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.
CONNECTOR16
Figure 17 — Connector End View
17
Figure 18 — FRPCM Solenoid Locations
PROCEDURE
100351a
30 31
PBT/ASA-GF20
32
1 23 15
44 45 46
1716
A12918
4633
17
FLOW CONTROLSOLENOID
FUELSUPPLY
SOLENOIDBLEED
SOLENOID
BLEED/VAPORPORT
100108c
Step Procedure Action
1 Disconnect the smart relay module (SRM) wire harness connector at the SRM. —
2 Energize the individual solenoids on the FRPCM by providing a ground to the following pins in the SRM connector:
• Pin 17 – Bleed Solenoid
• Pin 33 – Flow Control Solenoid• Pin 46 – Supply Solenoid
—
Page 53
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-150/250/350 Wiring Harnesses and Connector Layout
UNDERHOOD HARNESSCAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESSSOLENOID HARNESS
2124271
6
UNDER BODY LPAFUEL TANK
9
144B4A
9 1341
30
47
1527
8
11
23 9
5
1
135
12 1GNDGNDR2 PASS
THRUGNDR1
7
100129a
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
Page 54
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-150/250/350 Extended Range Wiring Harnesses and Connector Layout
UNDERHOOD HARNESSCAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESSSOLENOID HARNESS
IN-BED FUEL TANK JUMPER
212427
16
IN-V
EH
ICL
E L
PAF
UE
L T
AN
K
9 14
4B4A941
30
47
1527
8
11
23 9
5
1
135
GNDGNDR2 PASS
THRUGNDR1
13 12 1
7
916
13
41A1B GND
100152a
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
Page 55
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Custom Body Wiring Harnesses and Connector Layout
100153a
UNDERHOOD HARNESSCAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESSSOLENOID HARNESS
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
IN-BED FUEL TANK JUMPER
2124271
6
AFT-AXLE LPAFUEL TANK
9
144B4A
1 1241
30
47
1527
8
11
23 9
5
1
135
13 GNDGNDR2 PASS
THRUGNDR1
7
Page 56
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout
IN-B
ED
LPA
IN-B
ED
LPA
FU
EL
TA
NK
FU
EL
TA
NK
UNDERHOOD HARNESSCAN HARNESS
REAR FRAME HARNESS
IN-TANK HARNESSSOLENOID HARNESS
IN-BED FUEL TANK JUMPERFTPT JUMPER HARNESS
212427
16
IN-B
ED
LPA
FU
EL
TA
NK
9 41
4B4A
9
41
30
47
15
27
8
11
23 9
5
1
1
35
5155
GND
GNDR2
PASSTHRU
GNDR1
BATTERY
+–
1 13 12
7
913
16
41A1BGND
1
4
*FTPT Harness depends upon the Ford Fuel Tanks
6
*
100187a
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
Page 57
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Chassis Cab Wiring Harness and Connector Layout
