Home

Ford E-150/E-250/E-350/E-450 F-250/F-350

Contents

1. 1 Electronic Fuel Pump Relay B i ouam ed Ae a 12 Integrated Pressure Temperature Sensor 13 evel SENG bed 15 DIAGNOSTIC TESTS 5 16 Scuocllbntonri m P r 16 INO FU v U nrwEMm 17 mn IE oe eben ____ _ 6 6__ _ _ _ 6 6_ _ _6_6_6_ _ _ 19 OVer lee ccwscet estos base cee d RUE cael ese eee aes 21 Engine Docs NOt EDI uoa 22 Ensme Cranks drea euro qa Oa aad RESP qu Kod qnd PM qua acd Fur 23 Engine Stumble Stall Rough Idle 25 Excess Plow Valve Check ctunc seed 0d dde sees 26 Maximum Pressure Bl o eee 21 Supply Solenoid 27 0 29 30 Fuel Level Indication Check uua 31 Tank Solenoid Electrical Beck 32 Fuel Rail Pressure Control Module Electrical 34 Integrated Pressure Temperature Sensor Electrical 36 Puch Pu
2. _ 55 05 __ Lo m T T Fm 47 U b rm ers U PLUS a 1 1 OROT FRAME V a HARNESS a W LAMP RTN 1 P m X i eua X FRAME GROUND GND R1 iv eA T v DELPHI TERMINAL 02984172 X TOCAN y 24 HARNESS Z Z 100130b 1 2 3 4 5 6 7 8 9 10 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 ROUSH CLEANTECH E Series Extended Range and E 450 Electrical Schematic CAN Bus Harness 1 2 3 4 5 6 5 55 _ E KEY PWR 1 X j Connector n 9 CONNECT TO ROUSH UNDERHOOD HARNESS 7 8 9 17 18 19 20 20 21 21 22 22 23 24 ruc 6 2 lt gt a CAN 2 25 51 26 27 28 29 30 32 33 CONNECT FORD HARNESS CONNECTOR C2142 31 32 33 34 FUSE 33 1 TOW BRK 34 35 35 36 CONNECT TO TRAILER 14 BRAKE MODULE 37 38 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS N 100131b 39 Page 55 issa WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E Series Extended Range and E 450 Electrical Schematic Rear Frame Harness 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2
3. HARNESS VPWR RO VPWR RI Connector UNDERHOOD 55 ee bond TO ROUSH FPCM CONTROL MODULE 2 25 26 27 oo VPWR P2 58 T FG SND FG RTN FORD HARNESS FUEL PUMP MODULE 25 26 27 ENS 3 A FLS 1 A FLSRTN 1 A SOLRTN 1 A SOL 1 61 56 SHILED FRAME GROUND GND3 DELPHI TERMINAL 02984626 TANK SENDER SOLONOID 30 31 CONTROL MODULE 1 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS 35 36 37 38 39 PLUG e FPM 1 ENS 1 PLUG 2 GND 1 za CONNECT TO FORD PLUG HARNESS VPWR 1 1 RT Connector it LUE B M AL S OT ll ule yr f 24 FUEL TANK 1 PWR 100190a 35 36 37 38 39 Page 61 TEC WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F 250 350 Pickup Tank Solenoid Harness Electrical Schematic 1 2 3 4 5 6 7 8 9 10 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 WIRE NO DESCRIPTION CIRCUIT RED 16 AWG 5 SOLENOID V BLACK 16 AWG SUPPLY SOLENOID V gt 6 BLACK ORANGE 18 AWG FUEL LEVEL SENDER V YELLOW WHITE 18 AWG FUEL LEVEL SENDER V G REAR FRAME HARNESS G CONNECT TO H TANK FUEL SUPPLY H 100 mm SOLENOID 1 L L M M
4. js mm MIN p J Fas ATENI y 100078a Figure 9 Rear Frame Harness Connectors Page 40 TROUBLESHOOTING 100077a ROUSH TROUBLESHOOTING PROCEDURE 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 Check Ford FPCM circuit continuity to Ford harness Yes Go to Step 2 Disconnect rear frame harness connectors 1 and 12 No Repair circuit wiring 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 Is there good continuity in each circuit Check FPCM circuit continuity to Ford harness Yes Go to Step 3 a Disconnect rear frame harness connector 13 No Repair circuit wiring b Check wire VPWR V for continuity across e Pin 1 connector 13 rear frame harness and pin A connector 30 rear frame harness e 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 Is there good continuity in each circuit Check Roush CleanTech FPCM circuit continuity to For
5. Is the resulting fuel pressure reading within the expected range Determine if the excess flow valve XFV is tripped Yes Refer to the Excess Flow Valve Check procedure off the engine i No Go to Step 7 b Wait one minute and then restart the engine Is the fault condition resolved Check fuel pump operation Yes Go to Step 11 a Usinga current clamp check current draw on both fuel pump No If both circuits are showing no power wires at the fuel tank Refer to n Tank Harness for correct Current check the OEM fuel pump FP circuits fuse If only one fuel pump circuit shows Turn ignition switch to start position and release Vehicle will start Current check the ROUSH CleanTech fuel the flush cycle and pumps should be running Check current draw bs See ROUSH Clean Tech fuse A minimum of 2 amps should be recorded on both fuel pump ox for location circuits If both fuel pump fuses OEM and ROUSH Do fuel pumps draw current CleanTech are good go to Step 8 Verify that there is power and proper grounding in the wiring Yes Go to Step 9 circuit to the tank No Check for an open short in the wiring a Check for 12 volts at the fuel pump 1 FP1 and fuel pump 2 circuit and repair FP2 connectors Refer to the Fuel Rail Pressure Control Module Electrical Check procedure Is 12 volts present at the connector Is 12 volts present at the FP2 connector Page
6. to Step 3 Disconnect the FLS connector 6 solenoid harness No Replace the FLS Using a multimeter measure the resistance across the FLS connector pins Is resistance between 24 260 ohms Check circuit wiring continuity between FLS connector and SRM Yes Go to Step 4 connector No Repair circuit wiring Disconnect connector 1 of the solenoid harness Check continuity between pin B connector 6 solenoid harness and pin C connector 1 solenoid harness Is there good continuity in the circuit Check circuit wiring continuity between FLS connector and SRM Yes Go to Step 5 connector No Repair circuit wiring Disconnect connector 30 of the rear frame harness Check continuity between pin C connector 21 rear frame harness and pin D connector 30 rear frame harness Is there good continuity in the circuit Check circuit wiring continuity between FLS connector and SRM Yes Go to Step 6 connector No Repair circuit wiring 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 Check circuit wiring continuity between FLS connector and SRM Yes Go to 7 connector No Repair circuit wiring a Check continuity between pin A connector 6 solenoid harness and pin D connector 1 solenoid harness b Is there good continuity in
7. AN 5 E P R R 12162000 4 5 CONNECT TO FUEL FUEL LEVEL SENDER 5 LEVEL SENDER CONNECTOR FROM TANK T T U U V V W W 100191a 1 2 3 4 5 6 7 8 9 10 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 ROUSH CLEANTECH F 250 350 Pickup In Bed Fuel Tank Jumper Harness Electrical Schematic 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CONNECT TO REAR C FRAME HARNESS E 2 FUEL PUMP 1 PWR FUEL PUMP 2 PWR F S 0 01 51 SHIELD 3 Connector 1B 55 SHILED FRAME GROUND GND DELPHI TERMINAL 02984626 31 32 33 34 35 36 37 CONNECT TO TANK SOLENOID HARNESS gt Connector PUMP 1 lt OL OO ae CONNECT TO TANK 55 NO 10 FUEL LEVEL SENDER POWER Ol Pe 5 FUEL LEVEL SENDER RETURN oL E rm TANK FUEL SUPPLY SOLENOID RETURN F gt TANK FUEL SUPPLY SOLENOID POWER i qe CONNECT TO REAR P FRAME HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CONNECT TO TANK SOLENOID HARNESS 31 32 33 34 35 36 37 38 38 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS 39 100192a 39 Page 63 ista WIRING DIAGRAMS AND ELECTR
8. Yes Replace fuse No Go to Step 5 Yes Go to Step 6 No Repair circuit wiring Yes E Series Go to Step 8 F Series Go to Step 9 No Go to Step 7 Yes Replace fuse No Repair circuit wiring Yes Go to Step 9 No Repair circuit wiring Yes Go to Step 10 No Repair circuit wiring Yes Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for functional testing of the CAN bus No Repair circuit wiring Page 43 ROUSH TROUBLESHOOTING Fuel Level Sender Electrical Check NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS 100081a 100082a 0000 FAA N 100083 Figure 14 Solenoid Harness Connectors Page 44 ROUSH TROUBLESHOOTING PROCEDURE ME For fuel level sender FLS functional testing and diagnostic trouble codes use Diagnostic Tests and Procedures and 1 Diagnostic Trouble Codes Check resistance in FLS circuit wiring Yes Refer to the Smart Relay Module Electrical he Fuel Level a Disconnect the SRM connector 1 underhood harness 2 b Using multimeter measure the resistance between pin 3 and No Go to Step 2 pin 40 of the harness connector C Is resistance between 24 260 ohms Check resistance of the FLS Yes
