FORD DIGITAL CODE READER (Front Cover)
Table of Contents Title Page No. YOU CAN DO IT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii CHAPTER 1 - GENERAL INFORMATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 1 to 1 9 9 5 appropriate Code Definition List. 9 Pinpoint Problem Areas • Locate fault code(s) in the 1 • • s 3 Read Fault Codes • Turn on ignition. DO le 2 test connector (test connector is usually found under the hood).
General Information SAFETY PRECAUTIONS 1 SAFETY PRECAUTIONS To avoid personal injury, instrument damage and/or damage to equipment under test; do not operate the Ford Digital Code Reader before reading this manual. This manual describes common test procedures used by experienced service personnel and technicians. Many test procedures require precautions to avoid accidents that can result in personal injury, and/or vehicle or equipment damage.
General Information 1 HOW TO USE THIS MANUAL h. The vehicle’s battery produces highly flammable hydrogen gas. To prevent an explosion, keep all sparks, high temperature items or open flames away from the battery. i. Don't wear loose clothing or jewelry when working on an engine. Loose clothing can get caught on the fan, pulleys, belts, etc. Jewelry is highly conductive, and can cause a severe burn if it makes contact between a power source and ground.
General Information 1 VEHICLE SERVICE MANUALS • Attempt to fix the problem yourself: If you choose to fix the problem yourself, read and follow all of the manual’s recommendations and procedures. Additional tools, text equipment (multimeter, timing light, etc.) and a vehicle repair manual containing Ford’s Diagnostic Trouble Code Service Procedures for your vehicle will be needed.
General Information 1 VEHICLES COVERED - CARS VEHICLES COVERED CAR - Ford, Lincoln, Mercury Computer System/Code Reader Application Table The following table is applicable to all models (excluding Diesel) of Ford, Lincoln and Mercury vehicles. Engine Fuel Systems 8th VIN (Carburetor Digit** Model) Application/Special Notes Computer System 1981-1982 2.3L I-4 OHC A FBC (6500-2V)* Capri, Cougar, Fairmont, Granada, Mustang, Zephyr 3.8L V-6 3 4.
General Information 1 VEHICLES COVERED - CARS Engine Fuel Systems 8th VIN (Carburetor Digit** Model) Computer System Application/Special Notes 1987-1993 5.8L V-8 G FBC 1987-91 Police vehicles only (7200 VV-2V)* (carbureted) 1.9L I-4 J, 9 EFI, CFI, SFI 2.0L I-4 A SEFI Probe (1993 manual transmission only) 2.3L I-4 A FBC (YFA)* Capri, LTD, Marquis, Mustang (1996 models) 2.3L I-4 OHC A, M EFI 2.3L I-4 T, W EFI Turbo 2.3L I-4 HSC S, X 2.
General Information 1 VEHICLES COVERED - TRUCKS/VANS NOTES * Carburetor Model. Carburetor model numbers are usually stamped on top of the carburetor, or on a metal tab attached to the carburetor. Consult your vehicle’s repair manual for proper identification. **VIN Number. The VIN number(s) used in this column identify the vehicle’s engine type. This number is the 8th digit of the VIN (Vehicle Identification Number). Consult your vehicle’s repair manual for details. Application Table Definitions.
General Information 1 VEHICLES COVERED - TRUCKS/VANS Engine Fuel Systems 8th VIN (Carburetor Digit** Model) Computer System Application/Special Notes 1985-1990 (Cont) 5.8L V-8 7.3L V-8 7.5L V-8 G M G FBC (2150A)* Diesel EFI E and F Series Trucks/Vans (8500 lb. GVW or less only) EEC-IV 2.3L I-4 OHC A EFI, MFI 2.9L V-6 T EFI 3.0L V-6 U 4.0L V-6 X EFI, MFI 4.9L I-6 5.0L V-8 5.8L V-8 Y, H N H, R EFI, MFI, SFI EFI, MFI, SFI EFI, MFI, SFI 7.3L V-8 7.3L V-8 7.
General Information 1 PRELIMINARY VEHICLE DIAGNOSIS WORKSHEET PRELIMINARY VEHICLE DIAGNOSIS WORKSHEET The purpose of this form is to help you gather preliminary information on your vehicle before you retrieve codes. By having a complete account of your vehicle's current problem(s), you will be able to systematically pinpoint the problem(s) by comparing your answers to the fault codes you retrieve.