BATTERY
T3T2T1+ –
FB C4
C3C3
C1
G1
C2
14
7
14
7
C7
C9C8
C10 C16 C15 C14C15 C14
C13C19 C13 C11C12
C13C13C19
C18
C18
C11C12
C6
C5
T4
UNDERHOOD HARNESS
CAN HARNESS
IN-TANK HARNESSTANK SOLENOID HARNESSFUEL TANK JUMPER HARNESS
IN-TANK HARNESS (LH AND RH)1 FUEL PUMP #1 INLINE 2-PIN4 FUEL PUMP #2 INLINE 2-PIN7 GROMMET
UNDERHOOD HARNESSC3 UNDERHOOD/CAN INLINE
CONNECTOR 2-PINC4 SRM 46-PIN
UNDERHOOD HARNESS (CONT.)C5 IPTS 4-PINC6 FRPCM 6-PINC7 FLIM 4-PINC8 FORD EFPR 8-PINC9 RCT EFPR 8-PINC10 TO FORD INLINE CONNECTOR 8-PINC11 UNDERHOOD/IN-TANK FP#1 INLINE
(LEFT TANK) 2-PINC12 UNDERHOOD/IN-TANK FP#2 INLINE
(LEFT TANK) 2-PINC13 TANK SOLENOID INLINE CONNECTOR
(LEFT TANK) 4-PINC14 UNDERHOOD/FUEL TANK JUMPER
INLINE CONNECTOR 2, 4-PIN
UNDERHOOD HARNESS (CONT.)C15 UNDERHOOD/FUEL TANK JUMPER
INLINE CONNECTOR 1, 4-PINC16 UNDERHOOD/FUEL PUMP AND
SENDER INLINE CONNECTOR 4-PINFB AUX FUSE BOXT1 PWR #1 RING TERMINALT2 PWR #2 RING TERMINALT3 GROUND RING TERMINALT4 TERMINAL INSERTED IN SPLICE PACK
TANK SOLENOID HARNESS (LH AND RH)C13 UNDERHOOD/TANK SOLENOID INLINE
CONNECTOR 4-PINC18 SUPPLY VALVE SOLENOID 2-PINC19 FUEL SENDER 2-PIN
FUEL TANK JUMPER HARNESSC11 FUEL TANK JUMPER/IN-TANK INLINE 1
(RIGHT TANK) 2-PINC12 FUEL TANK JUMPER/IN-TANK INLINE 2
(RIGHT TANK) 2-PINC13 FUEL TANK JUMPER/TANK SOLENOID INLINE
(RIGHT TANK) 4-PINC14 FUEL TANK JUMPER/UNDERHOOD INLINE 2, 4-PINC15 FUEL TANK JUMPER/UNDERHOOD INLINE 1, 4-PIN
CAN HARNESSC1 BODY MODULE 12-PINC2 TO FORD HARNESS CONNECTOR 12-PINC3 CAN/UNDERHOOD IN-LINE CONNECTOR 2-PING1 GROMMET
100254a
APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS
Page 58
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-450/550 Roush Wiring Harnesses (Note: This wiring harness print does not include the attachment locations for the ROUSH CleanTech tank jumper harness to the rear chassis harness.)
100257a
CAN HARNESS
FUEL TANK JUMPER HARNESS
FORDHARNESS
CONNECTOR
TRAILER BRAKEMODULE CONNECTOR(IF EQUIPPED)
TO ROUSHHARNESS
TO ROUSHHARNESS
TO ROUSHHARNESS
TO ROUSHHARNESS
TO ROUSHHARNESS
TO ROUSHHARNESS
TO CANHARNESS
SYSTEMGROUND
MODULEGROUND
TO FORD AUXENGINE INLINE
MODULE
TO FORDHARNESS
TO REARFRAME
HARNESS
TO REARFRAME
HARNESS
TO IPTSSRM
TO FLM
BATTERYPOSITIVE
FUSE BOX
TOSOLENOID
MODULE
UNDERHOODHARNESS
TO ROUSHUNDERHOOD
HARNESS
TO ROUSHUNDERHOOD
HARNESS
CONNECT TOFORD HARNESS
FPCM
TO FUEL TANKSENDER
SOLENOIDTO FUEL
TANK 2 PWR
TO FUELTANK 1 PWR
FRAMEGROUND