9. Diagnostic is complete Does the fuel tank fill at greater than six 23 L per minute No Go to Step 8 Replace the overfill protection device OPD valve in the vehicle Yes to Step 9 fuel tank No Go to Step 10 Is the OPD valve located in the end cap of the fuel tank Attempt to fill the vehicle fuel tank as follows Yes Diagnostic is complete No Call ROUSH CleanTech Customer NOTE Service at 800 597 6874 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 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 Remove the fuel fill pressure tester Attempt to fill the remaining tank volume to 8096 full capacity at full flow from the dispensing nozzle Did the tank fill Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank fill at greater than six gal 23 L per minute No Call ROUSH CleanTech Customer Service at 800 597 6874 Fill station is not providing enough pressure to fill Yes Go to Step 12 a Using the tables provided at the front of this section determine No Locate a dispensing facility with expect
10. Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for a list of other causes 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 Page 11 ROUSH TROUBLESHOOTING Electronic Fuel Pump Relay B U016C Lost Communication with Fuel Pump Control Module B 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 Symm T 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 P027A Fuel Pump Control Module Circuit Range Performance 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 e Refer to the Ford Powertrain Control Emissions Diagnosis
11. 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 or there is a propane odor when the vehicle is running refer to the Fuel Line Leak Detection procedure Verify fuel supply line pressure prior to cranking engine Read fuel rail pressure and tank pressure Yes Check is OK No Repair the leak in the fuel supply line Energize bleed solenoid until rail pressure is at least 50 psi 845 kPa below tank pressure If rail is bled skip to Step D Let pressure stabilize for 1 minute Open the supply solenoid Read fuel rail pressure and tank pressure Does fuel rail pressure jump to tank pressure Page 26 ROUSH CLEANTECH 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
12. 2 EL 8 z 9 alg gt 4 9 ul 218 2 ad a E a gt gt ul 1 gt 21 E oy 2 23 21 A 2 iL SOLENOID PWR 51 mM SRM PWR 2 i TO FLIM FG RTN SRM FG RTN 9191910 FRAME GROUND GND R2 DELPHI TERMINAL 02984626 FG SND TANK 501 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS Page 59 ista WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F 250 350 Pickup CAN Bus Jumper Harness Electrical Schematic 1 2 3 4 5 6 7 8 9 10 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 B A 55 2142 9 D E E COVERED WITH 3 8 SPLIT CONVOLUTE PASS THROUGH FUSE 18 G E CAN H 4 1 c i Crue C PLuG BRK PED 2 GND CAN H _2 4 F4 FUSE 33 J NO CONVOLUTE TOW L L CONNECT TO TRAILER BRAKE MODULE CONNECT TO ROUSH UNDERHOOD M HARNE M N 100189 10 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 N C A o 60 ROUSH CLEANTECH F 250 350 Pickup Rear Frame Harness Electrical Schematic 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 UNDERHOOD 30
13. AWG INLINE FUEL PUMP 2 V BLACK 12 AWG INLINE FUEL PUMP 2 V PINK BLACK 12 AWG FUEL PUMP 1 V BROWN WHITE 12 AWG FUEL PUMP 1 V DARK BLUE 12 AWG FUEL PUMP 2 V BLACK 12 AWG FUEL PUMP 2 V a 200MM DO NOT COVER THIS LENGTH WITH ANY CONVOLUTE lt 100MM DO NOT COVER THIS LENGTH WITH ANY CONVOLUTE EN 2 L J 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 55 HARNESS 21 22 23 24 25 26 27 28 29 30 31 32 33 PASS THRU THIS AREA TO BE FREE OF TAPE DO NOT APPLY TAPE ONTO THIS SEALING SURFACE 14 15 16 17 18 19 20 NO TAPE OR ADHESIVE TAGS ON THIS SIDE OF THE e MH X M Mz PASS THROUGH GROMMET 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 38 1001330 39 57 ista WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E Series Extended Range and E 450 Electrical Schematic Solenoid Harness 1 2 3 4 5 6 7 8 9 10 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 WIRE DESCRIPTION CIRCUIT SOLENOID HARNESS B 4 I RED 16 SUPPLY SOLENOID B lt 5 jJBLACK16AWG SUPPLY SOLENOID V _ BLACK ORANGE 18 AWG FUEL LEVEL SENDER V 7 YELLOW WHITE 18 AWG FUEL LEVEL SENDER V E E CONNECT TO THE 55 _
14. Alt Fuel Module Wrong SRM Heated Exhaust Gas Oxygen Sensor P2195 P2197 Electronic Fuel Pump Relay B 0016 P027A Integrated Pressure Temperature Sensor Heated Exhaust Gas Oxygen Sensor Stuck Lost Communication with Fuel Pump Control Module B Fuel Pump Control Module Circuit Range Performance P0182 Fuel Temperature Sensor A Circuit Low P0183 Fuel Temperature Sensor A Circuit High P0190 Fuel Pressure Sensor A Circuit Fuel Pressure Sensor A Circuit Low Fuel Pressure Sensor A Circuit High Page 6 ROUSH TROUBLESHOOTING Fuel Level Sender P0460 Fuel Level Sender A Circuit P0461 Fuel Level Sender A Circuit Range Performance P0462 Fuel Level Sender A Circuit Low Flow Control Solenoid P0090 Fuel Pressure Regulator Circuit Open 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 e 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 Refer to the Fuel Hail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures Bleed Solenoid POO9E Fuel Pressure Relief Control Performance Stuck Off Description Fuel rail failed t
15. Test NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS IE E 24 1 xo 19 oO 100075 Figure 6 Rear Frame Harness Connectors 100076a Figure 7 In Tank Harness Connectors PROCEDURE 1 Check fuel pump circuit continuity Yes Go to Step 2 a Unplug the FPCM connector 12 for fuel pump 1 Check fuel pump No Go to Step 3 circuit continuity b Using a multimeter measure resistance between pin 5 and pin 8 C Is resistance between 0 4 1 0 ohm 2 Check fuel pump circuit continuity Yes Refer to the Fuel Pump Control Module Electrical inuity a Unplug the FPCM connector 13 for fuel pump 2 K Continuity Test b Using a multimeter measure resistance between 5 and pin 8 No Go to Step 3 Is resistance between 0 4 1 0 ohm 3 Check resistance of each fuel pump Yes Go to Step 4 Unplug the fuel pump connectors in tank harness at the fuel No Replace fuel pump assembly pump assembly Using a multimeter measure resistance for fuel pump 1 across the terminals of the fuel pump Is resistance between 0 4 1 0 ohm Page 38 ROUSH TROUBLESHOOTING Check resistance continued Yes Go to Step 5 a Usinga multimeter measure resistance for fuel pump 2 across No Replace fuel pump assembly the terminals of t
16. Tests and Procedures Page 15 ROUSH CLEANTECH DIAGNOSTIC TESTS AND PROCEDURES General Information Measuring Fuel Rail and Fuel Tank Pressure Measuring Fuel Tank Pressure Fuel tank pressure can be measured two ways Refer to Tools and Equipment Special Tools in the 2012 Ford 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 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 150 250 850 450 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 th
17. at the TS and SS connectors Refer to the Tank Solenoid Electrical Check procedure Is 12 volts present at the TS connector Is 12 volts present at the SS connector Verify that there is power and grounding in the wiring circuit to the tank 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 Is 12 volts present at the connector Is 12 volts present at the FP2 connector Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification TROUBLESHOOTING sep Yes 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 Yes to Step 11 No Go to Step 7 Yes Go to Step 8 No Determine the cause of the short and repair replace the fuse Yes Determine the cause of the short and repair replace the fuse No Go to Step 9 Yes Voltage present at SS replace Voltage present at TS replace fuel supply valve assembly No Check for an open short in the wiring circuit and repair Yes Refer to Engine Stumble Stall Rough ldle Step 12 No Check f
