Symptom Troubleshooting (Engine/Fuel Control)

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Foreword
Engine OBD II Monitors
- Notes
- Catalyst Efficiency Monitor - Federal Test Procedure
- Comprehensive Component Monitor
- Evaporative Emission (EVAP) Vapor Management Flow System Monitor
- Evaporative Emission (EVAP) Running Loss System Monitor
- Exhaust Gas RECIRCULATION (EGR) System Monitor - Differential Pressure Feedback EGR
- Fuel System Monitor
- Heated Oxygen Sensor (Ho2S) Monitor
- Misfire Detection Monitor
- Malfunction Indicator Lamp (Mil)
Electronic Engine Control (EEC) System
- Overview
- Modifications To OBD II Vehicles
- Powertrain Control Software
- Powertrain Control Hardware
- Power & Ground Signals
- Fuel Systems
  - Mechanical Returnless Fuel System
- Exhaust Gas RECIRCULATION Systems
  - Overview
  - Differential Pressure Feedback EGR System
- Evaporative Emissions System Outline
  - Overview
- Intake Air Systems
- Positive Crankcase Ventilation System
  - Overview
- Catalyst & Exhaust Systems
  - Overview
- Communication Error
- Vehicle Check/Preparation
  - Visual Checks
  - Vehicle Preparation
- Intermittent Diagnostic Techniques
- On-Board System Readiness
  - Description
- Freeze Frame Data
  - Description
- Output Test Mode
  - Description
- Powertrain Control Module (Pcm) Reset
  - Description
  - Resetting Keep Alive Random Access Memory (RAM)
On-Board Diagnostic Tests - NGS Tester
- On-Board Diagnostic (OBD) Test Description
On-Board Diagnostic Tests - WDS
- On-Board Diagnostic (OBD) Test Description
- On-Board Diagnostic Test
Drive Cycle
- Description Of OBD II Drive Cycle
- Drive Cycle Recommendations
- Vehicle Preparation
- OBD II Drive Cycle
- Monitor Repair Verification Drive Cycles
Diagnostic Trouble Code Index
Diagnostic Trouble Code Numbers
Diagnostic Trouble Code Application Chart
Pcm Quick Test
DTC P0100, P0102, P0103, P1100, P1101, P1102, P1103, P1793: Mass Air Flow (MAF/IAT) Sensor
DTC P0110, P0111, P0112, P0113, P0115, P0117, P0118, P0125, P0128, P0298, P1110, P1112, P1113, P1116, P1117, P1285, P1288, P1289, P1290, P1299, P1798: IAT & ECT /CHT Sensors
DTC P0120, P0121, P0122, P0123, P0510, P1120, P1121, P1122, P1123, P1124, P1125, P1126, P1771, P1772, P1791: TP Sensor Circuit Malfunction
P0031, P0130, P0131, P0150, P0151: Heated Oxygen Sensor (Ho2S)
DTC P0038, P0044, P0132, P0133, P0138, P0144, P0152, P0153, P0154: Upstream Heated Oxygen Sensor (Ho2S)
DTC P0032, P0051, P0052, P0057, P0058, P0134, P0135, P0141, P0155, P0161, P1135, P1136, P1141, P1142, P1153, P1154, P1169, P1170: Ho2S Heater Circuit
DTC P0037, P0043, P0136, P0140, P0142, P0146, P0147, P0156, P0157, P0158, P0160, P1133, P1134, P1137, P1138, P1143, P1144, P1157, P1158, P2270, P02271, P2272, P2273: Ho2S
DTC P0170, P0171, P0173, P0174: Adaptive Fuel Control
DTC P0172, P0175: Adaptive Fuel Control
DTC P0201, P0202, P0203, P0204, P0205, P0206: Fuel Injector Malfunction
DTC P0230, P0231, P0232, P1645: Fuel Pump (FP) Primary Or Secondary Circuit
DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0315, P0316: Misfire Detection Monitor
DTC P0320, P0335, P0336: Crankshaft Position (CKP) Sensor Malfunction
DTC P0325, P0326, P0327, P0328, P0330: Knock Sensor Malfunction
DTC P0340, P0341, P1336, P1345, P1382, P1387: Camshaft Position Sensor (CMP) Malfunction
DTC P0350, P1364: Ignition Coil Primary Circuit Malfunction
DTC P0651, P0352, P0353, P0354, P0355, P0356: Integrated Ignition Coil 1, 2, 3, 4, 5, Or 6 Failure
DTC P0400, P0401, P0404, P0408: EGR System Malfunction
DTC P0402: EGR System Malfunction
DTC P0420, P0421, P0430, P0431: Catalyst Efficiency Monitor Malfunction
DTC P0442, P0456: Evaporative Emission (EVAP) Monitor And System Malfunction