General Information 1 PRELIMINARY VEHICLE DIAGNOSIS WORKSHEET WHEN DID YOU FIRST NOTICE THE PROBLEM: ❑ ❑ ❑ ❑ Just Started Started Last Week Started Last Month Other: LIST ANY REPAIRS DONE IN THE PAST SIX MONTHS: PROBLEMS STARTING ❑ No symptoms ❑ Will not crank ❑ Cranks, but will not start ❑ Starts, but takes a long time ENGINE QUITS OR STALLS ❑ No symptoms ❑ Right after starting ❑ When shifting into gear ❑ During steady-speed driving ❑ ❑ ❑ ❑ IDLING CONDITIONS ❑ No symptoms ❑ Is too slow at all tim
1 General Information PRELIMINARY VEHICLE DIAGNOSIS WORKSHEET AUTOMATIC TRANSMISSION PROBLEMS (if applicable) ❑ No symptoms ❑ Vehicle does not move when in gear ❑ Shifts too early or too late ❑ Changes gear incorrectly ❑ Jerks or bucks PROBLEM OCCURS ❑ Morning ❑ Afternoon ❑ Anytime ENGINE TEMPERATURE WHEN PROBLEM OCCURS ❑ Cold ❑ Warm ❑ Hot DRIVING CONDITIONS WHEN PROBLEM OCCURS ❑ Short - less than 2 miles ❑ With headlights on ❑ 2 ~ 10 miles ❑ During acceleration ❑ Long - more than 10 miles ❑ Mostly
About Diagnostic Systems WHAT ARE THE ADVANTAGES OF COMPUTER CONTROL SYSTEMS? 2 WHAT ARE THE ADVANTAGES OF USING COMPUTER CONTROL SYSTEMS ON VEHICLES? Vehicle Computer Control Systems can perform millions of calculations in one second, making them an ideal substitution for the much slower mechanical engine controls.
About Diagnostic Systems 2 HOW DOES A COMPUTER SYSTEM WORK ON A VEHICLE? The on-board computer receives information (inputs) from sensors and switches located throughout the engine. These devices monitor critical engine conditions (coolant temperature, engine speed, engine load, throttle position, air/fuel ratio etc.).
About Diagnostic Systems HISTORY OF FORD’S EEC SYSTEMS 2 • The computer also assigns a numeric code (OBD I systems utilized a 2 or 3 digit code) for each specific problem that it detects, and stores these codes in it’s memory for later retrieval. The codes can be retrieved from the computer’s memory with the use of a device called a “Code Reader” or a “Scan Tool”.
About Diagnostic Systems 2 FORD COMPUTER SYSTEM OVERVIEW 1994: Ford introduces the EEC-V system (OBD-II). This is a highly sophisticated system that uses more special programs to enhance the computer's capability to monitor, detect and report failures, especially to the vehicle's emission system. This system was introduced on a limited number of 1994 and 1995 vehicles. Starting in 1996, all Ford vehicles (cars and light trucks) sold in the US are equipped with the EEC-V system.
About Diagnostic Systems FORD COMPUTER SYSTEM OVERVIEW 2 IMPORTANT: When the computer is in Self Test mode (is testing the sensors or actuators for proper operation), it relies on voltage signals that it sends to and/or receives from the sensors or actuators to determine whether or not these components are operating properly. The sensors and actuators are all connected to the computer by wires.
2 Chapter 2 About Diagnostic Systems 16
About the Ford Code Reader BEFORE YOU BEGIN 3 BEFORE YOU BEGIN • Fix any known mechanical problems before performing any test. Make a thorough check before starting any test procedure. Loose or damaged hoses, wiring or electrical connectors are often responsible for poor engine performance, and in some cases they may cause a "false" fault code. Please read your vehicle's service manual for proper connection of vacuum hoses, electrical wiring and wiring harness connectors. Check the following areas: a.
About the Ford Code Reader 3 TEST CONNECTORS b. Match battery terminals with battery connector contacts. c. Place batteries into battery compartment. d. Reinstall battery compartment cover. TEST CONNECTORS • The gateway to your vehicle's onboard computer. Ford equips its vehicles with special Test Connectors that make it possible to connect specialized testing equipment that communicates with the vehicle's onboard computer.
About the Ford Code Reader FUNCTIONS OF THE FORD CODE READER ■ 1. 2. For the EEC-IV Computer System (most vehicles built after 1984) connect the Code Reader to BOTH. large, six pin female connector with molded housing EEC-IV TEST small, single pin female CONNECTOR connector NOTE: 1988 and newer vehicles may have more than one similar connector for other systems (i.e. Anti-Lock Brakes), only the connector with an extra single pin is the correct test connector for computer service codes use.
About the Ford Code Reader 3 FUNCTIONS OF THE FORD CODE READER The vehicle's computer generates and assigns fault codes whenever it detects a problem in any of the various systems that it monitors and/or controls. Once the Code Reader is connected to the vehicle's Test Connector(s), the user can signal the computer to perform the Self-Tests (by pressing the TEST/HOLD button). The computer then starts performing a Self Test of all the components and/or circuits it controls.
About the Ford Code Reader 3 FUNCTIONS OF THE FORD CODE READER 6. MEMORY Button - When pressed, displays on demand, one at a time, the retrieved Diagnostic Trouble Codes that are saved in the Code Reader's memory (the Code Reader memory has the capacity to store up to 12 retrieved numeric Diagnostic Trouble Codes). Display Functions 1 2 3 ORC CYL 4 5 6 1. CYL Icon: When visible, this icon indicates that the number shown on the the Code Reader's display is a cylinder identification code.