18. 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 Pressure Condition Part Throttle Fill Pp Procedure NOTE 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 ina 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 lt venice to check for kinked fill lines Yes Replaced kinked fill lines Determine the of the overflow protection device Yes Go to Step 3 Check the the instrument cluster Yes Go to Step 4 NOTE Yes Go to Step 5 No Go to Step 6 to relieve any pressure in the fill line and release the OPD valve Install a fuel fill pressure tester on the fill valve and close the ball Connect the fuel dispensing nozzle to t
19. the circuit Check circuit wiring continuity between FLS connector and SRM Yes Go to Step 8 connector No Repair circuit wiring 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 Check circuit wiring continuity between FLS connector and SRM Yes Refer to the Smart Relay Module connector Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure a Check continuity between pin D connector 15 rear frame harness and pin 40 SRM connector underhood harness No Repair circuit wiring b Is there good continuity in the circuit Page 45 ROUSH TROUBLESHOOTING Fuel Level Interface Module Electrical Test NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS Figure 15 Underhood Harness Connectors Figure 16 Rear Frame Harness Connectors PROCEDURE Step Procedure Action For FLIM functional testing and diagnostic trouble codes use Diagnostic Tests and Procedures and Diagnostic Trouble Codes Check FLIM circuit wiring for continuity to SRM Yes Go to Step 2 No Repair circuit wiring a Disconnect underhood harness connector 1 to SRM b Check underhood harness continuity between pin A connector 35 and pin 2 co
20. 25 ROUSH CLEANTECH TROUBLESHOOTING Check wiring Drain the propane from the fuel tank Refer to the Fuel Tank Yes Replace harness No Go to Step 10 Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information Remove tank service cover Check for open or short circuits on tank pass through harness Is a wiring problem present Check fuel hoses and quick connect fittings Are in tank fuel hoses and quick connect fittings connected and in good condition Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification Refer to the ntegrated Pressure Temperature Sensor Electrical Check procedure Yes Replace fuel pump assembly No Replace hose assemblies as needed 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 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 the XFV trips
21. 60 E Series Extended Range and E 450 Electrical Schematic Rear Frame 55 61 250 350 Pickup Tank Solenoid Harness Electrical 62 F 250 350 Pickup In Bed Fuel Tank Jumper Harness Electrical 63 F 250 350 Pickup FTPT Jumper Harness Electrical 5 64 Page iv ROUSH CLEANTECH INTRODUCTION INTRODUCTION Page 1 ROUSH CLEANTECH SAFETY INFORMATION The 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 sourc
22. 7 28 29 30 31 32 33 34 35 36 37 38 39 REAR FRAME HARNESS BU ke TO FORD FPCM B TO ROUSH FPCM MODULE FUEL MODULE FUEL PUMP CONTROL PUMP CONTROL B MODULE 2 41 MODULE 1 B C TO ROUSH UNDERHOOD t a HARNESS el gt c e g gt D S PLUG y 2 i PLUG ENS 1 2 E ROUSH UNDERHOOD 6 aa rm p E HARNESS 30 PLUG 2 un 5 Al GND 1 i 1 es CONNECT E TOFORD 5 G VPWR_RI VPWR 1 G LLL _ o 1 21 SHILED FRAME e ajal GROUND GND 0 DELPHI TERMINAL B 8 al lt lt 02984626 2 15 K ES K 000 7 L 1 OG TO FUEL M TANK SENDER SOLONOID M FUEL TANK 2 PWR FUEL TANK 1 PWR N N 55 FUEL PUMP MODULE 1001320 1 2 3 4 5 6 7 8 9 10 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 56 ROUSH CLEANTECH WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E Series Extended Range and E 450 Electrical Schematic In Tank Harness 1 2 3 4 5 6 7 8 9 10 11 12 13 WIRE NO DESCRIPTION CIRCUIT PINK BLACK 12 AWG INLINE FUEL PUMP 1 6 BROWN WHITE 12 AWG INLINE FUEL PUMP 1 V V DARK BLUE 12
23. B 100 mm TANK SOLENOID H H L L M M N N P P Q Q R R S CONNECT TO FUEL S LEVEL SENDER T T U U V V 1001346 1 2 3 4 5 6 7 8 9 10 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 CLEANTECH F 250 350 Pickup Underhood Harness Electrical Schematic 1 2 3 PWR W 5 6 7 8 10 11 12 A PWR Delphi Terminal To Battery Positive SRM_PWR PWR_W_6 KEY PWR 2 IT REL A11CSQ 20A 14VDC ee ee aah ELECTRICAL M CENTER FUSE BOX TO FORD AUX ENGINE INLINE MODULE GND1 FRAME GROUND GND R1 DELPHI TERMINAL 02984172 13 14 15 TO FORD HARNESS 12C508 C1168 16 17 18 19 20 21 22 ES a 5 SRM PWR 1 OOOO 2 2 5 0 2 gt lt FL RIN 2 S3 FL 1 FRAME 55 VPWR RI MES VPWR OW PLUG i 2 1 TO REAR X FRAME 55 LAMP RTN 1 PLUG PLUG Cy CAN H 16 1 55 7 100188 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 27 28 29 30 31 32 33 34 35 36 37 38 39 4 2 Ws c i 3 TO IPTS IPTS GND IPTS PWR IPTS PRES OUT IPTS TEMP OUT
24. ICAL SCHEMATICS F 250 350 Pickup FTPT Jumper Harness Electrical Schematic 1 2 3 4 5 6 7 8 9 10 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 A A FTP REF FTP REF B B C SIGRTN C D FTP FTP D E E F F VERSION DEPENDS ON G TANK CONFIGURATION sonnet Toa G H H ESN Pat ue r r J ili IG RTN K SIG_RTN SIG_ K L M M N N 100193a 1 2 3 4 5 6 7 8 9 10 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 64 2013 ROUSH CleanTech rights reserved The information in this publication was accurate and effective at the time the publication was approved for publishing and 15 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 LocTite5679 and LocTite2429 are registered trademarks of Henkel
25. Measure and compare vehicle fuel tank and fill station pressures Yes Go to Step 22 Connect a pressure gauge service tool to the fuel tank bleeder No Fill station is not providing enough valve and record fuel tank pressure pressure to fill vehicle tank Go to Step 22 Using a fuel fill pressure tester installed on the fill valve attempt to Locate a dispensing facility with pump fill the vehicle output capacity in excess of 100 psi 689 kPa preferably an Auto Gas type With the dispensing pump on and dispensing nozzle open facility measure and record fill station pump pressure Is fill station pump pressure at least 20 psi 138 kPa greater than fuel tank pressure Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank 112 No Go to Step 12 Slow Fill o Procedure Action 18 vehicle to check kinked fill lines Yes Replaced kinked fill lines Are fill lines kinked No Go to Step 2 Determine flow rate at which the vehicle fuel system fills Yes System fill rate is OK diagnostic is Time the fill station pump for 10 seconds and record the number of gallons dispensed No Fill station is not providing enough Multiply the gallons dispensed by six to determine the flow rate in gallons per minute Is the fill station pump flow rate at least 6 gal 23 L per minute Measure and compare vehicle fuel t
26. OUSH CLEANTECH TROUBLESHOOTING Over Fill KS 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 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 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 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 Refuel the vehicle as follows NOTE 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 Install the fuel fill pressure tester on the fill valve and close the ball valve Connect the fuel dispensing nozzle to the pressure tester Verify that the bleeder valve is open With the bleeder valve open turn on the pump Open the ball valve slightly to very slowly refuel the vehicle While refueling observe the bleeder valve for fuel discharge Stop filling when a solid stream of liquid fuel flows from the bleed
27. OUSH CLEANTECH TROUBLESHOOTING 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 DTOs refer to the Ford Powertrain Control Emissions Diagnosis Service Manual at www motorcraft com System and Diagnostic Terminology O O O Abbreviation Description GRD Ground Original Equipment Manufacturer ORD 00 5 ROUSH TROUBLESHOOTING Acronym or Abbreviation Description Tank Solenoid Vapor Management Valve VPWR Voltage Power VREF Voltage Reference OT Wide Open Throttle Diagnostic Trouble Code List Code Flow Control Solenoid P0090 Bleed Solenoid POO9E POO9F POO9B Tank Solenoid P0005 Fuel Shutoff Valve A Control Circuit Open Fuel Rail Pressure Control Module Supply Solenoid and Wiring P26B5 Fuel Shutoff Valve B Function Check Fuel Pump B Control Circuit Open Description Fuel Pressure Regulator Circuit Open Fuel Pressure Relief Control Performance Stuck Off Fuel Pressure Relief Control Stuck On Fuel Pressure Relief Control Circuit Open Supply Solenoid Circuit Fault SRM CAN Bus Circuit Wiring U0108 Fuel System P0148 Lost Communication with Alternative Fuel Control Module Fuel Delivery Error Maximum Pressure P0171 P0174 System Too Lean Bank 1 and Bank 2 Misfire