DTC P0440, P0441, P0443, P0444, P0445, P0446: EVAP Canister Purge Solenoid Malfunction
DTC P0451, P0461: EVAP System Malfunction
DTC P0450, P0452: Fuel Tank Pressure (Ftp) Sensor Malfunction
DTC P0453: Fuel Tank Pressure (Ftp) Sensor Malfunction
DTC P0455, P1439,P1443, P1446, P1449, P1455, P14556, P1457: EVAP System Malfunction
DTC P0457: Evaporative Emission (EVAP) System Malfunction
DTC P0505, P0506, P0507, P1251, P1504, P1505, P1507, P1508, P1509, P1510, P1511, P1525, P1526, P1527, P1528, P1540, P1652: IAC Valve Assembly Malfunction
DTC P0605, P0606, P0614, P1562, P1600, P1601, P1602, P1603, P1604, P1605, P1608, P1609, P1621, P1622, P1623, P1633, P1639: Pcm Malfunction
DTC P0571, P0703, P1572, P1703: Brake Pedal Position (BPP) Switch Malfunction
DTC P0704, P1708, P1709, P1797: Clutch Pedal Position (CPP) Switch Malfunction
DTC P1000: OBD II Drive Cycle Malfunction
DTC P1001: Data Link Connector Malfunction
DTC P1127: Ho2S Heater(S)
DTC 1128: Heated Oxygen Sensor (Ho2S) Signals
DTC 1130, P1150, P1173: Fuel System Not Switching At Fuel Trim (Rich Or Lean)
DTC P1131, P1151, P2195, P2196, P1697, P2198: Upstream Heated Oxygen Sensor (Ho2S) Not Switching
DTC P1132, P1152: Upstream Heated Oxygen Sensor (Ho2S) Not Switching
DTC P0622, P1246, P1630, P1631, P1634: Generator/Regulator System Malfunction
DTC P1260: Anti-Theft System
DTC P1270: Engine Rpm/Vehicle Speed Limiter
DTC P1309: Misfire Detection Monitor Disabled
DTC P1400, P1401, P1402, P1407, P1485, P1486, P1487, P1496, P1497, P1498, P1499: DPFEGR Sensor Malfunction
DTC P0405, P0406, P1405, P1406: DPFEGR Sensor Malfunction
DTC P0403, P1409, P1412: EGR Vacuum Regulator (EGRVR) Solenoid Circuit Malfunction
DTC P1450: Evaporative Emission (EVAP) Monitor & System
DTC P1451: Canister Vent (CV) Solenoid Malfunction
DTC P0645, P1460: A/C Clutch Relay (ACCR) Malfunction
DTC P1464, P1465: A/C Control Signal (ACCS) Malfunction
DTC P1461, P1462, P1463: A/C Pressure Sensor (ACP) Malfunction
DTC P0481, P1473-P1477, P1479, P1480, P1481: Cooling Fan Malfunction
DTC P1506: Idle Air Control (IAC) System Malfunction
DTC 0551, P0552, P0553, P1650, P1651: Power Steering Pressure (PSP) Switch Malfunction
DTC P1780: TCS Or TCIL Circuit Malfunction
Diagnostic Index
Starting Concerns
Hard Start/Long Crank/Erratic Start/Erratic Crank
Cranks Normal But Will Not Start
Unique Idle Concern
Fast Idle
Low Idle/Stalls During Deceleration
Engine Poor DRIVEABILITY
Backfires
Lack/Loss Of Power
Knocking/Pinging
Poor Fuel Economy
Emission Compliance
Mil/TCIL Never On & Mil/TCIL Always On
Exhaust System Concerns
Fuel Odor In Engine Compartment
Engine Noise
Exhaust Sulfur Smell
All Supported On Board System Readiness Tests Not Completed
Fuel Pump Always On
Engine Inspection
Engine
- Inspection & Verification
- Component Tests
  - Engine Oil Leaks
  - Fluorescent Oil Additive Method
- Compression Test
- Excessive Engine Oil Consumption
- Oil Consumption Test
- Intake Manifold Vacuum Test
  - Notes
  - Interpreting Vacuum Gauge Readings
Evaporative Emission System
- Evaporative Emission System
  - Duratec Engine
  - Zetec Engine
- Principles Of Operation
- Inspection & Verification
Evaporative Emission System Leak Test
Evaporative Emission Repair Verification Drive Cycle
- Drive Cycle Recommendations
Canister Vent Solenoid Closing Procedure
Acceleration Control
- Inspection & Verification
Charging System
- Notes
- Principles Of Operation
- Inspection & Verification
- Component Tests
Battery
- Inspection & Verification
Starting System
- Inspection & Verification
- Component Tests
  - Starter Motor - Motor Feed Circuit
  - Starter Motor - Ground Circuit Test
Symptom Troubleshooting Chart - Engine
Symptom Troubleshooting Chart - Drive Belts
Symptom Troubleshooting Chart - Engine Cooling System