About the Ford Code Reader 3 FUNCTIONS OF THE FORD CODE READER 4. "FLASHING" SQUARE Icon: This icon flashes when the Code Reader receives Diagnostic Trouble Codes from the vehicle's computer. The icon flashes each time a code is received; the code is then shown on the Code Reader’s display. 5. LINK Icon: When visible, this icon indicates that the Code Reader is linked to the vehicle's computer, and the computer is in test mode. 6.
Retrieving Codes OVERVIEW OF FAULT CODES 4 OVERVIEW OF FAULT CODES IMPORTANT: Retrieving and utilizing Diagnostic Trouble Codes (DTC's) for troubleshooting vehicle operation problems is only one part of an overall diagnostic strategy. Never replace a part based only on the Diagnostic Trouble Code Definition. Always consult the vehicle's service manual for more detailed testing instructions.
Retrieving Codes 4 OVERVIEW OF FORD CODE RETRIEVAL PROCESS 3. It records and retains in its memory (not applicable to MCU systems) a record of faults that occurred in the past but are no longer present. The vehicle's computer keeps these Fault Codes in its memory for a specific period of time (40 Warm Up cycles* for most fault Codes, 80 Warm up cycles for others) even if the problems that caused these codes to be set in the first place are no longer present.
Retrieving Codes 4 KOEO TEST PROCEDURES (EEC-IV SYSTEMS) tests are designed to activate components and test their operation only with the Key On and Engine Running. Do not take short cuts. If you fail to perform a test, or you perform a test out of sequence, you might miss a problem that is only detected during that particular test procedure. To properly receive Diagnostic Trouble Codes from the Ford computer control system, perform the Self Tests in the following order: 1.
Retrieving Codes 4 KOEO TEST PROCEDURES (EEC-IV SYSTEMS) 3. With Code Reader off, connect to the vehicle's test connectors (see page 18 for test connector location). ■ 4. Both the large and small connectors must be connected. If your vehicle is equipped with one of the following configurations, perform the added procedures as described below. ■ For 4.9L engines with standard transmission: press and hold the clutch until all Codes are sent (Steps 4 to 10). ■ For 7.
Retrieving Codes 4 KOEO TEST PROCEDURES (EEC-IV SYSTEMS) 8. WARNING: On some vehicles equipped with an Electric Cooling Fan, the computer activates the cooling fan to check its operation. To avoid injury, keep hands or any part of your body a safe distance from engine during the test. After 6 to 10 seconds (it may take longer on some vehicles) the computer will start sending the KOEO Self Test results to the Code Reader in the form of numerical codes.
Retrieving Codes 4 KOEO TEST PROCEDURES (EEC-IV SYSTEMS) ■ Code 10 is not a fault code. Code 10 is a “separation code” used to separate the first group of codes (KOEO Self Test Codes) from the Continuous Memory group of codes. ■ Code 10 also serves as an indication to the user that the vehicle's computer has completed the first part of the KOEO Self Test, and that the next groups of codes to be displayed are Continuous Memory codes. 11.
Retrieving Codes 4 KOEO TEST PROCEDURES (EEC-IV SYSTEMS) 14. If any KOEO Self Test Fault Codes were retrieved: ■ Refer to page 46 for "Fault Code Definitions for EEC-IV Systems". Match the codes retrieved with the codes shown in the Fault Code Definition list to determine the fault. C ■ Use the code definitions as a guide, and follow the manufacturer's service procedures in the vehicle's service repair manual to troubleshoot and repair faults.
Retrieving Codes 4 ENGINE TIMING CHECK (EEC-IV SYSTEMS) ENGINE TIMING CHECK (EEC-IV SYSTEMS) IMPORTANT: Before performing the KOER Self Test, the vehicle’s Ignition Base Timing and the computer’s ability to electronically control timing advance must be checked for proper operation. Maladjustment of ignition timing, or a problem in the advance circuit, might generate false fault codes when performing the KOER Self Test that would cause the test to be invalid.
Retrieving Codes ENGINE TIMING CHECK (EEC-IV SYSTEMS) 5. 4 Press and release the TEST/HOLD button to put the Code Reader in test mode. The vehicle's computer will perform a Key On Engine Running Self test. ■ 6. A square icon (on the right-hand side of the screen) displays and flashes each time the Code Reader receives a code. The code is then shown on the Code Reader's display.
Retrieving Codes 4 KOER SELF TEST (EEC-IV SYSTEMS) ■ 9. Turn the engine off and disconnect the Code Reader from the test connectors. Refer to the vehicle's service manual for instructions on adjusting and/or repairing ignition timing. If timing light readings are within the acceptable range, base timing and the vehicle's computer ability to advance timing are working properly. ■ Turn engine off and disconnect the Code Reader from test connectors. Proceed to page 32 and perform the KOER Self Test. B.