28. ROUSH CLEANTECH 2011 2013 Ford E 150 E 250 E 350 E 450 F 250 F 350 Liquid Propane Autogas Fuel System 3rd Generation Includes E 150 E 250 E 350 Cargo Van Wagon E 150 E 250 E 350 Extended Range Cargo Van Wagon E 450 Custom Body F 250 F 350 Revision History Intital Release 2 2013 DIAGNOSTIC MANUAL P 01B101 AB ROSH TABLE OF CONTENTS SAFETY INFORMATION 55 kE E AEREE E 2 ees 2 Installation Garaging and Training 3 Purging and Venting Tanks and 3 DIAGNOSTIC TROUBLE CODES 2242446 5 About Diagnostic Trouble Codes 5 System and Diagnostic Terminology 5 Diagnostic Trouble Code 6 2 acetum aue 0 558 e 7 lido 4 sed 7 Tank SOlCNGIG rETPPPT 8 Fuel Rail Pressure Control Module Supply Solenoid and 9 Bus Circuit WirIl9 aucem 45648 ARES S 10 ent yee ee 10 Heated Exhaust Gas Oxygen Sensor
29. S AND CONNECTOR LAYOUT APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS UNDER BODY LPA FUEL TANK UNDERHOOD HARNESS CAN HARNESS HEAR FRAME HARNESS N TANK HARNESS SOLENOID HARNESS 100129a Page 50 25 WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E 150 250 350 Extended Range Wiring Harnesses and Connector Layout E 150 250 350 EXTENDED RANGE WIRING HARNESSES AND CONNECTOR LAYOUT APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS LPA K N ICLE LTA 2 UNDERHOOD HARNESS HARNESS REAR FRAME HARNESS Sc HARNESS SOLENOID HARNESS N BED FUEL TANK JUMPER 100152a Page 51 ROUSH CLEANTECH WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E 450 Custom Body Wiring Harnesses and Connector Layout Page 52 E 450 WIRING HARNESSES AND CONNECTOR LAYOUT APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS B AFT AXLE LPA P HIS UNDERHOOD HARNESS CAN HARNESS REAR FRAME HARNESS IN TANK HARNESS SOLENOID HARNESS IN BED FUEL TANK JUMPER 100153a WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS F 250 350 Pickup In Bed Tank Wiring Harnesses and Connector Layout Y dv 4 1 4 F 250 350 PICKUP IN BED TANK WIRING HARNESSES AND CONNECTOR LAYOUT APPROXIMATE LOCATION OF SYSTEM HARNE
30. SSES AND CONNECTORS 478 UNDERHOOD HARNESS FIPT Harness depends upon the Ford Fuel Tanks CAN HARNESS REAR FRAME HARNESS HARNESS SOLENOID HARNESS IN BED FUEL TANK JUMPER FTPT JUMPER HARNESS 100187 53 ista WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E Series Extended Range and E 450 Electrical Schematic Underhood Harness 1 2 3 4 5 6 7 8 9 10 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 UNDERHOOD HARNESS elphi Terminal Mt E xm To Battery Positive 4 Connector TO SOLENOID 2 8 MODULE M 27 TO IPTS pp TN NTE D PWR Wi 254 SRM PWR _ ci Lr o 2 H o a E 3 7 N zi 2 a E G ul 218 gt gl 9 Of sd 5 i S5 n e H E Z 215 H i a Ld TET 3E NE CIT RELAY A11CSQ 20A 14VDC AS K eR K SOLENOID PWR S1 L TANK SOL RTN FL 2 S3 FL RTN 1 TO REAR FRAME R M ELECTRICAL CENTER KEY PWR 4 FG RTN SRM Oin E em 1 FUEL O LL LEVEL INTERFACE MODULE P P FRAME GROUND GND R2 FG SND DELPHI TERMINAL 02984626 i i m Q
31. Service Manual for a list of other causes Symptom Poor starts rough idle hesitation surge Diagnostic Aid Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures Page 12 ROUSH TROUBLESHOOTING Integrated Pressure Temperature Sensor P0182 Fuel Temperature Sensor A Circuit Low 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 Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures P0183 Fuel Temperature Sensor A Circuit High 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 e SRM failure Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures Pa
32. When the POM starts controlling the fuel pump a P116E code is set While this TROUBLESHOOTING 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 rapped 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 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 Supply Solenoid Check NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics 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 15 battery voltage above 10 volts Yes Go to Step 2 No Correct fault and retry Check for diagnostic trouble codes DTC
33. Yes Go to Step 3 Are any codes present No Go to Step 4 Is the DTC identified on the ROUSH liquid propane autogas DTC list Check fuel pressure a Measure and record fuel rail pressure and fuel tank pressure at key on engine off KOEO Yes Refer to Diagnostic Trouble Codes No Refer to the Ford service manual DTC chart Yes Go to Step 11 No Go to Step 5 While monitoring fuel pressure attempt to start engine Record the highest pressure observed Does fuel pressure rise 20 psi 138 kPa before engine crank Page 27 ROUSH CLEANTECH Check fuel pump operation a Using a current clamp check current draw on both fuel pump power wires at the fuel tank Refer to n Tank Harness for correct circuits 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 Do fuel pumps draw current Check XFV Turn off engine Wait 1 minute and then restart engine Measure and record fuel rail pressure and fuel tank pressure Is problem resolved Check ROUSH FP fuse Is fuse intact and OK 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 Are the fuses blown Verify that there is power and grounding in the TS and SS wiring circuits Check for 12 volts
34. ank and fill station pressures Yes Go to Step 4 Connect a pressure gauge service tool to the fuel tank bleeder No Fill station is not providing enough valve and record fuel tank pressure pressure to fill vehicle tank Go to Step 11 Using a fuel fill pressure tester installed on the fill valve attempt to fill the vehicle With the dispensing pump on and dispensing nozzle open measure and record fill station pump pressure Is fill station pump pressure at least 50 psi 345 kPa greater than fuel tank pressure Check fuel fill valve it may not be opening completely Yes Replace the filter in the fuel fill line ill 1 7 Loosen the fuel fill line connection at the fill valve at the inlet to and then go to Step fuel filter to relieve any pressure in the fill line No Replace the fuel fill valve and then Attempt to push open the piston in the fill valve to determine if itis 9 19 Step 5 opening completely Piston should travel 1 4 inch Is the fill valve piston opening completely Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank fill at greater than six gal 23 L per minute No Go to Step 6 Page 19 ROUSH TROUBLESHOOTING Replace the filter in the fuel fill line Yes Diagnostic is complete ul Does the vehicle fuel tank fill at greater than six gal 23 L per minute No Go to Step 7 7 Attempt to fill the vehicle fuel tank Yes
35. battery voltage Corrosion Incorrect connections e 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 Refer to the Fuel Hail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures Tank Solenoid P0005 Fuel Shutoff Valve A Control Circuit Open 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 5 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 Page 8 ROUSH TROUBLESHOOTING Fuel Rail Pressure Control Module Supply Solenoid and Wiring P26B5 Fuel Shutoff Valve B Function Check 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
