''F'' Series

Super Dutv
Features • DescriPlion • Service F

t...!
 FOREWORD

This publication is intended to provide technicians and service personnel with the latest technical advancements incorporated
in the 7.3 DIT Diesel Engine. The information contained in this publication will supplement information contained in available
service literature.

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe,
reliable operation of all motor vehicles, as well as, the personal safety of the individual
doing the work. This manual provides general directions for accomplishing service and
repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing
vehicles, as well as, in the skill of the individual doing the work. This manual cannot
possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instructions provided in this manual must first
establish that he compromises neither his personal safety nor the vehicle integrity by his
choice of methods, tools or parts.

The following list contains some general WARNINGS that you should follow when you work
on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the vehicle.

• Be sure that the ignition switch is always in the OFF position, unless otherwise
required by the procedure.

• Never perform any service to the engine with the air cleaner removed and the engine
running unless a turbocharger compressor inlet shield is installed.

• Set the parking brake when working on the vehicle. If you have an automatic
transmission, set it in PARK unless instructed otherwise for a specific service
operation. If you have a manual transmission, it should be in REVERSE ( engine OFF)
or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation.

• Operate the engine only in a well- ventilated area to avoid the danger of carbon monoxid~.

• Keep yourself and your clothing away from moving parts when the engine is running,
especially the fan, belts, and the turbocharger compressor.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator,
turbocharger pipes, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle .

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose
clothing before beginning to work on a vehicle. Tie long hair securely behind the head.

• Keep hands and other objects clear of the radiator fan blades.
 7.3L DIT
Direct Injection
Turbocharged Diesel
Engine
 7.3L DIT DIESEL ENGINE

TABLE OF CONTENTS
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . .. . . . . . . . . . . 4
New Features .........................................................4
Engine Serial Number .. . .. . ..... ............. .. . ...... ....... . ..........4
Emission Label ............... .. .. ....... .. . .. . . ............ ...........5
Horsepower Comparison ......... ... .. . ......... ........... ....... .......5
Torque Comparison . ....... . ...... . ..... .. .. . . ......................... .5

PHYSICAL ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .&

AIR CHARGING SYSTEM .. . . . . . . . . . . . . ... . . . . . . . . . 13

Turbo Id .................... .... .. .. . ... ......... ....................13
Wastegate Control .... . ...... . ...... .. ............ . . ......... . .........15

TURBO REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . 18

FUEL CHARGING SYSTEM . . . . . . . . . . . . . . . . . . .. . . . . . 21

Injectors ...... ........ ............... .. ..............................21
Fuel Filter and Supply ........... . ... .. ......... ......... ......... ......24
High Pressure Oil System ...............................................29

NEW AND REVISED SENSORS . . . . . . . . . . . . . . . . . . . . . . 31

-sP ECIAL T DR OUE DAT A . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3

7.3L DIT ANTHOLOGY . . . . . . . . . . . .. . . . . . . . . . . . . . . . 35
Fuel filter service ................. .............................. .. ... . .35

DIAGNOSTIC GUIDES AND FORMS . . . . . . . . . . . . . . . . . . . 50

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 71

INDEX .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . 73

1
ENGINE SPECIFICATIONS

New Features
■a arsapawer an arq
ga Air Caalad
ronically Canlralled Waslegaled Turbo
Iii Shat lnjaclars
to Connacl ICP Oil Lines
ignad Fual Syslam

nap lo Connect ICP Oil Lines

ed■■ignad Fual Supply System
II Split Shat lnjaclars (Carryover lram
1117 Modal Yaar)

Cka■■i■ Maunlad Electric Fuel Pump

ZF I Spaad Manual Transmission (F-Series anly)
Law Gaar Addad lar Heavy Loads
Dilf■ ranlial Ratios Available:
•r• Sari ■ s: 3.73, 4.10, 4.30, 4.88
lcanalina: 3.55, 4.10, 4.63
Singla 35 gallon Fu ■ I Tank (F-Series anly)

Engin ■ S ■ rial Number

• There is now an engine serial number on
the valve cover as opposed to the oil
reservoir.
• As with previous Power Stroke engines, the
engine serial number is still stamped into
the crankcase at the rear oil cooler pad.
• The vehicle production date break for most
of the material covered in the front section
of this book is Jan. '98, unless otherwise
stated in text.

4
 ENGINE SPECIFICATIONS

1999 MODEL/MODELE A250

250 e 2100
CURB IDLE, FUEL RATE @ ADVERTISED POWER, AND INJECTION TIMING ARE
NON-ADJUSTABLE.
LE REG IME DE RALENTI, LE DEBIT DE CARBURANT A LA PUISSANCE
NOMINALE ET LE CALAGE DE L'INJECTION SONT NON-REGLABLES.
EMISSION CONTROL SYSTEM: - SYST. DE DEPOLLUTION: ECM, TC, DI, OC, CAC Emission Labal
RENSEIGNEMENTS
DE DEPOLLUTION • The emission label is located on the right
ENGINE MANUFACTURED BY: valve cover and identifies the engine model,
MOTEUR FASROUtpAR
NAVISTAR INTERNATIONAL gross horsepower, and fuel delivery rate.
TRANSPORTATION CORP.