Retrieving Codes 4 KOER SELF TEST (EEC-IV SYSTEMS) 1. Warm up the vehicle to normal operating temperature. ■ Start the engine, increase engine speed to 2000 RPM, and maintain engine speed for approximately two to three minutes. In most cases, this is sufficient to allow the engine to warm up to normal operating temperature. NOTE: Failure to warm engine to normal operating temperature before performing KOER test might result in a false Fault Code being sent to the code reader. 2. Turn ignition off. 3.
Retrieving Codes 4 KOER SELF TEST (EEC-IV SYSTEMS) NOTE: If code 98 or 998 disR plays instead of a cylinder ID code, the vehicle is operating in "Failure Mode". The computer goes into failure mode when it detects a signal from a sensor R that indicates the sensor has failed and is completely out of specifications. The computer substitutes a fixed signal value for the failed sensor to keep the vehicle running.
Retrieving Codes 4 KOER SELF TEST (EEC-IV SYSTEMS) ■ Code 10 is not a fault code. The vehicle's computer uses code 10 to signal the Code Reader operator to perform a Wide Open Throttle (WOT) test (quickly press and release the accelerator pedal). This procedure is called the Dynamic Response Check. The computer uses this brief Wide-Open Throttle (WOT) test to verify the operation of the Throttle Positioning, Mass Airflow, Manifold Absolute Pressure and Knock Sensors.
Retrieving Codes 4 KOER SELF TEST (EEC-IV SYSTEMS) 13. To view codes stored in the Code Reader's memory, press the ON/OFF button to turn the Code Reader on, then press and release the MEMORY button; the first stored code will display. Continue pressing and releasing the MEMORY button to scroll through the stored codes until all the codes have been displayed.
Retrieving Codes ERASING CODES FROM EEC-IV SYSTEMS 4 ERASING CODES FROM EEC-IV SYSTEMS IMPORTANT: Continuous Memory Codes are the only ones that are saved in the vehicle’s computer long-term memory. KOEO and KOER Self Test fault codes represent problems that are present at the time these tests are performed and are detected by the computer only while the problem is present.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS NOTE: As soon as the TEST/HOLD button is pressed the vehicle's computer enters the Self Test mode. Clicking sounds will be heard coming from the engine. This is normal. It indicates that the vehicle's computer is activating relays, solenoids, and other components to check on their operation. 6. WARNING: On some vehicles equipped with an Electric Cooling Fan, the computer activates the cooling fan to check its operation.
Retrieving Codes ADDITIONAL TESTS FOR EEC-IV SYSTEMS 4 Relay and Solenoid Test (Output State Check) The "Output State Check " is a special program in the vehicle's computer that allows the user to energize (turn ON) and deenergize (turn OFF), on command, most of the actuators (relays and solenoids) that are controlled by the computer. • Use this test to check computer output voltages and relay/solenoid operation. NOTE: The fuel injectors and fuel pump are not energized during this test.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS ■ 6. The vehicle’s computer sends a voltage output signal or a ground signal to energize the actuators. If an actuator is not responding to the Output State Check, follow the procedures described in the vehicle's service manual to check computer actuator output circuit voltages and/or grounds. After performing the Output State Check, turn off the ignition and disconnect the Code Reader from the test connectors.
Retrieving Codes ADDITIONAL TESTS FOR EEC-IV SYSTEMS 4 Cylinder Balance Test Procedure • Always observe safety precautions before and during testing process. • ALWAYS check Code Reader battery before retrieving fault codes. • The vehicle must pass the KOEO test before performing this test. 1. Turn ignition off. 2. Turn the Code Reader off (press the ON/OFF button, as necessary), then connect the Code Reader to the vehicle's test connectors. ■ 3. 4.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS ■ 7. The computer is now in Cylinder Balance Test Mode, and will start cutting fuel to each cylinder in sequence to determine if all the cylinders are contributing equally. It may take up to five minutes before the test results are transmitted to the Code Reader. After the computer finishes performing the Cylinder Balance Test, the test results are sent to the Code Reader in the form of two digit codes.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS ■ The Cylinder Balance Test can be repeated by pressing and releasing accelerator pedal (as described in step 6, on page 41) within two minutes after the last cylinder balance code is retrieved. Use the A, B, C, and D examples in the "TEST RESULTS CHART" to determine the meaning of the test results. The chart uses the #2 cylinder as an example, but the procedures are the same for any cylinder.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS B: If a cylinder problem code (Code 20 in example B in TEST RESULTS CHART) is retrieved the 1st time the test is performed, repeat the test again. If the system passes the 2nd time (Code 90) the test is performed, testing is complete. Consult the Test Chart for “Problem Indication” and “Possible Cause”, then proceed to step 8.