36. d harness b Is there good continuity in the circuit Page 33 ROUSH TROUBLESHOOTING Fuel Rail Pressure Control Module Electrical Check NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS m Eq FUSE BOX 100073a Figure 4 Underhood Harness Connectors PROCEDURE Procedure Sep the fuel rail pressure control module FRPCM connector MX to Step 2 from connector 11 of underhood harness Using a multimeter check the resistance of each solenoid Yes Go to Step 3 a Check resistance across the terminals of the FRPCM connector in No Replace the if resistance for sequence as follows any one of the solenoids is not within the e Supply Solenoid Pin A and pin F specified range e Flow Control Solenoid Pin B and pin E e Bleed Solenoid Pin C and pin D Is the measured resistance for each solenoid within 6 35 ohms Check supply voltage to FRPCM solenoids Go to Steps 4 6 Using a multimeter measure voltage between the terminal for each solenoid at the harness side connector 11 and ground as follows Page 34 TROUBLESHOOTING Supply Solenoid Pin A and body ground B Voltage Go to Step 5 Flow Control Solenoid Pin B and body ground B Voltage Go to Step 6 No Voltage to Step 6 if Step 4 has v
37. d harness Yes Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for functional testing of the FPCM No Repair circuit wiring 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 Is there good continuity in each circuit Page 41 ROUSH TROUBLESHOOTING Smart Relay Module Electrical Test NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS FUSE BOX HO JT nl 100079a Ue S5 ES ES 5 EN On 100080a Figure 11 CAN Harness Connectors PROCEDURE Check for battery voltage B to the SRM Yes Go to Step 5 a Using a multimeter check for B voltage at cavity 2 No Go to Step 3 connector 1 Use a body ground for reference b Is there voltage B Check for battery voltage B to the SRM Yes Go to Step 4 No Repair circuit wiring a Check circuit continuity between cavity 2 connector 1 and cavity E2 auxiliary fuse box 15 there good continuity in the circuit Page 42 ROUSH CLEANTECH Check for battery voltage B to the SRM a Check condition of SRM p
38. e No Go to Step 4 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 Yes Find and repair the short replace the fuse No Go to Step 8 Yes Refer to Engine Stumble Stall Rough Idle Step 9 No Check for an open short in the wiring circuit and repair Yes to Step 8 No Verify that wiring in circuit is OK If not repair wiring If OK replace sensor Refer to the appropriate Ford Powertrain Control Emissions Diagnosis Service Manual at www motorcraft com Page 30 ROUSH CLEANTECH Fuel Level Indication Check The ROUSH CleanTech fuel level indication TROUBLESHOOTING NOTE system differs from the gasoline system as the The gauge on the sending unit must not be used fuel level sender is not wired directly to the for any diagnostics The gauge 15 not accurate instrument cluster Instead the fuel level sender Only resistance or voltage outputs should be is wired to the SRM which reads the fuel level used for diagnostic purposes 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 Symptom Caus
39. e Action to be taken 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 to reflect the fill Fuel gauge does not move on a partial fill Malfunction Indicator Lamp MIL Gauge points below E Doesn t read full after a fill There is a circuit fault that has been identified by the 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 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 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 Page 31 ROUSH CLEANTECH Tank Solenoid Electrical Check NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS FUSE BOX Figure 3 Solenoid Harness Connectors Page 32 1 boleh TROUBLESHOOTING c ROUSH TROUBLESHOOTING PROCEDURE 5 Pedum O Ad
40. e Blown fuse Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage corrosion and water intrusion Check for power at the SRM Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures Fuel System P0148 Fuel Delivery Error 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 e 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 P116E Maximum Pressure 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 e 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 Acion Refer to t
41. e O O Unplug the solenoid harness connector 9 from the tank solenoid Go to Step 2 2 Using a multimeter measure resistance of the solenoid Yes Go to Step 3 Is the measured resistance within 6 35 ohms No Replace the tank solenoid Using a multimeter measure voltage at the tank solenoid as Yes Supply circuit OK follows No Go to Step 4 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 WE INN testes Is fuse blown No Fuse OK go to ee 5 Is relay Replace relay Check supply circuit continuity from solenoid harness to fuse Yes Go to Step 7 box No Repair supply circuit wiring a Check continuity between e Pin A connector 9 and pin A connector 1 solenoid harness connector 21 and pin A connector 30 rear wiring harness Pin A connector 15 and cavity A5 fuse box underhood harness lsthere good continuity in the circuit Check ground circuit continuity from solenoid harness to smart Yes Refer to the Smart Relay Module relay module SRM connector Electrical Test procedure a Check continuity between No Repair ground circuit wiring 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 underhoo
42. e 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 Page 2 INTRODUCTION A DANGER 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 9 gt A DANGER 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 A DANGER 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 S 5 A DANGER 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
43. e tool box tab then select Powertrain near bottom of selection OBD Test Modes Mode 1 Powertrain Data Then locate and select pressure from selection table Method 2 Empty the fuel rails and fuel lines Refer to the Fuel Line Purging Procedure in the 2012 Ford 150 250 350 450 or 2013 F 250 850 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 Page 16 TROUBLESHOOTING 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 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 ROUSH CLEANTECH TROUBLESHOOTING The fuel
44. ed propane tank pressure based on ambient temperature pump output capacity in excess of 100 psi 689 kPa preferably an Auto Gas type b Is the vehicle fuel tank pressure greater than 20 psi 38 kPa over facility Then go to Step 2 the nominal expected pressure Vehicle fuel tank is at a higher pressure When tank pressure is within 10 psi a Higher pressure is likely caused by heavy vehicle usage heating TM the fuel b Allow the vehicle fuel tank to cool and then recheck pressure in the fuel tank Measure and compare vehicle fuel tank and fill station pressures Yes Go to Step 14 Connect a pressure gauge service tool to the fuel tank bleeder No Fill station is not providing enough valve and record fuel tank pressure pressure to fill vehicle tank Go to Step 14 Using a fuel fill pressure tester installed on the fuel fill valve Locate a dispensing facility with pump attempt to fill the vehicle Output capacity in excess of 100 psi 689 facility With the dispensing pump on and dispensing nozzle open kPa preferably an Auto Gas type facility measure and record fill station pump pressure Is fill station pump pressure at least 50 psi 345 kPa greater than fuel tank pressure Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank fill at greater than six gal 23 L per minute No Go to Step 4 Page 20 R
45. er valve or the dispensing pump stops automatically Did a solid stream of liquid flow from the bleeder valve 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 15 the additional amount of fuel dispensed less than 5 of the tank water capacity determined in Step 4 Yes Go to Step 2 No Drive vehicle until gauge reads below 1 4 tank Yes Go to Step No Bleeder valve is not functioning properly Replace the valve Yes Go to Step 4 No Using a jack raise the vehicle to obtain a level condition Then go to Step 4 With the value recorded go to Step 5 Yes Record the volume of fuel dispensed and then go to Step 6 No Go to Step 7 Yes Tank does not overfill Diagnostic 15 complete Tank is overfilling Replace the fill valve in the fuel tank then go to Step 8 The dispensing pump stopped automatically and a liquid fuel Tank does not overfill Diagnostic is stream was not observed flowing from bleeder valve complete Page 21 ROUSH CLEANTECH TROUBLESHOOTING Refuel the vehicle as follows NOTE If the key is on during refueling it will take the fuel level gauge in the instrument cluster longer to register full Verify that the ignition is in the off position Install the fuel fill pressure tester on the fill valve and cl