250

200

150 Horsapowar Comparison

al
~ 1999 "F" Sarias
X
'"Cl
100 Peak Horsepower is 9 % more than previous
models and occurs @ 2700 RPM versus 3000
RPM.
50

0
1500 2000 2500 3000

Engine RPM

550

500

450
Tarqua Comparison
Similar to the horsepower increase, peak
400
torque is higher at 500 lb/ft. between 1600
and 2300 RPM. This is a 15% increase over
prior models.
350

300
1500 2000 2500 3000 3500
Engine RPM

5
PHYSICAL ID
- - ----- - -- -

Crankshaft Engine Serial Engine Serial

#576010 and above #576009 and below
• For improved strength and ease in
machining, the crankshaft no longer has
Counterweight has a
lightening holes drilled into the connecting
larger radius
rod pins.
• The counterweights are larger to counteract
the extra weight in the connecting rod pin.
• The engine serial number break for this --,
change is 576010.
Note: The "larger" crankshafts may only
be used in crankcases with serial numbers
higher than 571930. Lightening
hole

Crankcasa 7
• The lower section of the crankcase has
been modified to allow larger crankshaft
counterweights to clear the crankcase.
• The serial number break for this change is:
571930-
• This change occurred on the crankcase
prior to the crankshaft.
Note: This crankcase may be used with
either crankshafts described above.

--,
Mechanical lift pump eccentric eliminated

Camshaft
• The 1999 model year engine incorporates
a chassis mounted electric fuel pump.
• Due to the use of an electric fuel pump the
eccentric lobe on the camshaft has been
eliminated.

&
- - - - - - -
PHYSICAL ID

Pre. Jan. '98

0.185"
Rings
• The intermediate ring width has been
0.137"
increased to increase ring tension in the
bore.
Larger chamfer • The intermediate ring has a larger chamfer
on its inside face and increased width to
distinguish it from the prior second ring.
Note: The intermediate ring must not be
used on earlier pistons.

Pre. Jan. '98 Past Jan. '98

0.435" Slightly deeper

intermediate
0.402" ring groove
Pistons
• The new piston has a deeper intermediate
ring groove to accommodate the new
increased intermediate ring width.
Note: Pistons and rings cannot be
intermixed due to increased and narrow
intermediate ring widths.

Under Valve Caver harness [UVC)

Yaiva Cover &askat and UVC

Harnass
• To reduce the number of electrical
connections and improve reliability, the
valve cover gasket now uses a single 9 pin
connector (versus two 5 pin), for injectors
and glow plugs.

• This new one piece design UVC is still

removable, and uses larger wires and
terminals for the glow plug circuit.

7
PHYSICAL ID

Engine Harness
• Similar to the UVC harness, the engine
harness also has two 9 pin connectors,
incorporating larger wires and terminals for
the glow plugs.

9 pin valve cover connector

Yaiva Covar Daskal Breakout Taal

• Because of the new 9 pin connector,
essential tool #418-F221 has been released
for testing glow plug and injector circuits.
Essential tool
• The four White pins are for glow plugs.
#418-F221
• The Black pin is common for the four
injectors.
• Red, Green, Blue, and Yellow pins are
injector ground.

Pre Jan. '98 "F" Series

Drivers side up pipe

Exhaust Up Pipas
• To improve joint serviceability, the exhaust
up pipes are now common for both "E" and
"P' Series.
• On previous engines the exhaust up pipes
were model specific. The previous "F"
series drivers side exhaust up pipe is
shown.

Common for "E" and "F" Series.

8
□
I PHYSICAL ID

Post Jan. '98

Exhaust Manifolds
• The driver side "F" Series exhaust manifold
has changed to allow the use of a common
exhaust up pipe.

Pre Jan. '98

Measuring Exhaust Back Pressure

without Cold Weather Package
• With the 1999 model year "F" Series, a
"Cold Weather option delete" package is
available. If the cold weather package has
been deleted, a new procedure for
checking exhaust back pressure is
described below.
• To check exhaust back pressure on a
vehicle that is not equipped with an
exhaust back pressure sensor, you will
have to make your own cooling coils.
• The coils are to cool exhaust gases before
they reach the pressure gauge to avoid
damage to the gauge.
• The coil should be made out of copper
tubing obtained locally.
• After making coil, attach tubing to the
exhaust manifold by removing the: plug in
front of the right exhaust manifold where
the exhaust back pressure sensor tube
would normally be located.
• Use gauge bar tool number 014-00761 or
equivalent to read pressure; on vehicles
equipped with EPB this can be read using
the NGS tool.
CAUTION: TURBO WILL BE HOT. Do not
touch during or immediately after test.
Route tubing away from parts that can be
damaged by heat and keep away from
accessory drives and fan.