Retrieving Codes 4 ADDITIONAL TESTS FOR EEC-IV SYSTEMS NOTE: After the Cylinder Balance Test is done, the KOER Test Fault Codes will be saved in the Code Reader's memory together with Cylinder Balance fault codes. To distinguish between the KOER codes and Cylinder Balance codes, consult the "Cylinder Balance Test Code Description Chart" preceeding. Cylinder Balance fault codes are two digit codes, and are defined by the following numbers: 10, 20, 30, 40, 50, 60, 70, 80 and 90.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (11 - 15) ■ For 1986 and older vehicles: Wiggle test is now active. Proceed to step 4. ■ 4. For 1987 and newer vehicles: Set Code Reader switch to TEST, then HOLD, then TEST. Wiggle test is now active. Proceed to Step 4. Perform "Wiggle Test" on circuit. ■ 5. Wiggle sensor, connector and wiring that needs to be tested; a code will display if a fault is detected.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (15 - 24) CODE TEST CONDITION FAULT CODE DEFINITION 15 C Power Interruption to computer memory or EEC (PCM) Keep Alive Memory (KAM) test failed 15 O Read Only Memory test failed 16 O (Cars ONLY): Signal from Ignition Diagnostic Monitor (IDM) not received 16 R RPM too low to perform HEGO (HO2S) test 16 R Idle RPM high with ISC retracted 16 R RPM above self test limit with ISC off 17 R (Cars ONLY): RPM below self-test limit
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (25 - 33) TEST CONDITION FAULT CODE DEFINITION 25 R Knock not sensed during Dynamic Response Test 26 O, R (Cars ONLY): Mass Air Flow (MAF) sensor or Vane Air Flow (VAF) sensor or Transmission Oil Temperature (TOT) sensor out of range 26 O, R (Trucks ONLY): MAF sensor or circuit fault (4.0L models) 26 O, R (Trucks ONLY): Transmission oil temperature sensor fault (ex. 4.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (34 - 42) CODE TEST CONDITION FAULT CODE DEFINITION 34 R (Cars ONLY): EGR valve not opening properly 34 O, R, C (Cars ONLY): Insufficient EGR flow or EVP voltage high (SONIC) or PFE sensor voltage high or out of specification 34 O, R, C (Trucks ONLY): EGR control circuit fault (ex.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (42 - 55) TEST CONDITION FAULT CODE DEFINITION 42 C No O2S switching detected 43 C (Cars ONLY): Lean HEGO (HO2S) at wide open throttle 43 R, C (Trucks ONLY): Throttle position sensor below idle spec (Diesel) 44 R Thermactor air system fault 45 R Thermactor air upstream 45 C DIS coil pack circuit failure 46 R Thermactor air is not bypassed 46 C (Cars ONLY): DIS coil pack circuit failure 47 O 4 x 4 switch closed (E4OD)
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (55 - 62) TEST CONDITION FAULT CODE DEFINITION 55 R (Trucks ONLY): Charging system fault 56 O, C (Cars ONLY): Mass or vane air flow sensor above maximum voltage transmission sensor failure 56 C (Trucks ONLY): Mass Air Flow sensor fault (voltage higher than normal) (4.0L models) 56 O, C (Trucks ONLY): Transmission oil temperature sensor fault (ex. 4.
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (63 - 68) TEST CONDITION FAULT CODE DEFINITION 63 O, C Throttle Position (TP) circuit fault, below minimum voltage 63 C, O Fuel injection pump lever sensor input is less than self test minimum (Diesel) 64 O, C ACT (IAT)/vane air temperature sensor fault or circuit grounded 65 R Overdrive Cancel Switch not changing state (E40D); transmission fault 65 R (Trucks ONLY): Charging system (1985 through 1988 models) 65 C (Cars O
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (68 - 79) CODE TEST CONDITION FAULT CODE DEFINITION 68 O (Trucks ONLY): Idle tracking switch (1985 through 1989 models) 69 O (Cars ONLY): AXOD 4/3 or 3/2 pressure switch circuit failure; circuit closed 69 O (Trucks ONLY): Vehicle Speed Sensor fault 69 C AXOD 4/3 or 3/2 pressure switch circuit failure, circuit open; or 3-4 shift error (E4OD) 70 C (Cars ONLY): ECM failure 71 C (Cars ONLY): ECM reinitialization detected on Clus
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (79 - 89) TEST CONDITION FAULT CODE DEFINITION 79 - (Trucks ONLY): Air conditioner on while performing test 81 O Air diverter solenoid fault, intake air control circuit fault / air injection diverter 82 O Air diverter solenoid circuit fault or supercharger bypass circuit fault 82 O Integrated relay control module 83 O EGR solenoid circuit fault (2.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (89 - 112) TEST CONDITION FAULT CODE DEFINITION 89 O Exhaust heat control 91 O Shift Solenoid 1 (SS1) circuit failure 91 R (Cars ONLY): HEGO (HO2S) sensor voltage low / system lean 91 C (Cars ONLY): HEGO (HO2S) sensor signal out of range /always lean 92 O Shift Solenoid 2 (SS2) circuit failure 92 R (Cars ONLY): HEGO (HO2S) sensor voltage high / system rich 93 O (Cars ONLY): Throttle position sensor signal input low at maxi