46. ete No Call ROUSH CleanTech Customer Service at 800 597 6874 Page 22 ROUSH TROUBLESHOOTING Engine Cranks No Start NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics Yes Go to Step 2 No Correct fault and retry 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 Is battery voltage above 10 volts Check for diagnostic trouble codes DTC Yes Go to Step 3 Are any codes present No Go to Step 4 Is the DTC identified on the ROUSH LPA DTC list Yes Refer to Diagnostic Trouble Codes No Refer to Ford service manual DTC chart Check fuel pressure Yes Go to Step 11 Measure and record fuel rail and fuel tank pressure key on No Go to Step 5 engine off KOEO While monitoring fuel pressure attempt to start engine Record the highest pressure observed Does fuel pressure rise 25 psi 172 kPa before engine crank Check fuel pump operation Yes Go to Step 6 Using a current clamp check current draw on both fuel pump No If both circuits are showing no power wires at the fuel tank Refer to n Tank Harness for correct Current check the OEM fuel pump FP circuits fuse If only one fuel pump circuit shows Turn ignition switch to start position and relea
47. ge 13 ROUSH TROUBLESHOOTING P0190 Fuel Pressure Sensor A Circuit 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 Diagnostic Aid VREF should be between 4 6 volts Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures P0192 Fuel Pressure Sensor A Circuit Low CAN bus fault between the SRM and PCM e Wiring fault between IPTS and SRM IPTS FRP signal short to SIG RTN or PWR GND Damaged IPTS or FRP IPTS failure SRM failure 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 Possible Causes CAN bus fault between the SRM and PCM e Wiring fault between IPTS and SRM IPTS signal short to VREF or VPWR IPTS or FRP open signal Damaged IPTS or FRP IPTS failure SRM failure Diagnostic Aid Verify the FRP PID value to determine open or short Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures Page 14 ROUSH TROUBLESHOOTING Fuel Level Sender P0460 Fuel Level Sender A Circuit Descriptio
48. h pressure to fill Go to Step 19 Using a fuel fill pressure tester installed on the fill valve attempt to fill the vehicle With the dispensing pump on and dispensing nozzle open measure and record fill station pump pressure Is fill station pump pressure at least 20 psi 138 kPa greater than tank pressure 1 Check body side fuel fill valve it may be stuck closed Yes Replace body side fill valve and go ill 13 Loosen the fuel fill line connection at the fill valve or at the inlet to E uu the fuel filter to relieve any pressure in the fill line No Replace filter in the fuel fill line and Attempt to push open the piston in the fill valve to determine if itis 9919 Step 15 stuck closed Is the fill valve piston stuck closed 13 Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank fill No Go to Step 14 1 Replace the filter in the fuel fill line and then attempt to fill the Yes Diagnostic is complete vehicle fuel tank No Go to Step 16 Does the vehicle fuel tank fill Does the fuel tank fill No Go to Step 16 Is the OPD valve located in the end cap of the fuel tank No Go to Step 18 Attempt to fill the vehicle fuel tank as follows Yes Diagnostic is complete No Call ROUSH CleanTech Customer NOTE Service at 800 597 6874 When filling a new tank that has the OPD valve mounted in the end cap of the fuel tank fuel splashing off the side
49. he Maximum Pressure Check procedure in Diagnostic Tests and Procedures Page 10 ROUSH TROUBLESHOOTING P0171 P0174 System Too Lean Bank 1 and Bank 2 Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for more descriptive information Possible Causes e he 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 Acion Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures PO3xx Misfire Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for more descriptive information Possible Causes e he 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 Acion Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures Heated Exhaust Gas Oxygen Sensor P2195 P2197 Heated Exhaust Gas Oxygen Sensor Stuck Refer to the Ford Powertrain Control Emissions Diagnosis Service Manual for more descriptive information Possible Causes e he LPA system was operated in the vapor region
50. he fuel pump b Is resistance between 0 4 1 0 ohm Check harness circuit continuity from fuel pumps to FPCM Yes Refer to the Fuel Pump Control Module Electrical Continuity Test procedure No Repair circuit wiring a Check continuity for pump 1 wire FPPWHR V across e Pin A connector 4A in tank harness to pin A connector 1 in tank harness e Pin A connector 24 rear frame harness and pin 5 connector 12 rear frame harness Check continuity for pump 1 wire FPRTN across e Pin B connector 4A in tank harness to pin B connector 1 in tank harness e Pin B connector 24 rear frame harness and pin 8 connector 12 rear frame harness Check continuity for pump 2 wire FPPWR V across e Pin A connector 4B in tank harness to pin A connector 2 in tank harness e Pin A connector 27 rear harness and pin 5 connector 13 rear harness Check continuity for pump 2 wire FPRTN across e Pin B connector 4B in tank harness to pin B connector 2 in tank harness e Pin B connector 27 rear frame harness and pin 8 connector 13 rear frame harness Is there good continuity in all circuits Page 39 ROUSH CLEANTECH Fuel Pump Control Module Electrical Continuity Test NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS S a
51. he pressure tester and turn on the pump Slightly open the ball valve to slowly add Remove the fuel fill pressure tester and attempt to fill the vehicle Yes Diagnostic is complete fuel tank to full 80 capacity Does the vehicle fuel tank fill to capacity the fuel gauge in the instrument cluster Is the gauge more than 1 2 full Check to see if the OPD is ea 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 Retighten the fill line valve approximately 10 gal 38 L of fuel Did the tank fill No Go to Step 6 Yes Go to Step 7 No Go to Step 11 Reverse direction of vehicle at the pump and try to fill the vehicle Yes Vehicle not on level ground Does the vehicle fuel tank fill Diagnostic is complete No Drive vehicle until fuel gauge indicates less than 1 2 full and go to Step 8 Page 17 ROUSH TROUBLESHOOTING Sep Pmcdue _ Does the fuel tank fill No Go to Step 11 Does liquid fuel vent No Go to Step 12 Does fuel gauge read full No Refer to Fuel Level Indicator Check 11 Check for sufficient fill station pressure Yes Go to Step 12 Connect pressure gauge service tool to the fuel tank bleeder valve No Fill station may not be providing and record pressure enoug
52. hematics refer to System Wiring Diagrams and to System Electrical Schematics CONNECTORS a 5 CON N ECTO R 100074a INSERTION VIEW 100238a POWER TERMINAL PRESSURE OUTPUT w TERMINAL lt VOLTAGE OUT TEMPERATURE OUTPUT TERMINAL Sy TERMINAL VOLTAGE OUT X p GROUND IPTS CONNECTOR FACEVIEW IPTS SENSO SOR PINOUT 100241a 100240 Figure 5 Underhood Harness Connectors PROCEDURE Aem Unplug the connector 8 underhood harness to the IPTS Go to Step 2 Check resistance of the integrated pressure temperature sensor Yes Go to Step 3 IPTS No Replace the 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 Page 36 ROUSH TROUBLESHOOTING 3 Check circuit continuity between the IPTS and the smart relay Yes Refer to the Smart Relay Module module SRM Electrical Test procedure a Using a multimeter check continuity in the underhood harness No Repair circuit wiring 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 Is there good continuity in the circuits Page 37 ROUSH TROUBLESHOOTING Fuel Pump Electrical