9
PHYSICAL ID

Turhina lnlat and Clamp

• The turbine inlet now uses a V-band style
clamp for mounting.

• To insure proper alignment a dowel pin is

used as a locator.

Engine oil fill location Dipstick tube

Oil Fill Location and Dipstick

• The engine oil fill location has been
extended to make it easier to change or
add oil to the engine.
• The dipstick is now common for both "E"
and "F" series. This makes it easier to
check the oil level on "F" series.

Crankcasa Prassura Tast

• Place crankcase pressure adapter on oil fill
extension to check pressure.
• Crankcase pressure should not be more
than 4 inches of water using the
Magnahelic gauge.
Note: Be sure to block off crankcase
ventilation system (breather tube) before
performing test.

10
 PHYSICAL ID

Waler Pump
• Water pump seals are dynamic seals.
During engine cranking, seepage past the
seal occurs.
• A reservoir has been added to the housing
to allow the small amounts of seepage past
the seal to accumulate and evaporate.
• This eliminates the staining seen on prior
Reservoir water pumps.

Post Jan. '98 "F" Series

thermostat housing

Tharmaslal Housing
• To provide clearance for charge air cooler
piping and improve serviceability during
normal service operations, the "F" Series
thermostat housing is shorter, has a thicker
flange and a new seal.

Pre Jan. '98

Post Jan. '98

Waler Pump Pulley

• The water pump pulley diameter has been
decreased.
• If service is required, be sure to use the
proper pulley to obtain proper pump speed
and avoid cooling system concerns.

11
PHYSICAL ID

Pre Jan. '98 Post Jan. '98

Engina Maunls - nrn Sarias

• With the new Super Duty "F" Series
chassis, the driver side engine mount is
made from cast iron instead of stamped
steel.

"F" Series "F" Series

Left engine mount Left engine mount

Air Claanar
• The air cleaner for the 1999 model year
"P' series has been totally redesigned to
use a flat rectangular filter element.
• The air filter housing continues to
incorporate a filter minder restriction gauge
to monitor air filter condition.

Singla Mass Flywhaal

• A single mass flywheel replaces the
previously utilized dual mass flywheel for
manual transmission applications.
• The flywheel can be identified by the
absence of bolts that would normally
connect the inertia member from the clutch No bolts in
surface. this location

Note: The single mass flywheel can

only be used with the ZF 6 speed manual Single mass
transmission. flywheel

12
□
 AIR CHARGING SYSTEM

Turbo Charger
• "F" Series turbochargers are wastegated in
"F" Series conjunction with charge air cooling.
Wastegate with EBP • "F" Series may be ordered without ESP.

Wastegate without EBP • All "E" Series turbochargers are equipped

with ESP and no wastegate.
"E" Series
All with EBP - Non-Wastegated

Turbo mounting bolt

Turbo •r• Series with Waslegale

and EBP
• In the front view shown, the ESP regulator
and new top down turbo to pedestal
mounting bolts are depicted.
• The wastegate regulates maximum speed
of the turbocharger by allowing excess
exhaust gases to bypass the turbine
housing and be directed into the exhaust
stream to atmosphere.

Turbo mounting bolt

Wastegate Turbo nrn Series with Waslagale
actuator Location for dowel and EBP
• From the rear view, ESP and wastegate
actuators are shown. In addition, note the
locator dowel hole for positioning the
turbine inlet.
Exhaust • As previously stated, the turbocharger
back assembly is now attached to the pedestal
pressure with two bolts from the top. This is for in
actuator chassis removal and installation of turbo
assembly which is explained in detail
starting on page 17.

13
AIR CHARGING SYSTEM

Turbo mounting bolt

TurbD HFH Sarias with Waslegale

and wilhDUI EBP
• Front view shown with EBP regulator
removed from turbo pedestal.

No EBP regulator

Wastegate actuator

TurbD arnSeries with Waslegale

and withDUI EBP
• Rear view shown without EBP actuator
assembly.
• The turbine inlet, not shown, utilizes an
alignment dowel for positioning on the
turbine housing. Location for dowel
No EBP actuator

Turbo mounting bolt

TurbD RER Series wilhDul

Waslegale and with EBP
• Front view shown with EBP regulator
moved to front of pedestal and top down
mounting bolts.

• Because the "E" Series does not utilize

charge cooling, wastegated turbochargers
are not incorporated in the Econoline
engines.