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (112 - 138) TEST CONDITION FAULT CODE DEFINITION 112 O, C (Trucks ONLY): Air charge temperature sensor below minimum voltage 113 O, C Intake air charge temperature sensor above maximum voltage / -40° indicated 114 O, R Air charge temperature sensor higher or lower than expected voltage 116 O, R Engine coolant temperature higher or lower than expected 117 O, C Engine coolant temperature sensor below minimum voltage / 254° F
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (139 - 181) CODE TEST CONDITION FAULT CODE DEFINITION 139 C (Cars ONLY): HEGO (HO2S) sensor switch fault 141 R Flexible fuel control / fuel system lean 144 C HEGO (HO2S) sensor switch fault 157 C Mass Air Flow sensor fault, low voltage 158 O, C Mass Air Flow sensor fault, high voltage 159 O, R Mass Air Flow sensor fault, above or below normal 167 R Throttle Position sensor fault during dynamic response test 171 C (Cars
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (181 - 216) TEST CONDITION FAULT CODE DEFINITION 181 C (Trucks ONLY): HEGO (HO2S) sensor fault unable to switch / lean during part throttle 182 C Fuel system at lean adaptive limit at idle / system rich 183 C Fuel system at rich adaptive limit at idle / system lean 184 C Mass Air Flow sensor above normal 185 C Mass Air Flow sensor below normal 186 C Fault in injector pulse width circuit / high 187 C Fault in injector
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (217 - 311) TEST CONDITION FAULT CODE DEFINITION 217 C DIS fault ignition system - coil #3 218 C Loss of Ignition Diagnostic Monitor (IDM) signal/left side 219 C (Cars ONLY): SPOUT signal defaulted to 10° BTDC / SPOUT circuit open 221 C Spark timing error 222 C Distributorless Ignition System - loss of right side ignition Diagnostic Monitor (IDM) signal 223 C Distributorless Ignition System - loss of dual plug inhibit (DPI) c
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (312 - 416) TEST CONDITION FAULT CODE DEFINITION 312 R Thermactor air system/fault during engine run self-test 313 R Thermactor air system/air not bypassed during self-test 314 R (Cars ONLY): Thermactor air system/fault during engine run self-test / left side 326 R, C (Cars ONLY): EGR sensor circuit voltage lower than expected 327 O, R, C EGR valve position circuit below minimum voltage 327 * EVP/EPT circuit below minimu
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (452 - 533) CODE TEST CONDITION FAULT CODE DEFINITION 452 R (Cars ONLY): Vehicle Speed Sensor (VSS) signal fault 452 C (Trucks ONLY): Vehicle Speed Sensor (VSS) signal fault 453 * Servo leaking down during test 454 * Servo leaking up during test 455 * Insufficient RPM increase during speed 456 * Insufficient RPM decrease during test 457 * Speed control command switches circuit not functioning 458 * Speed control comman
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (536 - 568) TEST CONDITION FAULT CODE DEFINITION 536 R, C Brake On/Off (BOO) circuit not activated during KOER 538 R Insufficient RPM change during KOER Dynamic Response Test/ 538 R (Trucks ONLY): invalid cylinder balance test due to throttle movement during test 539 O A/C on/Defrost on during KOEO 542 O, C Fuel pump secondary circuit fault 543 O, C Fuel pump secondary circuit fault 551 O Idle Air Control solenoid cir
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (569 - 631) CODE TEST CONDITION FAULT CODE DEFINITION 569 O (Trucks ONLY): Auxiliary Canister Purge (AUX-CANP) circuit failure 571 O EGR circuit failure 572 O EGR circuit failure 578 C A/C pressure sensor circuit 579 C Insufficient A/C pressure change 581 C Power to fan circuit over current 582 O Fan circuit open 583 C Power to fuel pump over current 584 C Power ground circuit open 585 C Power to A/C clutch over
Retrieving Codes 4 CODE FAULT CODE DEFINITIONS FOR EEC-IV SYSTEMS (632 - 655) TEST CONDITION FAULT CODE DEFINITION 632 R Overdrive Transmission Cancel Switch/ no action during self engine run test 633 O 4 x 4 switch is closed 634 C Manual Lever Position sensor voltage higher or lower than expected or A/C on 636 O, R Transmission Oil Temperature higher or lower than expected 637 O, C Transmission Oil Temperature circuit above maximum voltage 638 O, C Transmission Oil Temperature circuit
Retrieving Codes 4 RETRIEVING FAULT CODES FROM MCU SYSTEMS CODE TEST CONDITION FAULT CODE DEFINITION 656 C Converter Clutch Control (CCC) continuous slip error 659 R High vehicle speed in park indication 662 O Shift solenoid 2 circuit 667 C, O Transmission range sensor circuit below maximum voltage 668 C, O Transmission range sensor circuit above maximum voltage 675 O, R Transmission range sensor circuit voltage out of range 675 C Cluster center control circuit failed dynamic respo
Retrieving Codes 4 KOEO SELF TEST (MCU SYSTEMS) ■ In-Line 4 and In-Line 6 with canister control valve: Remove hose from connector port B. Reconnect after testing is completed. ■ V-6 and V-8: Remove PCV valve: Reconnect after testing is completed. ■ 2.3L with GK code: Locate the anti-backfire vacuum switch tee behind the MCU module and remove the cap. Reconnect after testing is completed. ■ 2.3L with EGR vacuum load control valve: Cover vacuum valve vent holes with tape.