53. mp 91599 91339 95 9 38 Fuel Pump Control Module Electrical Continuity Test 40 Smart Relay Module Electrical 42 Fuel Level sender Electrical Check 44 Fuel Level Interface Module Electrical 46 E 150 150 350 Extended Wiring Harnesses and Connector 50 E 150 250 350 Extended Range Wiring Harnesses and Connector 51 E 450 Custom Body Wiring Harnesses and Connector 52 F 250 350 Pickup In Bed Tank Wiring Harnesses and Connector Layout 53 E Series Extended Range E 450 Electrical Schematic Underhood Harness 54 E Series Extended Range E 450 Electrical Schematic CAN Bus Harness 55 E Series Extended Range E 450 Electrical Schematic Rear Frame Harness 56 E Series Extended Range E 450 Electrical Schematic In Tank 55 24 Page iii ROUSH TABLE OF CONTENTS E Series Extended Range and E 450 Electrical Schematic Solenoid 55 58 250 350 Pickup Underhood Harness Electrical 59 F 250 350 Pickup CAN Bus Jumper Harness Electrical Schematic
54. n 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 Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures P0461 Fuel Level Sender A Circuit Range Performance 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 P0462 Fuel Level Sender A 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 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
55. nnector 1 Is there good continuity in the circuit Check FLIM circuit wiring for continuity to SRM Yes Go to Step 3 a Checkunderhood harness continuity between pin B connector 35 No Repair circuit wiring and pin 37 connector 1 b Is there good continuity in the circuit Check FLIM circuit wiring for continuity to SRM Yes Go to Step 4 No Repair circuit wiring a Check underhood harness continuity between pin C connector 35 and body ground b 15 good continuity in the circuit Check FLIM circuit wiring for continuity to SRM Yes Go to Step 5 Disconnect underhood harness connector 15 to rear frame No Repair circuit wiring harness Check underhood harness continuity between pin D connector 35 and pin F connector 15 Is there good continuity in the circuit Page 46 ROUSH TROUBLESHOOTING CLEANTECH Check FLIM circuit wiring for continuity to SRM Yes Refer to the Smart Relay Module Electrical Test procedure No Repair circuit wiring Disconnect rear frame harness connector 9 to Ford harness Check rear frame harness continuity between pin F connector 30 and pin 2 connector 9 Is there good continuity in the circuit Page 47 ROUSH CLEANTECH WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS Page 48 RI WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS E 150 150 350 Extended Wiring Harnesses and Connector Layout E 150 250 350 WIRING HARNESSE
56. o 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 check valve leaked supply solenoid leaked Bleed port bleed rate restrictor in outlet to VMV clogged EVAP line kinked e 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 Acion Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures Page 7 ROUSH TROUBLESHOOTING POO9F Fuel Pressure Relief Control Stuck On 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 e Short to GRD e Armature stuck in post e Solenoid seal compromised Symptom There is a potential for fuel odor Diagnostic Aid _ ___ ___ _ ________ Refer to the Fuel Hail Pressure Control Module Electrical Check procedure Diagnostic Tests and Procedures P009B Fuel Pressure Relief Control Circuit Open 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
57. oltage if Step 4 has no voltage go to Step 7 Bleed Solenoid Pin C and body ground B Voltage Continue with Step 9 No Voltage to Step 8 if Step 4 has voltage if Step 4 has no voltage go to Step 7 Check fuses F1 F2 10A in auxiliary fuse box Yes Replace fuse Is a fuse blown No Go to Step 8 Check solenoid supply circuit continuity Yes to Step 9 a Check continuity between No Repair wiring circuit 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 Is there good continuity in all three circuits Check solenoid ground circuit continuity Yes Refer to the Smart Relay Module Electrical Test procedure a Check continuity in the underhood harness between MAN 2 No Repair wiring circuit e Supply Solenoid Pin F connector 11 and pin 46 connector 1 at SRM e Flow Control Solenoid Pin E connector 11 and pin 33 connector 1 at SRM e Bleed Solenoid Pin D connector 11 and pin 17 connector 1 at SRM b Is there good continuity in all three circuits Page 35 ROUSH TROUBLESHOOTING Integrated Pressure Temperature Sensor Electrical Check NOTE For harness and connector layout diagrams and system electrical sc
58. or an open short in the wiring circuit and repair Yes Go to Step 12 No Verify that wiring in circuit is OK Refer to the ntegrated 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 ROUSH CLEANTECH Fuel System Fails to Bleed TROUBLESHOOTING Determine if fault condition repeats Start the engine and allow it to run for a few minutes Turn off the engine and wait one minute Measure and record the fuel rail pressure fuel rail temperature and fuel tank pressure with the engine off KOEO Energize the bleed solenoid Refer to the Manual Solenoid Activation Procedure With the engine off monitor fuel rail pressure for 15 minutes Does fuel rail pressure drop more than 20 psi 138 kPa 2 Verify solenoid restrictor function Start the engine and allow it to run for a few minutes urn off the engine Disconnect the EVAP line from the port Energize the bleed solenoid Refer to the Manual Solenoid Activation Procedure ls there propane flowing from the port Verify that wiring is in good condition and functioning a Perform wiring checks of the FRPCM harness b Is the wiring OK Check for a kinked EVAP line a Inspect the EVAP line between the FRPCM and EVAP canister b Are there kinks in the line Check for leaks
59. ose the ball valve Connect the fuel dispensing nozzle to the pressure tester Verify that the bleeder valve is open With the bleeder valve open turn on the pump Open the ball valve slightly to very slowly to refuel the vehicle While refueling observe the bleeder valve for fuel discharge Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically Did a solid stream of liquid flow from the bleeder valve 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 Engine Does Not Crank Yes Record the volume of fuel dispensed and then go to Step 9 No Go to Step 7 Yes Tank does not overfill Diagnostic is complete No Tank is overfilling Replace the fuel tank assembly Is battery voltage above 10 volts Verify that the smart relay module SRM has communication Can fuel rail pressure and temperature be read with a scan tool Refer to the Ford Powertrain Control Emission Diagnosis Service Manual Is the problem corrected Yes to Step 2 No Determine cause of low battery voltage Yes to Step 3 No Go to the Smart Relay Module Electrical Test procedure Yes Diagnostic is compl
60. ower fuse E1 E2 25A in the auxiliary fuse box b Is fuse blown 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 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 Is there good continuity in the circuit Check fuse a Check condition of fuse F5 F6 5A in auxiliary fuse box b Is fuse blown E Series Only Check CAN harness for SRM circuit continuity a Check continuity between pin A connector 9 and pin 12 connector 5 b 15 there good continuity in the circuit Check CAN and underhood harness continuity a Check CAN H continuity across e Pin 28 SRM connector 1 underhood harness and pin C connector 23 underhood harness e Pin C connector 9 CAN harness and pin 2 connector 5 CAN harness b Is there good continuity in the circuits Check CAN and underhood harness continuity a Check continuity across e Pin 43 SRM connector 1 underhood harness and pin B connector 23 underhood harness e Pin B connector 9 CAN harness and pin 3 connector 5 CAN harness b Is there good continuity in the circuits TROUBLESHOOTING L Prose