14 □
 AIR CHARGING SYSTEM

Turbo mounting bolts

Turbo HEH Sarias without

Wastagata and with EBP
• Rear view shown
pressure
actuator

CAC Housing and

Wastagata Control
Note: The inside of this housing will be
damp with oil mist carry over from the
closed crankcase ventilation system.
• Oil is not an indicator of a turbocharger
concern.

Ta wastegate actuator

Wastegate solenoid Wastagata Control Solanoid and

Lines
Ta air induction inlet • With the electronically controlled
wastegate, a pressure differential between
the induction system and the intake is used
to regulate boost pressure, via a duty cycle
controlled (PCM) solenoid.
Ta manifold
pressure

15
 AIR CHAR GING SYST EM

Wastega te Actuator Operatio n

• The wastegate actuator is a spring loaded
diaphragm acted on by manifold pressure
Open-+-----+- Closed
and controlled by the wastegate control
(WGC) solenoid.
• The wastegate control solenoid, duty cycle
controlled by the PCM, is allowed to bleed Green
Hose
pressure via a hose connected to the air (Vacuum)
intake system for precise control.
• Spring pressure closes the wastegate. INLET
Note: A tampered or disabled wastegate
will result in decreased performance and Charge Air
potential turbocharger damage. Cooler
Housing
Intake

Wastega te Actuator Diagnost ics

• To test the wastegate actuator, apply
regulated air pressure to the actuator,
starting at zero and slowly increasing
pressure while observing actuator rod Open ----► Closed
movement. Apply pressur e
here
• The actuator should start to move at 5 psi.
• The actuator should hold 5 psi for
30 seconds.

--,

Non Charge Air Cooled Charge Air Cooled

Intake to CAC Housing Hoses

• The CAC intake air hose has offset
diameter inlet and outlet, this is due to the
difference in the CAC housing and intake
covers.
Note: Hoses are of special material and
should not be substituted during service.

16
 TURBO REMOVAL AND INSTALLATION

Note: Because of the addition of the charge air cooling piping, ii is normal lo
hear some turbo noise (whine).
• If turbo noise is reported, first check to insure all sound insulating material is in its proper location,
if not, install all insulation in proper locations.
• If all insulation material is in the proper locations, check for wheel to housing contact at the turbine or
compressor, if there are signs of contact then replace the turbo.
• If the insulation is present and no wheel to housing contact is present, the sound may be normal.

Sound
insulating
material
shown from
Door inside the
hinges vehicle

Sound Insulating Material for

Engine Noise
• When diagnosing engine noise complaints,
such as turbo whine, you must first check
to see that all sound insulating material is
in place as shown in accompanying
photos.
• The material is in the fender and mounted
between the fender and the A-piller and is
used to isolate the engine compartment
from the vehicle's interior.
• There should not be any holes or gaps
Sound between the A-piller and the fender.
insulating Sound
material insulating
shown from material shown
inside the out of vehicle,
fender side view

17
 TURB O REMO VAL AND INSTA LLAT ION

CAC Pip ■ s

• First remove the two nuts holding the

Power Stroke cover in place.
• Then, loosen the four clamps that are
holding the charge air cooler pipes to the
charge air cooler housing.
Important: When reinstalling clamps,
tighten to 71 lbf/in (8 Nm), to insure joint
Integrity, performance, and internal engine
protection.

CAC Cannactia ns
Note: After removing the charge air pipes
it is normal to see oil inside the flexible
hose area.
CAUTION: When the intake system is
open, care must be used to avoid any
foreign objects from entering the engine
or charge air cooler system.

CAC Cannactia ns
• Next loosen the two clamps on both lower
charge air cooler pipe connections at the
--,
charge air cooler, and move charge air
cooler pipes out of the way to access the
turbo.

18
 TURBO REMOVAL AND INSTALLATION

CAC Cannaclians
• Remove all wiring and hoses going to the
charge air cooler housing.
• Loosen hose clamps holding charge air
cooler housing to turbo and intake covers.

Air Induction Hase

• Loosen the two clamps holding the air
intake hose to the turbo.
• Remove the air intake hose.

Exhaust Pipe
• Next loosen v-band clamp holding exhaust
pipe to turbo.
• Move exhaust pipe out of the way for turbo
removal.
• When reinstalling clamp, tighten to
50 lbf/in (5.6 Nm).

... 19
TURBO REMOVAL AND INSTALLATION

Exhaust Inlet Adapter

• Loosen the v-band clamp holding the
exhaust inlet adapter to turbine.
• When reinstalling clamp, tighten to
100 lbf/in (11.3 Nm).

Turbocharger Assembly
Note: In-chassis removal and installation
of turbo requires leaving the pedestal
attached to the engine.
• Remove the two bolts holding the turbo to
the mounting pedestal.
• When reinstalling bolts, tighten to 35 lbs/ft
(4 Nm).
• To install turbo, reverse above steps.