Retrieving Codes 4 KOEO SELF TEST (MCU SYSTEMS) 4. Press and release the ON/OFF button to turn the Code Reader "ON". ■ Three zeros should be visible on the display at this time. 5. Press and release the TEST/HOLD Button to put the code reader in TEST mode. 6. Turn on ignition. DO NOT START THE ENGINE. ■ 7. The display will show a "Triangle" Icon on the lower right hand corner of the screen to indicate that the code reader is in test mode.
Retrieving Codes 4 KOER SELF TEST (MCU SYSTEMS) NOTE: All retrieved codes will stay in the Code Reader's memory and will only clear from the Code Reader's memory if the Self Test procedure is performed again (codes from a prior test will clear automatically when new Self Test is performed) or if batteries are removed from the Code Reader. 11. Go to page 72 for "FAULT CODE DEFINITION FOR MCU SYSTEMS".
Retrieving Codes 4 KOER SELF TEST (MCU SYSTEMS) NOTE: For vehicles with 2.3L HSC (High Swirl Combustion) engines: Locate vacuum tee and restrictor in the thermactor vacuum control line, and uncap during KOER Test Reconnect after testing is completed. 1. Turn ignition off. 2. Press the ON/OFF Button to turn Code Reader OFF, then connect the Code Reader to the vehicle's test connector. ■ 3. MCU systems are equipped with only one 6-pin connector (see page 18 for details).
Retrieving Codes 4 KOER SELF TEST (MCU SYSTEMS) 6. 7. ■ The first code displayed by the Code Reader is the Cylinder Identification (ID) Code. The cylinder ID code identifies the number of cylinders of the vehicle that is under test. ■ A small "R" will show in the upper right hand corner of the display to indicate that the code being retrieved is a Key On Engine Running (KOER) code. NOTE: If all the procedures are followed and the Code Reader fails to work, refer to "Troubleshooting" on page 75.
Retrieving Codes 4 FAULT CODE DEFINITIONS FOR MCU SYSTEMS (11 - 45) ■ Refer to page 72 for "Fault Code Definitions for MCU Systems". Use the code definition as a guide and follow the manufacturer's service procedures in the vehicle's service repair manual to troubleshoot and repair faults. ■ All KOER codes that are received by the Code Reader during the KOER Self test represent problems that are present now (at the time the test is performed).
Retrieving Codes 4 FAULT CODE DEFINITION FOR MCU SYSTEMS (46 - 64) CODE FAULT CODE DEFINITION 46 All Engines: Thermactor Air System unable to bypass. 51 I-4: Low or Mid Temperature Switch is open when engine is hot. I-6: Low or Mid Temperature Vacuum Switch is open when engine is hot. V-6: Hi or Hi/Low Vacuum Switch is always open. V-8: Hi or Hi/Low Vacuum Switch is always open. 52 I-4 (car): Idle Tracking Switch (ITS) - voltage does not change from closed to open throttle.
Retrieving Codes 4 FAULT CODE DEFINITION FOR MCU SYSTEMS (65 - 66) CODE FAULT CODE DEFINITION 65 NOTE: "High Altitude" refers to vehicles that are computer adjusted for high elevation operation. I-4: (All except High Altitude): Altitude circuit is open. I-4: (High Altitude Only): System OK. V-6: Mid Vacuum Switch is closed constantly. V-8: Mid Vacuum Switch is closed constantly. 66 73 I-6: Closed Throttle Vacuum Switch is closed constantly.
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Troubleshooting 5 CODE READER TROUBLESHOOTING GUIDE CODE READER TROUBLESHOOTING GUIDE If all procedures are followed and the Code Reader will not retrieve codes when performing the Key On Engine Off (KOEO) Self Test, check the following: 1. Code Reader's batteries, change batteries as required. Check the vehicles Test Connector pins for corrosion and clean as necessary.
Troubleshooting 5 CODE READER TROUBLESHOOTING GUIDE MCU Systems (Most 1981-84 vehicles) The 6-pin MCU Test Connectors for some vehicle models are not equipped with a ground terminal at position "F". This terminal is required by the code reader to provide a ground signal to the vehicle's computer to initiate the Self-Test. "F" If no codes are displayed during the testing procedure, check the Test Connector for ground JUMP TO GROUND terminal at position "F".