TO FORD FUEL PUMPHARNESS CONNECTOR
TO FORD FPCM MODULEFUEL PUMP CONTROLMODULE 1
TO ROUSH FPCM MODULEFUEL PUMP CONTROL
MODULE 2
REAR CHASSISHARNESS
Page 59
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Chassis Cab, Roush Wiring Harnesses
SRMC4
FRPCMC6
IPTSC5
FLIMC7
UH/CANInline
C3
GND-BATT
TO SPLICEPACK(PIN D)
TERMINAL
FUSE_BOX
C4-FA
R_PWR_1 R_PWR_2
C4-MA
ROUSH EFPRC9
FORD EFPRC8
UH/FORDINLINE
C16
UH/FORDInlineC10
UH/IN-TANKINLINE 1
(FUEL PUMP)C11
(LH TANK)
UH/IN-TANKINLINE 2
(FUEL PUMP)C12
(LH TANK)
UH/TANKSOLENOID
INLINEC13
(LH TANK)
UH/TANKJUMPERInline 1
C15
UH/TANKJUMPERInline 2
C14
100255a
FORD HARNESSCONNECTOR
(12-PIN)C2
BODY MODULE(12-PIN)
C1
GROMMET
CAN HARNESS
TANK JUMPERHARNESS
UNDERHOODHARNESS
TANK SOLENOID HARNESS(LONG AND SHORT TANKS)
CAN/UNDERHOODINLINE CONNECTOR
(2-PIN)C3-F
BA
AB
TANK SOLENOID/UNDERHOOD INLINE
(4-PIN)C13-M
FUEL SENDER(4-PIN)
C19
SUPPLYVALVE
SOLENOID(2-PIN)
C18
UNDERHOOD/FUEL TANK JUMPERINLINE CONNECTORC14
FUEL TANK JUMPER/IN-TANK INLINE 2(RH TANK)C12-M
UNDERHOOD/FUEL TANK JUMPERINLINE CONNECTOR
C15
IN-TANK INLINE 1(RH TANK)
C11-M
FUEL TANK JUMPER/TANK SOLENOIDINLINE (RH TANK)
C13-F
Page 61
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Underhood Harness
To BatteryPositive
2
AB
FDD EE
SUPP
LY_S
OL
BLEE
D_S
OL_
RTN
BLEE
D_S
OL
FLO
W_C
NTL
_SO
L
SUPP
LY_S
OL_
RTN
S1
E2E1
F6F5
F2F1
E4E3F4F3E6E5
PWR_W
A2A4A1
A3
A5
Normally Open12V/20A Relay
F1 25A
Connector
8
Connector
1
3 5 7 15 17 20 43
28
25 26 29
33 34 35 36 3731
40
44 46
1 2 3 4
FLO
W_C
NTL
_SO
L_R
TN
SOLENOID_PWR
IPTS
_PW
R
IPTS
_TEM
P_O
UT
IPTS
_PR
ES_O
UT
IPTS
_GN
D
A
B
C
D
E
F
VPWR_RO
S2
VPWR_RI
FL_SND
FL_RTN_1S3
FG_RTN
FG_SND
TANK_SOL_RTN
GN
D1
GND2 GND3
SRM_PWR
A
B
C
D
E
F
KEY_PWR_1
KEY_PWR_2
PLUG
LAMP_RTN_1
CAN-H_1(-)
CAN-H_1(+)
TO REARFRAME
HARNESS
TO CANHARNESS
Connector
11
Connector
15
Connector
23
Connector
27
FL_RTN_2
TO IPTS
TO SOLENOIDMODULETO SRM
TO FUELLEVEL
BLACK BOX
A
B
C
D
FG_RTN_SRM
S5
Connector
35
PWR
S4
PWR_W_1
PWR_W_2
PWR_W_3
PWR
_W_6
PLUG
FRAME GROUND(GND_R2)
TO REARFRAME
HARNESS
Connector
47
A
BPLUG
FPM_2
C
SRM_PWR_1
SRM_PWR_2
F2 10A
F3 20A
F6 5A
RELAY A
R2
FRAME GROUND(GND_R1)
R1
100130c
ELECTRICAL CENTER(FUSE BOX)
4
32
1
4544
29
15
46
163
PBT/ASA-GF2018
32
21
3130
17
A1
D1
D4
D2D5D3
A1
A4
A2A5A3
B1
B4
B2B5B3
C1
C4
C2C5C3
RELAY C RELAY B
E6 E5 E4 E3 E2 E1
F6 F5 F4 F3 F2 F1
RELAY A
RELAY DFUSE 2FUSE 4FUSE 6
FUSE 1FUSE 3FUSE 5
Page 62