20
 FUEL CHARGING SYSTEM

Injectors
• Split Shot
• 0-Ring Pack

Split Shat Dp ■ Hlian

Split shot injectors provide improved exhaust

emissions and quieter engine operation,
particularly at idle, by tailoring the injection of
fuel, without a decrease in performance.
Split shot injectors (prime) have been used in
California engines since the 1996 model year
Fill Stage and all 1997 Econolines. Now they are in all
Power Strokes.
Step #1

0 FUEL SUPPLY PRESSURE

INJECTION PRESSURE

Intensifier
\.,,,-::~.Ip)-'---
Piston

Plunger

First Injection
Step #2

While the lower land of the

plunger covers the upper
port in the barrel, plunger
movement increases
pressure, unseats the
delivery check ball, and
begins fuel delivery

... 21
FUEL CHARGING SYSTEM

End al First Injection

Step #3
D FUEL SUPPLY PRESSURE
When the lower land travels
ll!il INJECTION PRESSURE
past the upper port in the
barrel, pressure decreases
and fuel delivery is slowed.

Closed

Second Injection
Step #4
When the upper land seals
the upper port in the barrel,
as the plunger continues to
move down, the delivery
cycle is completed.

Injection Pressure

- Without Split-Shat

With Split-Shat

1
22
 FUEL CHARGING SYSTEM

Injector 0-rings
• The injector now uses a more robust one
piece seal to replace the two previously
used for the center position. No change
was made to the injector.
• This change was incorporated as of engine
serial number 642092.
Does not fill Note: The O-rings are to be used when
entire groove More robust servicing all previous DIT engines. O-ring
one piece seal
will fit loosely in groove.

Fuel filter housing Post Jan. '98 oil

reservoir

Oil Reservoir
• The new reservoir has the fuel filter
assembly mounted to it via two bolts that
pass through the housing.
Note: These bolts are not open to oil and
must be removed for removal and
installation of fuel filter assembly. In-
chassis fuel filter assembly removal does
not require reservoir removal.

Reservoir top

• The oil reservoir is now a two-piece design

which allows for reservoir cleaning when
required, such as during an engine
overhaul.
• The reservoir top is attached by six bolts
and is sealed by a one piece molded
silicone gasket.

23
FUEL CHARGING SYSTEM

Fuel Filter
• The fuel filter continues to incorporate a
water separator and drain, while supplying
fuel to both cylinder heads. hose

Fuel supply to right rear head

Fuel Filler
• The fuel filter assembly is equipped with a
heater to warm fuel to allow it to pass E□T
through the filter element in cold ambient
temperatures.
• The fuel heater enables at temperatures
less than 45° F (7° C) and disables at
75° F (24° C).

Fuel heater and

water in fuel switch

Fuel Pressure Regulatar

• Fuel is returned to the tank via a fuel
pressure regulator and fuel return line.
• When reinstalling regulator, tighten bolts to
50-70 lbf/in (5.6-7.9 Nm).
• Fuel pressure is regulated to a minimum
of 30 psi independent of engine speed.
• Spool and spring are serviceable (not shown).

24
0
□
 FUEL CHARGING SYSTEM

Fuel Filter Service

Fuel Filter Removal
Tab Tab • Loosen the filter lid with a standard oil filter
wrench.
Element
• To release fuel filter, depress tabs on side
of filter.

• A dual element fuel filter will be released

during the 1999 model year.
• Note: The fuel filter element is smaller
than previous DIT engines and a correct
filter element is required in the housing
for fuel to flow to the injectors.

Drain valve

Fuel/Water Drain Removal

• For service, all parts of the assembly are
available separately.
• To remove the fuel drain, remove the four
retaining screws, tilt the drain away from
the housing and pull downward.
• When servicing, tighten retaining screws to
20-25 lbf/in (2.3-2.8 Nm).

Fuel Heater/Water in Fuel

Sensor Removal
• The fuel heater connector and water in fuel
sensor are combined in one unit.
• To remove heater/sensor remove the two
retaining screws and pull away from
housing far enough to disconnect the wire
going to the heating element.
• When servicing, tighten retaining screws to
20-25 lbf/in (2.3-2.8 Nm).

... 25
FUEL CHARGING SYSTEM

Fuel
heater

Fual Haalar Sarvica

• To remove the fuel heater, first remove the
heater/sensor as shown previously.
• Then remove the two screws that hold
down the fuel heating element.
--,
• When replacing the element, tighten
retaining screws to 20-25 lbf/in
(2.3-2.8 Nm).

Fual Fillar Standpipe Sarvica

• To remove the fuel standpipe, first remove
the fuel heater element as shown above.
• Then pull the standpipe straight out.
• When installing, be sure to install spring
and valve.