Glossary 6 INTRODUCTION INTRODUCTION The Society of Automotive Engineers has issued a Standard (SAE J1930) for Electrical/Electronic Systems Diagnostic Terms, Definitions, Abbreviations, and Acronyms. However, at the present time, this Standard is not in wide use by vehicle manufacturers. This Glossary contains definitions for abbreviations and terms you may find in this manual or in your vehicle service manual. These definitions may not agree with those contained in SAE J1930.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS BASE IDLE – Idle RPM when the throttle lever rests on the throttle stop and the Idle Speed Control is fully retracted and disconnected. BCM – Body Computer Module. BOO – Brake On-Off input to the computer. BOOST – Condition of over-pressure (above atmospheric) in the intake manifold; caused by intake air being forced in by a turbocharger or supercharger. BP – Barometric Pressure sensor. Used to compensate for altitude variations. BPA – ByPass Air solenoid.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS CKT – Circuit. CL – Closed Loop. CLC – Converter Lock-up Clutch. CO – Carbon Monoxide. COC – Conventional Oxidation Catalyst. COMPUTER TIMING –Total spark advance in degrees before top dead center. Calculated by Ford EEC-IV processor, based on sensor input. CONTINUOUS SELF-TEST – Continuous test of Ford EECIV system conducted whenever vehicle is in operation. CPS – Crankshaft Position Sensor.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS DV TW – Delay Valve, 2 Way. DVM (10 MEG) – Digital voltmeter with a minimum of 10 million ohms resistance. Allows measurement in circuit without affecting the circuit operation. DWELL – Amount of time (recorded on a dwell meter in degrees) that current passes through a closed switch. E4OD – Ford Electronic 4 speed Overdrive transmission. EAS – Electronic Air Switching, directs airflow to catalytic converter or exhaust ports of the engine.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS ELECTRONIC SPARK TIMING – PCM controlled timing of the ignition spark. EMR – Electronic Module Retard, controls spark retard. ENGINE CONTROL MODULE – A microprocessor based device which contains electronic circuitry to control and monitor air/fuel and emission systems, and aid in diagnostics. EPC – Electronic Pressure Control solenoid. EPROM – Erasable Programmable Read Only Memory. ER – Engine running, used on some Ford system tests.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS GND, GRD or GRND – Ground. Common line leading to the negative side of the battery. HALL EFFECT –Process where current is passed through a small slice of semiconductor material at the same time as a magnetic field to produce a small voltage in the semiconductor. HARD FAULT – Fault present during current engine operating cycle. Opposite of an intermittent fault which does not stay present.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS KAPWR – Keep Alive Power, used to power KAM circuit of the processor. KNOCK SENSOR (KS) – Input device that responds to spark knock, caused by over advanced ignition timing. KOEO – Key On/Engine Off. KOER – Key On/Engine Running. LEAN MIXTURE – Air/fuel mixture that has excessive oxygen left after all fuel in combustion chamber has burned, 1 part fuel to 15 or more parts air. LED – Light Emitting Diode.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS OHC – Overhead Cam OXYGEN SENSOR – Sensor that changes its voltage output as exhaust gas oxygen content changes as compared to the oxygen content of the atmosphere. The constantly changing electrical signal is used to control fuel mixture. PCM – Powertrain Control Module. Computer that controls engine fuel, ignition and emission related functions. PCV – Positive Crankcase Ventilation.
Glossary GLOSSARY OF TERMS AND ABBRREVIATIONS 6 SCC – Spark Control Computer. SEFI – Sequential Electronic Fuel Injection. Injectors located in intake ports that inject fuel triggered by ignition timing. SELF-TEST – One of 3 subsets of Ford EEC-IV quick test modes. SES – Service Engine Soon light. SFI – Sequential Fuel Injection,type of MFI with injectors pulsed individually based on engine firing order. SHO – Super Height Output SIG RTN – Signal Return circuit for all sensors except HEGO.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS THERMACTOR AIR BYPASS SOLENOID – Solenoid switches engine manifold vacuum. Vacuum reacts on thermactor bypass valve to bypass thermactor air to the atmosphere. Used on Ford MCU feedback carburetor system. THERMACTOR AIR CONTROL VALVE – Combines function of a normally closed air bypass valve and an air diverter valve in one integral valve. THERMACTOR AIR DIVERTER SOLENOID – Solenoid switches engine manifold vacuum.
Glossary 6 GLOSSARY OF TERMS AND ABBRREVIATIONS VM – Vane Meter or air flow meter. VSS – Vehicle Speed Sensor. WOT – Wide Open Throttle or Wide Open Throttle switch. ZONED VACUUM SWITCHES – 3 switches used on Ford MCU system that provides input signals to MCU, regarding engine load.
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Warranty and Service 7 LIMITED ONE YEAR WARRANTY LIMITED ONE YEAR WARRANTY The Manufacturer warrants to the original purchaser that this unit is free of defects in materials and workmanship for a period of one (1) year from the date of original purchase. If the unit fails within the one (1) year period, it will be repaired or replaced, at the Manufacturer's option, at no charge, when returned prepaid to the Technical Service Center with Proof of Purchase. The sales receipt may be used for this purpose.
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Notes
Notes
FORD DIGITAL CODE READER (Back Cover)