61. s of the empty tank could be activating the OPD float and shutting off the fuel fill line 15 16 17 Install a fuel fill pressure tester on the fill valve and close the ball valve 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 Remove the fuel fill pressure tester Attempt to fill the remaining tank volume to 8096 full capacity at full flow from the dispensing nozzle Did the tank fill 18 Attempt to fill the vehicle fuel tank Yes Diagnostic is complete Does the fuel tank fill No Call ROUSH CleanTech Customer Service at 800 597 6874 Page 18 ROUSH TROUBLESHOOTING Fill station is not providing enough pressure to fill Yes Go to Step 20 a Using tables provided at the front of this section determine No Locate a dispensing facility with expected propane tank pressure based on ambient temperature pump output capacity in excess of 100 psi b Is the vehicle fuel tank pressure greater than 20 psi 1 Pos Gas type 138 kPa over the nominal expected pressure y 9 p rai Vehicle fuel tank is at a higher pressure When tank pressure is within 10 psi 69 m kPa of a Higher pressure is likely caused by heavy vehicle usage heating e the fuel b Allow the vehicle fuel tank to cool and then recheck pressure in the fuel tank
62. se Vehicle will start Current check the ROUSH CleanTech fuel the flush cycle and pumps should be running Check current draw PUMP fuse See ROUSH CleanTech fuse A minimum of 2 amps should be recorded on both fuel pump box for location circuits If both fuel pump fuses OEM and ROUSH Do fuel pumps draw current CleanTech are good go to Step 10 Check excess flow valve XFV Yes Go to Step 11 Turn ignition key to the OFF position No Go to Step 7 Close the manual shutoff valve on tank Wait 1 minute and then slowly open manual shutoff valve Measure and record fuel pressure using a scan tool at integrated pressure temperature sensor IPTS Is problem resolved Check ROUSH fuel pump FP fuse Yes Go to Step 8 Is fuse intact and OK No Determine the cause of the short and repair replace the fuse Diagnostic is complete Check the tank solenoid TS and supply solenoid SS fuses Yes Determine the cause of the short iti ir replace the fuse a Locate the TS fuse E3 E4 and check its condition b b Locate the SS fuse F1 F2 and check its condition D MO osten c Are the fuses blown Page 23 ROUSH TROUBLESHOOTING 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 presen
63. sensor Yes Replace harness No Go to Step 13 Yes Replace fuel pump assembly No Replace hose assemblies as needed ROUSH TROUBLESHOOTING Engine Stumble Stall Rough Idle NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics Verify the following Yes Go to Step 2 No Correct the fault and retry a ls 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 Is battery voltage above 11 volts with engine running Check for diagnostic trouble codes DTCs Yes Go to Step 3 Are any codes present No Go to Step 4 Identify the DTC Yes Refer to ROUSH CleanTech Is the DTC covered the ROUSH CleanTech DTC listing for AS UIDES LPA fueled vehicles No Refer to the appropriate Ford m Powertrain Control Emissions Diagnosis b Correct all DTCs before continuing Service Manual at 0 4 Does the problem occur only after cold start Yes to Step 6 No Go to Step 5 Determine fuel pressure Yes Go to Step 7 Measure tank pressure with key on and engine off KOEO No Go to Step 6 Measure fuel rail pressure with key on and engine running KOER Subtract the KOEO pressure from the KOER pressure to obtain the difference Compare to the chart in Expected Fuel Rail Pressure
64. t at the TS connector C Is 12 volts present at the SS connector 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 connector C Is 12 volts present at the FP2 connector Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification procedure Check wiring Drain the propane from the fuel tank Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information Remove tank service cover Check for open or short circuits on tank pass through harness Is a wiring problem present Check fuel hoses and quick connect fittings Are in tank fuel hoses and quick connect fittings connected and in good condition Yes Voltage present at SS replace Voltage present at TS replace fuel supply valve assembly No Check for an open s in the wiring circuits and repair Diagnostic is complete Yes Go to Step 12 No Check for an open s in the wiring circuits and repair Yes Refer to the ntegrated Pressure Temperature Sensor Electrical Check No Verify that wiring in circuit is OK Refer to the ntegrated Pressure Temperature Sensor Electrical Check procedure If not repair wiring If OK replace
65. t the tank measurement from the KOER measurement Is the resulting fuel pressure in the expected range Determine if the excess flow valve is tripped a Turn off the engine b Wait one minute and then restart the engine c 15 the problem resolved Check fuel pump operation a Using a current clamp check current draw both fuel pump power wires at the fuel tank Refer to In Tank Harness for correct circuits 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 Do fuel pumps draw current 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 Verify that there is power and ground in the wiring circuit to the tank Check for 12 volts at the fuel pump 1 FP1 and fuel pump 2 FP2 connectors Refer to the Fuel Hail Pressure Control Module Electrical Check procedure Is 12 volts present at the connector Is 12 volts present at the FP2 connector Integrated Pressure Temperature Sensor Rationality Does temperature and pressure make sense to verification See the Integrated Pressure Temperature Sensor Electrical Check procedure Yes Go to Step 2 No Correct the fault condition and retry Yes Go to Step 4 No Go to Step 3 Yes Hefer to the Excess Flow Valve Check procedur
66. 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 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 ROUSH CLEANTECH 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 courtney gendron 2 propanecouncil org or vincent sibilia propanecouncil org INTRODUCTION 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 Page 3 R ROSH TROUBLESHOOTING TROUBLESHOOTING Page 4 R
67. to the FRPCM Start the engine and allow it to run for a few minutes Turn off the engine and unplug the FRPCM Measure and record fuel rail pressure Bleed pressure from fuel rail until fuel pressure drops more than 50 psi 345 kPa De energize bleed solenoid Let vehicle sit for 30 minutes Measure fuel rail pressure and fuel tank pressure Does fuel rail pressure rise more than 10 psi 69 kPa Yes Go to Step 5 No Go to Step 2 Yes Go to Step 4 No Go to Step 3 Yes Bleed solenoid stuck closed or port restrictor is plugged Replace the FRPCM No Repair wiring and repeat Step 1 Yes Replace the kinked EVAP line and then repeat Step 1 No Go to Step 5 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 Page 29 ROUSH CLEANTECH TROUBLESHOOTING Fuel Pressure Drop NOTE For harness and connector layout diagrams and system electrical schematics refer to System Wiring Diagrams and to System Electrical Schematics Verify the following ls there fuel in the tank of at least 1 8 tank b Is the tank supply manual shutoff valve fully open Is battery voltage above 10 volts Determine fuel pressure Measure and record fuel tank pressure Measure and record fuel rail pressure with key on engine running KOER Subtrac
68. tripped Tank solenoid stuck closed Tank manual valve closed Fuel pumps not powering on Blown fuse Vehicle does not start pumps run or not but 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 P2665 Supply Solenoid Circuit Fault 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 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 Refer to the Fuel Hail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures Page 9 ROUSH TROUBLESHOOTING SRM CAN Bus Circuit Wiring 00108 Lost Communication with Alternative Fuel Control Module 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 e Wiring between the SRM and PCM e SHM lacks power

Download Pdf Manuals

Related Search

Related Contents

μ1200 取扱説明書  User's Manual  Rust-Oleum Restore 291628 Instructions / Assembly  VOX Amplification USA V212NT User's Manual  RCS11 Manual - Comtech EF Data  attention - Kitagawa Europe  Ironhorse Trailers, Inc. Owner`s Manual  MAPA DO DSEI Mapa do Brasil com Localização dos DSEIs  Massive Ladybird  Gigaset C300/C300H  

Copyright © All rights reserved. Failed to retrieve file