Lid

Fuel filter
Fuel heater
element
_Ja element
Fual Fillar Sarvica Paris Fuel filter lid 'SI ◄
Stand pipe assembly Fuel filter
seal
• The fuel filter assembly is shown here
completely disassembled.
Fuel pressure

---II-
►

- --
regulator- .
0
C
, .. housing

Drain valve

Fuel heater/
water sensor - o
0
0

i
I =-
0
0

26
D
 FUEL CHARGING SYSTEM

Fua1 filter la cylindar head fuel supply lines

Fuel out to
right rear Fuel inlet

Fuel out to
left front

Fuel Supply System

Fuel inlet from filter • No return lines are attached to the cylinder
heads, only supply lines.
• Excess fuel is returned from the pressure
Fuel filter ta chassis connections regulator valve to the fuel tank.
• The fuel filter's fuel supply and return lines
Fuel supply
are a one-piece assembly.

7fum return
Fuel supply

Fuel return

Screen
Fuel Check Valve
• The new fuel system incorporates a fuel
inlet check valve in the fuel supply.fitting to
each cylinder head.
• The check valve insures that there is a
constant and steady fuel pressure in the
head for fuel delivery.
• If fuel pressure is low in one head and
normal in the other then inspect the check
valve for debris; if no debris is found then
replace the valve in the head that exhibits
low pressure.

• A screen in the valve is used to stop debris

from entering the valve.

... 27
FUEL CHARGING SYSTEM

- RETURN TO TANK FUEL PRESSURE C=:J SUCTION

Regulator Fuel filter

- - Fuel outlet I
..-----..;.~~;;_-~~~~ITT Fuel
filter
housing
Fuel Supply System
Right head
Fuel is supplied to the fuel filter by an electric Electric fuel pr essure
fuel pump test port
pump. The fuel filter is pressure regulated.
Excess fuel is returned from the fuel filter
through the pressure regulator valve, to the fuel
tank. Filtered fuel is delivered to the cylinder Left Ri ht
heads where it enters though check valves. No cylinder cy~nder
head head
fuel return from the cylinder heads exists.

Fual
tank
Check valves

Fuel Pressure Check in Righi Head

• To check fuel pressure in the right head
install a fuel pressure gauge in the plugged
passage at the end of the head opposite
the fuel supply line.

• Fuel pressure should not drop below

30 psi. It is not uncommon to see fuel
pressures as high as 80 psi.

• On Econoline, the left head should be

checked first. The alternator and bracket
must be removed to gain access to the fuel
pressure fitting on the right head.

Fuel Pressure Chack in Lall Head

• To check pressure in the left head install a
fuel pressure gauge in the rear of the head
near the turbocharger.
• Fuel pressure should not drop below 30 psi.
Note: When routing lines, be sure to route
them away from hot or moving parts.

28 □
 FUEL CHARGING SYSTEM

Fuel Pressure Check al Fuel Pump

• Voltage at the fuel pump should be
checked to insure that the pump is being
powered by the PCM.
• If there is no voltage at the pump the
inertia switch, located behind the left hand
kick panel, might have been tripped.
• To check fuel pressure at the pump
install the fuel pressure adapter tee
(Tool #014-00931-2) and install a fuel
pressure gauge (Tool #014-00761).

High pressure oil line snap

to connect fittings.
High Pressure Oil Line Snap lo
Connect Fillings
• The fittings allow the high pressure oil lines
to be connected to the high pressure pump
and heads simply by pushing them into
place.
Note: Whenever high pressure system is
opened, air enters the system and the
vehicle needs to be driven to remove the air.

Snap to connect
High Pressure Oil Lines
high pressure lines
Note: Push the lines into the fittings until
you hear/feel the snap ring "grab" the line.
Insure connection by pulling on the line.

• Hoses which have been specifically

designed to withstand the high pressures
(up to 3000 psi) and temperature
differentials are used to direct the high
pressure oil to the oil galleries in the heads.

29
 FUEL CHAR GING SYSTE M

Insert disconnect
tool here to release

Disconnec t Ta al
• To release line from fitting:
While firmly pushing the line straight into
the fitting with one hand, insert the tool
behind the black release sleeve and gently
pull on the line.

• The tool part number is 303-625.

Essential tool #303-625

ICPSensor
Injection Control Pressure Black
Off Taal
• The block off tools are also of a snap to Essential tool
connect style so that they can be connected #303-627
to the high pressure oil lines on the engines.
• The tool part number for the block off plug
is 303-628 and the ICP adapter is 303-627.

~ • These tools are necessary to accurately

Essential
diagnose the ICP system during hard
tool #303-628
start/no start diagnosis.

30 □
 NEW AND REVISED SENSORS

New MAT Sensor

Revised MAP Sensor
Revised CMP Sensor
Relocated EBP Sensor

Manifold air
temperature sensor

Manifold Air Temp Sensor

"F" Series Only
• The MAT sensor is used to control fuel and
timing when intake air is cold and adjusts
as air temperatures warm up.