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness
Connector
1CONNECT TO TRAILER
BRAKE MODULE
A
B
C
D
E
F
S1
PLUG
Connector
5
CONNECT TO FORD HARNESSCONNECTOR C2142
12347 56
89101114 1213
1
2
3
4
7
5
6
8
9
10
11
14
12
13
CAN-H(+)_1
CAN-H(-)_1
FUSE_18
BRK_PED_POS
GND
FUSE_33_1
TOW_BRK
FUSE
_33_
2
CAN-H(-)_2
CAN-H(+)_2
KEY_PWR_1
Connector
9
PLUG
PLUG
CONNECT TO ROUSH UNDERHOODHARNESS
7
14 8
1
D C
F A
1 8
7 14
100131b
Page 63
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Rear Frame Harness
Connector
1
Connector
9
CONNECTTO FORDHARNESS
FPCM
TO FORD FPCMMODULE (FUEL
PUMP CONTROLMODULE)_1
TO ROUSH FPCMMODULE (FUELPUMP CONTROL
MODULE)_2
1 2 3 4 75 68 1 2 3 4 75 68
CONNECT TOFORD HARNESS
FUEL PUMPMODULE
Connector
21
Connector
12Connector
13
Connector
30
1
2
3
4
7
5
6
8
S1
PLUG
PLU
G
VPWR_1
FPC_1
GND_1
A_F
PPW
R_1
ENS_1
FPM_1
A_F
PRTN
_1
VPW
R_2
VPWR_RI
S4
VPW
R_P
2
B A B A
S2
FPC
_2
FPC
_3
ENS_
2
ENS_
3
PLUG
PLUG
A_F
PRTN
_2
S3
PLU
G
GN
D_2
GN
D_3
D C B A
A_S
OL_
1
A_S
OLR
TN_1
A_F
LS_1
A_F
LSR
TN_1
S6
SHIE
LD_5
SHIE
LD_2 SH
IELD
_1
SHIE
LD_3
SHIE
LD_4
FRAME GROUND(SHIELD)
4 3 2 1
PLUG
PLUG FG
_SN
D
A
B
C
D
E
F
TO ROUSH UNDERHOODHARNESS
S5
VPWR_RO
VPWR_RI
TO FUELTANK_SENDER_SOLENOID
Connector
24
TOFUEL_TANK_1_PWR
TOFUEL_TANK_2_PWR
Connector
27
A_F
PPW
R_2
Connector
41TO ROUSH UNDERHOOD
HARNESS
A
B PLUG
FPM_2
PLUG
100132b
4 1
8 5
4 1
8 5
14
58
Page 64
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450, E-450 Stripped Chassis, F-53/59, F-250/350, F-450/550/650 Electrical Schematic — In-Tank Harness
IN-TANKHARNESS
PASS THRU
4
PU
PU
AB
A
B
4
INLINE FUEL PUMP-1 (V+)
INLINE FUEL PUMP-1 (V-)
INLINE FUEL PUMP-2 (V+)
INLINE FUEL PUMP-2 (V-)
FUEL PUMP-1 (V+)
FUEL PUMP-1 (V-)
FUEL PUMP-2 (V+)
FUEL PUMP-2 (V-)
A
B
B
A
2
A
B
MP-1
MP-2
1
100133b
Page 65
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness
9
1
CONNECT TO FUELLEVEL SENDER
CONNECT TOTANK SOLENOID
CONNECT TO THEREAR HARNESS
SUPPLY SOLENOID V+
SUPPLY SOLENOID V-
FUEL LEVEL SENDER V-
FUEL LEVEL SENDER V+
100134b
D
A
B
C
A
B
A
B
6
Page 66
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Stripped Chassis CAN Harness
CAN-H (+)
CAN-H (-)
PLUG
PLUG
PLUG
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR PIN-23
SP3
C1-MPIN-21
SP2
C1-F
1
2
3
3 31 1
646 4
4
5
6
C2-F
A
A
B
C
C D
D
E
F
F
PIN-34
SP1
CBB80D
CBB80C
CBB80B
VDB05D
VDB04D
VDB04C VDB04A
VDB04B
VDB05B
VDB05C VDB05A
CBB80A
1
2
3
4
5
6
100262a
Page 67