- Notes
- Pinpoint Test 1: Loss Of Coolant
- Pinpoint Test 2: The Engine Overheats
- Pinpoint Test 3: The Engine Does Not Reach Normal Operating Temperature
- Pinpoint Test 4: The Engine Cooling Fan(S) Inoperative/Incorrect Operation
- Pinpoint Test 5: The Block Heater Does Not Operate Correctly
2.0L ZETEC Fan Diagnosis Chart
- Notes
- Pinpoint Test 1: Loss Of Power
Symptom Troubleshooting Chart - Fueling
- Notes
- Pinpoint Test 1: Hiss When Opening Fuel Cap
- Pinpoint Test 2: Excessive Fuel Odor
- Pinpoint Test 3: Unable To Refuel (ORVR)
Symptom Troubleshooting Chart - Accelerator
Symptom Troubleshooting Chart - Charging System
- Notes
- Pinpoint Test 1: Battery Is Discharged Or Voltage Is Low
- Pinpoint Test 2: The Charging System Warning Indicator Is On With The Engine Running (The System Voltage Does Not Increase)
- Pinpoint Test 3: Charging System Warning Indicator Is On With The Engine Running (The System Voltage Does Not Increase) - 2.0L ZETEC
- Pinpoint Test 4: The System Overcharges (Battery Voltage Is Greater Than 15.5 Volts)
- Pinpoint Test 5: The System Overcharges (Battery Voltage Greater Than 15.5 Volts) - 2.0L ZETEC
- Pinpoint Test 6: The Charging System Warning Indicator Is On With The Engine Running & The Battery Increases Voltage
- Pinpoint Test 7: Charging System Warning Indicator Is On With The Engine Running The System Increases Voltage - 2.0L ZETEC
- Pinpoint Test 8: The Charging System Warning Indicator Is Off With The Ignition Switch In The Run Position & The Engine Off
- Pinpoint Test 9: The Charging System Warning Indicator Is Off With The Ignition Switch In The Run Position And The Engine Is Off - 2.0L ZETEC
- Pinpoint Test 10: The Charging System Warning Indicator Flickers Or Is Intermittent
- Pinpoint Test 11: The Charging System Warning Indicator Lamp Flickers Or Is Intermittent - 2.0L ZETEC
- Pinpoint Test 12: The Generator Is Noisy
- Pinpoint Test 13: Radio Interference
- Pinpoint Test 14: Battery Condition Test
Symptom Troubleshooting Chart - Starting System
- Notes
- Pinpoint Test 1: The Engine Does Not Crank Or The Relay Clicks
- Pinpoint Test 2: Unusual Starter Noise
Symptom Troubleshooting Chart - Cruise Control
- Notes
- Pinpoint Test 1: The Speed Control Is Inoperative
- Pinpoint Test 2: The Set Speed Fluctuates
- Pinpoint Test 3: The Speed Control Does Not Disengage When The Brakes Are Applied
- Pinpoint Test 4: The Speed Control Does Not Disengage When The Clutch Is Applied
- Pinpoint Test 5: The Speed Control Switch Is Inoperative - Coast
- Pinpoint Test 6: The Speed Control Switch Is Inoperative - Set/ACCL
- Pinpoint Test 7: The Speed Control Switch Is Inoperative - Resume
- Pinpoint Test 8: The Speed Control Switch Is Inoperative - Off
- Pinpoint Test 9: The Speed Control Indicator Lamp Is Always On
Powertrain Control Module Symptom Troubleshooting Chart
- Symptom Troubleshooting Chart
Generic Electronic Module (Gem) Symptom Troubleshooting Chart
- Notes
- Pinpoint Test 1: No Module/Network Communication - SCP Link
- Pinpoint Test 2: Unable To Enter Self - Test
- Pinpoint Test 3: Generic Electronic Module (Gem) Symptom Troubleshooting
General Test Index
Test 1: Vehicle Reference Voltage (VREF)
Test 2: Malfunction Indicator Lamp (Mil)
Test 3: Intermittent
Test 4: Fuel Delivery System
Test 5: Positive Crankcase Ventilation (PCV) System
Test 6: Pcm Power Relay
Test 7: Fuel Pressure Regulator
Test 8: Fuel Pump Inspection
Test 9: Fuel Line/Fuel Pressure Hold Inspection
Test 10: Fuel Injector Inspection
Test 11: EGR Valve
Test 12: EGR Vacuum Regulator (EGRVR) Solenoid Inspection
Test 13: Differential Pressure Feedback EGR (DPFE) Sensor
Test 14: No Start
Test 15: Ignition Scope Test
- Notes
- 2.0L
- 3.0L