Manifold Absolute Pressure

Sensor
• The MAP sensor now sends an analog
signal to the PCM instead of the digital
signal previously used.
• The sensor is mounted to the heater and
air conditioner plenum on the passenger
side of the engine compartment.

31
 NEW AND REVIS ED SENS ORS

Camshaft Position Sansar Part number suffix location

• The camshaft position sensor circuitry has
been updated to be less sensitive of
clearance to the trigger wheel.
• The part number suffix on this sensor
is C93.
• The engine serial number break for this
sensor is 623916.
See CAMP sensor usage chart on page 45
for information regarding different CAMP
sensors and their identification.

a7ist bac
sensor lo
Exhaust Back Prassura Sansar
• The exhaust back pressure sensor has
been relocated to the front of the oil
reservoir.
• The tube has been redesigned to
accommodate the new sensor location.

32
 7.3 DIT POWER STROH£ SPECIAL TDROUE DATA

COMPONENT STANDARD METRIC

Turbocharger Mounting Baits (la pedestal) 35 lhl-lt 47.5Nm
Turbocharger Exhaust Inlet Adapter V-band Clamp 100 lhf-in 11.3 Nm
Turbocharger Compressor Housing (to center section) 11- 14 lbf- ft 15- 17 Nm
Turbocharger Turbine Housing (to center section) 15- 18 !bf-ft 22 Nm
Turbocharger EBP Valve Housing (MS bolt) (to turbine housing) 60-80 lbf- in 6.8- 9 Nm
Air Inlet Covers (MB) (Intake manifolds) 18 !bf-ft 24 Nm
Exhaust Manifold (to cylinder head) (M 1 OJ* 45 !bf-ft 61 Nm
Exhaust Manifold Flanges (to up pipe) (MB)* 18 lbf-ft 24 Nm
Exhaust Adapter Flange (to up pipe) (MB)* 18 !bf-ft 24 Nm
Turbine Outlet Clamp 50 lbf-in 5.6 Nm
Step 1 65 lbf-ft 88 Nm
Cylinder Head Bolt Torque Step 2 85 lbf-ft 115 Nm
Step 3 95 lbf-ft 129 Nm
Fuel Injector Hald Dawn Clamp Mounting Bait 120 lhl-in 14Nm
Fuel Injector Hald Dawn Clamp Shoulder Bait 120 lhf-in 14Nm
Fuel Rail End Plug 97 !bf-in 11 Nm
Glow Plug 124 !bf-in 14Nm
Injector Oil DeOeclar Mounting Bait 106 lbf-in 12Nm
Oil Rail Drain Plug 53 !bf-in 6Nm
Oil Rail End Plug ** 59 lbf-ft BO Nm
Valve Cover Mounting Bolt 97 lbf-in 11 Nm
Oil Pan Drain Plug 28 !bf-ft 38Nm
Crankshaft Vibration Dampener Bolt 212 lbf-ft 287 Nm
Oil Level Gauge Tube Adapter Nut 24 !bf-ft 33Nm
Front Cover Mounting Bolts 15 !bf-ft 20Nm
Water Pump Mounting Bolts 15 !bf-ft 20Nm
Oil Pick-up Tube Flange Bolts 18 lbf-ft 24Nm
(first step) 52 lbf-ft 7 1 Nm
Connecting Rod Nuts
(final) 80 !bf-ft 108Nm
Water Outlet Tube Mounting Bolt 15 !bf-ft 20 Nm
Injection Control Pressure Sensor (ICP)" 22 !bf-ft 30Nm
Flywheel Mounting Bolts 89 !bf-ft 121 Nm
[first step) 75 lbf-ft 102Nm
Main Bearing Cap Bolts
[final) 95 !bf-ft 129Nm
Rear Cover Mounting Bolts 15 lbf-ft 20Nm
High Pressure Pump Gear Bolt 95 lbf-ft 129 Nm
Injector Pressure Control Valve Body 35 lbf-ft 47 Nm
Injector Pressure Control Valve Nut 55 !bf-in 6Nm
Filter Drain Valve 20-25 lhf-in 2.3-2.BNm
Reservoir Lid Screws 75-95 lhl-in 8.5-10.7 Nm

To insure proper torque, all threads must be cleaned and lightly lubricated.
• Apply "Never Seez" compound to threads of bolts prior to assembly.
•• Threads of apply Loctite #277 to bolts prior to assembly.

Changes ar new infarmalian is in bald type.

33
 7.3L DIT Powe r Strok e Diagn ostic Inf arma lian
Diagn aslic &uidas , Scham alics, and Faull Cade

Lists lar all madal yaars ara provid ed in Iha back

al this public alian.