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup, F-450/550 Electrical Schematic — CAN Bus Jumper Harness
100189a
Connector
1
CONNECT TO TRAILERBRAKE MODULE
PLUG
Connector
5
CONNECT TO FORD HARNESSCONNECTOR C2142
147 56
9
1
2
3
4
7
5
6
8
9
10
11
14
12
13
CAN-H(+)_1
CAN-H(-)_1
FUSE_18
BRK_PED_POS
GND
FUSE_33
TOW_BRK
CAN-H(-)_2
CAN-H(+)_2
Connector
9
PLUG
CONNECT TO ROUSH UNDERHOODHARNESS
PLUG
PLUG
GROMMET
PASS-THROUGH
101114 1213 8
23
A
B
C
D
E
F
Page 68
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Stripped Chassis, F-53/59, F-250/350 Pickup, F-450/550 and F-650 Electrical Schematic — Tank Solenoid
SUPPLY SOLENOID V+
SUPPLY SOLENOID V-
FUEL LEVEL SENDER V-
FUEL LEVEL SENDER V+
100191a
1
A
B
CONNECT TO FUEL LEVEL SENDER
FUEL LEVEL SENDER CONNECTOR FROM TANK
CONNECT TO TANK (FUEL SUPPLY)SOLENOID
CONNECT TO REAR FRAME HARNESS
D
A
B
C
A
B
6
9
Page 69
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
E-450 Extended Range, F-250/350 Pickup Electrical Schematic — In-Bed Fuel Tank Jumper Harness
D
C
B
A
D
C
B
ATANK (FUEL SUPPLY) SOLENOID_POWER
TANK (FUEL SUPPLY) SOLENOID _RETURN
FUEL_LEVEL _SENDER RETURN
FUEL_LEVEL _SENDER POWER
PUMP_1
B
A
B
A
B
A
B
A
FUEL_PUMP_1_PWR
FUEL_PUMP_2_PWR
FUEL_PUMP_1_RTN
FUEL_PUMP_2_RTN
S1
Connector
1A
Connector
4Connector
9
Connector
13
Connector
16
PUMP_2
SHIELD_1
FRAME GROUND(SHIELD)
SHIELD_2
CONNECT TO REAR FRAME HARNESS
CONNECT TO REAR FRAME HARNESS
CONNECT TO REAR FRAME HARNESS
CONNECT TO TANK SOLENOID HARNESS
CONNECT TO TANK SOLENOID HARNESS
CONNECT TO TANK SOLENOID HARNESS
SH
IEL
D_3Connector
1B
100192a
Page 70
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-250/350 Pickup Electrical Schematic — FTPT Jumper Harness
r
Connector
1
CONNECT TO FTPT
CONNECT TO FTPT
Connector
4
C
VERSION DEPENDS ONTANK CONFIGURATION
ONNECT TO FORD HARNESS (14405)
1
2
3
1
2
3
FTP
SIGRTN
FTP_REF
FTP
SIGRTN
FTP_REF
Connector
1Connector
6
CONNECT TO FORD HARNESS (14405)
1
2
3
A
B
C
FTP
SIG_RTN
FTP_REF
FTP
SIG_RTN
FTP_REF
100193a
Page 71
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 CAN Harness
SP1909
SP1908
C1_FORD_HARNESS_CONNC1
6
910
87
7 6
12 1
32
12
54
11
C3-F
AB
FORD_Gateway_Module
MSCAN(-)MSCAN(+)LAPISBICPBPSHIP-1HSCAN(-)HSCAN(+)HIP-2HIP-3SCSNOT USED
1908C
2181218021845033814
1909B1909A1908A
1909C
1908B1045A1045B
151ZA100
100261a
1
6
910
87
32
12
12 1
7 6
54
11
1
Page 72
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Fuel Tank Jumper Harness
C15- F C13_F
C14- M
A
A
B
D
C
B
C
D
C12- M
C11- M
A
B_SOLRTN
B_FLRTN
B_FLSND
B_FPPWR_1
B_FPRTN_1
B_FPPWR_2
B_FPRTN_2
B_SOLPWR
B
A
B
A
B
C
D
A
B
C
D
100264a
Page 73
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-650 Underhood Harness Electrical Schematic
100269a
NOT USEDNOT USED
NOT USED
NOT USED
PLUG
NOT USED
NOT USED
PLUG
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
PLUG
NOT USED
PLUG
PLUG
PLUG
NOT USED
NOT USEDNOT USED
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
BATTERY +
BATTERY +
S7
PIN1
PIN2
PIN3
PIN4
PIN5
PIN6
PIN7
PIN8
PIN1
PIN2
S5
C8FORD EFPR
3
7
5
8
4
6
2
1
GND-BATT
S6
STERM_2
S4
STERM_4
C12PRI FUEL PUMP 2
A
B
C10FORD FUEL TANKHARNESS
1
2
3
4
5
6
7
8
C11PRI FUEL PUMP 1
A
B
A
B
S2
STERM_3
S1
R_PWR_2
S17
S12
S9
S8
STERM_1
S13
S14
R_PWR_1
S15
PIN1
PIN2
PIN3
PIN4
C16FORD FUEL TANK HARNESS
T4
T1
T2
T3
1
2
3
4
1
2
3
4
5
6
7
8
9
4516
312
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
A
B
C
D
C13PRIMARY TANK SOLENOID HARNESS
A
B
C
D
C3CAN
A
B
C6FRPCM
C
D
B
E
A
F
S3
C9ROUSH EFPR
3
7
5
8
4
2
6
1
A
B
C
D
S11
C15FUEL TANK JUMPER
A
B
C
D
AB
S16
C7FUEL LEVEL INTERFACE MODULE
A
B
C
D
S10
C14FUEL TANK JUMPER
A
B
C
D
A
B
C
D
TERMINAL C4-M1
FUSE BOX
F5
F6
E5
E6
F3
F4
E3E4
F1
F2
E1
E2
A3
A1
A2
A5
B3
B1
B2
B5
C3
C1
C2
C5
C4-F1
C5IPTS SENSOR
3
2
4
1
RELAY_B
SEC_TANK_PUMP_1
DEV432
PRI_FUEL_TANK
FUSE_5_20AA B
RELAY_C
SEC_TANK_PUMP_2
FUSE_3_20AA B
FUSE_6_5AA B
VPWR
NOT_USED_1
FUEL PUMP COMM.
GND
FUEL PUMP PWR
ENS
FUEL PUMP MONITOR
FUEL PUMP RETURN
FUSE_4_20AA B
FUSE_1_25AA B
FUSE_2_10AA B
DEV434
desc
KEY ON PWR
PWM DUTY CYCLE
GND
FUEL GAUGE SENDER SGN
SUPPLY_SOL
FLOW_CNTL_SOL
BLEED_SOL
BLEED_SOL_RTN
FLOW_CNTL_SOL_RTN
SUPPLY_SOL_RTN
VPWR
NOT_USED_1
FUEL PUMP COMM.
GND
FUEL PUMP PWR
ENS
FUEL PUMP MONITOR
FUEL PUMP RETURN
C4SRM MODULE
PIN1
BATT+
FUEL LEVEL SENDER # 1
PIN4
FUEL RAIL TEMPERATURE
PIN6
FUEL RAIL PRESSURE
PIN8
PIN9
FUEL LEVEL SENDER # 2
PIN11
PIN12
PIN13
SPARE INPUT_1
EFPR DIAGNOSTIC FEEDBACK
PIN16
BLEED SOLENOID
SPARE INPUT_2
PIN19
PIN20
PIN21
PIN22
PIN23
PIN24
XDRP +5V
WAKE
PIN27
FORD CAN+
SPARE INPUT_3
PIN30
GROUND
PIN32
FLOW CONTROL SOLENOID
FUEL PUMP RELAY
SPARE OUTPUT_1
SPARE OUTPUT_2
FUEL LEVEL OUTPUT (PWM)
PIN38
PIN39
XDRG
PIN41
PIN42
FORD CAN-
FUEL TANK SOLENOID
PIN45
SUPPLY SOLENOID
TEMP OUT
PRESSURE OUPUT
GND
PWR
FG_RTN
FG_RTN
PUMP_ACTIVE
B_FLRTN
GND_12
A_TANK_SOL
FL_SND
FPM_2
VPWR_P2
A_FLRTN
B_FLSND
CAN-H(+)
FLOW_CNTL_SOL
SUPPLY _SOL
BLEED_SOL
FG_SND
IP_TEMP
IP_GND
SRM_PWR_1
BLEED_SOL_RTN
FLOW_SOL_RTN
FL_RTN
CAN-H(-)
SUPP_SOL_RTN
SRM_PWR_2
IP_PRES
FG_RTN_SRM
IP_PWR
GN
D_1
B_SOL_1
B_FPPWR_2
GND
B_FPRTN_1
B_FPRTN_2
FORD_GND_1FORD_GND_3
FPC
_2
FPM_1
A_F
PP
WR
_1
A_F
PR
TN_1
VP
WR
_2
DRAIN_4
DR
AIN
_3
DR
AIN
_1
DRAIN_2
ENS_1ENS_3
A_F
PP
WR
_2
A_FPRTN_2
A_F
PR
TN_2
VPWR_1
FPC_1FPC_3
PUMP_PWR_6
PUMP_PWR_2
VP
WR
_RI
PWR_W
PWR_W_1
PWR_W_2
PUMP_PWR_3
PUMP_R2
PU_AC_2
B_FPPWR_1
PWR_W_6
B_SOLRTN
GND_4
GN
D_4
PUMP_PWR
PUMP_R1
B_F
PP
WR
_B
PUMP_PWR_4
PUMP_PWR_5
FOR
D_G
ND
_2
EN
S_2
ELECTRICAL CENTER(FUSE BOX)
D1
D4
D2D5D3
A1
A4
A2A5A3
B1
B4
B2B5B3
C1
C4
C2C5C3
RELAY C RELAY B
E6 E5 E4 E3 E2 E1
F6 F5 F4 F3 F2 F1
RELAY A
RELAY DFUSE 2FUSE 4FUSE 6
FUSE 1FUSE 3FUSE 5
Page 74
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59 CAN Harness
CAN-H (+)
CAN-H (-)
PLUG
PLUG
PLUG
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR
CAN-H (-)
CAN-H (+)
KEY_PWR PIN-13
SP3
C1-FPIN-4
SP2
C1-M
6
1 4 4 1
5 58 8
5
3
8
7
C2-F
A
A
B
C
C D
D
E
F
F
PIN-5
SP1
298D
298C
298B
1909D
1908D
1908C 1908A
1908B
1909B
1909C 1909A
298A
6
5
3
8
7
4
100263a
4
Page 75
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/250/350/450 Rear Frame Harness Electrical Schematic
Connector
1
Connector
9
CONNECT TO FORD FPCMHARNESS CONNECTOR
TO FORD FPCM MODULE (FUELPUMP CONTROL MODULE)
TO ROUSH FPCM MODULE (FUELPUMP CONTROL MODULE)
1 2 3 4 75 68 1 2 3 4 75 68
CONNECT TO FORD FUEL PUMPHARNESS INLINE CONNECTOR
Connector
21
Connector
24
Connector
12Connector
13
Connector
30
1
2
3
4
7
5
6
8
S1
PLUG
PLU
G
VPWR_1
FPC_1
GND_1
A_F
PP
WR
_1
ENS_1
FPM_1
A_F
PR
TN_1
VP
WR
_2
VPWR_RI
S4
VP
WR
_P2
TO FUEL TANK JUMPERHARNESS INLINE CONNECTORS
B A B A
S2
FPC
_2
FPC
_3
EN
S_2
EN
S_3
PLUG
PLUG
A_F
PP
WR
_2
A_F
PR
TN_2
S3
PLU
G
GN
D_2
GN
D_3
D C B A
A_S
OL_
1
A_S
OLR
TN_1
A_F
LS_1
A_F
LSR
TN_1
S6
SH
ILE
D_1
SH
ILE
D_2
SH
ILE
D_3
SH
ILE
D_4
SH
IELD
_5
FRAME GROUND(SHIELD)
4
3
2
1
PLUG
PLUG
FG_SND
A
B
C
D
E
F
TO ROUSH UNDERHOOD HARNESSINLINE CONNECTOR
A
BConnector
41
TO ROUSH UNDERHOOD HARNESSINLINE CONNECTOR
S5
VPWR_RO
FL_SRTN
VPWR_RI
PLUG
FPM_2
Connector
27
GRAY BLACK
TO FUEL TANK JUMPERHARNESS INLINE CONNECTOR
RING TERMINAL
GND
14
58
4 1
8 5
4 1
8 5
100266a
Page 76
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/250/350/450 Underhood Harness Electrical Schematic
100267a
To BatteryPositive
2
SUPP
LY_S
OL
BLEE
D_S
OL_
RTN
BLEE
D_S
OL
FLO
W_C
NTL
_SO
L
SUPP
LY_S
OL_
RTN
S1
PWR_W
A2A4A1
A3
A5
25A
10A
Connector
8
Connector
1
5A
3 5 7 1510 17 43
28
25 26 29
33 34 35 36 3731
40
44 46
1 2 3 4
FLO
W_C
NTL
_SO
L_R
TN
SOLENOID_PWR
IPTS
_PW
R
IPTS
_TEM
P_O
UT
IPTS
_PR
ES_O
UT
IPTS
_GN
D
A
B
C
D
E
F
VPWR_RO
20A
FRAME GROUND
S2
VPWR_RI
FL_SND
FL_RTN_1S3
FG_RTN
FG_SND
TANK_SOL_RTN
GN
D1
GND2 GND3
SRM_PWR
A
B
C
D
E
F
KEY_
PWR
_1
KEY_PWR_2
PLUG
CAN-H_1(-)
CAN-H_1(+)
TO REARFRAME
HARNESS
TO REARFRAME
HARNESS
TO CANHARNESS
Connector
11
Connector
15
Connector
47
Connector
23
Connector
27
FL_RTN_2
A1 = 85A2 = 86A3 = 30
A4 = 87AA5 = 87
TO IPTS TO SOLENOIDMODULE
TO SRM
ELECTRICAL CENTER(FUSE BOX)
TO FLIM
A
B
C
D
FG_RTN_SRM
S5
Connector
35
PWR
S4
PWR_W_1
PWR_W_2
PWR_W_3
PWR_W_6
PLUG
SRM_PWR_2
A
B
RELAYNO CONTACT20A@14VDC
16
15
14
13
12
11
9
10
8
7
6
5
4
3
1
2
TO FORD HARNESS12C508 (C1168)
TO FORD AUX ENGINEINLINE MODULE
Connector
51Connector
55
16
15
14
13
12
11
9
10
8
7
6
5
4
3
1
2
PLUG
S8J1 J1A
J2J9
J10J3
J11J4
J12J5
J6
J7
J8
J13
J14
J15
J16
PLUG
SRM_PWR_1
AB
FDD EE
C
FPM_2
F5
E1 E2
F1 F2
E4E3
GND_R2FRAME GROUND
Initial Print A.A20111403
Connector
GND
F6
4
32
1
4544
29
15
46
163
PBT/ASA-GF2018
32
21
3130
17
A1
D1
D4
D2D5D3
A1
A4
A2A5A3
B1
B4
B2B5B3
C1
C4
C2C5C3
RELAY C RELAY B
E6 E5 E4 E3 E2 E1
F6 F5 F4 F3 F2 F1
RELAY A
RELAY DFUSE 2FUSE 4FUSE 6
FUSE 1FUSE 3FUSE 5
Page 77
WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS
F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic
100268a
D
C
B
A
D
C
B
ASOLENOID_SPLY
SOLENOID _RTN
FUEL_LEVEL _RTN
FUEL_LEVEL _SPLY
B
A
B
A
B
A
B
A
FUEL_PUMP_PWR_1
FUEL_PUMP_PWR_2
FUEL_PUMP_RTN_1
FUEL_PUMP_RTN_2
FRAME GROUND(SHIELD)
S1
Connector
1B
Connector
4Connector
9
Connector
13
Connector
16
SHIELD_1SHIELD_2
CONNECT TO REAR FRAMEHARNESS INLINE CONNECTOR
CONNECT TO IN-TANK HARNESSINLINE CONNECTOR
CONNECT TO TANK HARNESSINLINE CONNECTOR
SHIE
LD_3
Connector
GND
BLACK
GRAY
Connector
1A
CONNECT TO REAR FRAMEHARNESS INLINE CONNECTOR
CONNECT TO REAR FRAMEHARNESS INLINE CONNECTOR
BLACK
GRAY
CONNECT TO IN-TANK HARNESSINLINE CONNECTOR
©2014 by ROUSH CleanTech. All rights reserved.
The information in this publication was accurate and effective at the time the publication was approved for publishing and is subject to change without notice or liability. ROUSH CleanTech reserves the right to revise the information herein and to make changes and discontinue pro-duction of described parts at any time.