34
□
 7.3L DIT ANTHOLOGY

7.3L DIT ANTHOLOGY

Pre January 1998

Fuel Filter Service
Fuel filter restriction sensor
Note: All individual parts are available for
repair as necessary.
Fuel Filter Restriction Sensor
Removal and Installation
• To remove the fuel filter restriction sensor
first disconnect the one wire connector.
• Then use a 1'/,s" sending unit socket and
remove the sensor in a counter clockwise
direction.
• To reinstall reverse steps and torque
sensor to 35-45 lbf/in (4-5 Nm).

Fuel Pressure Regulator Housing

Removal and lnstallalian
• Remove the two (2) 10mm regulator
retaining cap screws.
• Separate the regulator housing from the filter
housing by approximately 1/4" to enable the
fuel passage shoulder to properly clear the
Regulator housing housing.
• Slide the regulator housing upward to
disengage it from the metal fuel line.

• To reinstall slide regulator housing down to

reengage it with the metal fuel line.
• Align the regulator housing so that the
passage shoulder fits into the fuel filter
housing.

• Reinstall the two (2) 10mm cap screws and

torque to 100-120 lbf/in (11 .3-13.6 Nm).

• Reconnect the fuel pressure sensor one wire

connector.

.... 35
7.3L DIT ANTHOLOGY

Pre January 1998

Fuel Filter Service Water sensor

Water Sensor Removal and

Installation
• Disconnect the one wire connector.
• Use a 9/16" wrench and remove sensor.
• To reinstall reverse steps and torque
to 18-24 lbf/in (2-2.7 Nm)

Fuel H ■ at ■r Connector Removal

and Installation
Note: Water sensor must be removed
before removing fuel heater connector.

• Disconnect the external one wi re

connector.
• Rotate the fuel heater connector clockwise
until it clears the locking tab.
• Pull connector out and disconnect the
internal one wire connector.
• To reinstall reverse steps.

:--,
36
 7.3L DIT ANTHOLOGY

Pre January l 998

Fuel Filter Service
Fuel and Waler Drain Valve
Removal and lnslallalion
• Remove the two phillips head retaining
screws
• Tilt drain valve away from the filter housing,
note the location of the o-rings.
• Pull valve downward to separate from
housing.
• To reinstall drain valve reverse steps and
tighten screws to 20-25 lbf/in
(2.3-2.8 Nm).

Left hand threads

Stand Pipe and Healing Element
Removal and lnslallalion
• Drain fuel from filter housing.
• Remove fuel filter lid and filter element.
• Note: Stand pipe is plastic and has left
hand threads.
• Using a 7/8" crows foot remove stand pipe
by rotating it in a clockwise direction.
• Disconnect the internal one wire
connection at the fuel heater connector.
• Remove fuel heating element.
• To reinstall, reverse steps and tighten
standpipe to 120 lbf/in (13.6 Nm).

37
7.3L DIT ANTHOLOGY

Pre 1997 Model Year

Crankcase
• The crankcase was redesigned starting
with engine serial number 375549 with
thicker valley walls to increase stiffness to
the assembly which reduces radiated
1997 Model Year
engine combustion noise.

• The crankcase was also modified in the

tappet shelf area.

Pre 1997 Model Year

Valve Train t t
• The valve train was redesigned to replace
the cam follower guides and retainer to
redesigned cam follower guide assemblies
which bolt directly into the crankcase to
hold the follower in place.
• The redesigned roller follower guide
assemblies are now held in place with a
capscrew for each pair of tappets which has
led to the elimination of the roller follower
guide retainer. 1997 Model Year

• This change occurred at engine serial

number 375549.

38
□
 7.3L DIT ANTHOLOGY

Pre 1997 Model Year

Cylinder Head Gasket

• Due to the change in the crankcase and
valve train the cylinder head gasket was
also changed.

• The redesigned cylinder head gasket

provides individual holes for each push rod
which will guide the push rod ball seat into
the lifter.

• This redesigned cylinder head gasket can

be used on previous engines.

1997 Model Year

Front Caver
• A dearation valve was inserted in the front
cover beginning with engine serial number
201681 through engine serial number
375549.
• The front cover was redesigned starting with
engine serial number 375549 to help keep
Deaeration valve the oil pump primed for initial start up.
• To accommodate this change the pump inlet
port was rotated 90° which moved the
1997 Model Year pickup tube from the left to the right.
Pre 1997 Model Year
• The front oil cooler header gasket was also
redesigned because of the change to the
front cover.

• The front cover has been modified for the

updated reservoir to front cover gasket and
passages have been cast and drilled into
the front cover to incorporate the standpipe.

• The engine serial number that the standpipe

was incorporated is 201681.
Inlet port

39
7.3L DIT ANTHOLOGY

C... : : Ji :J
One piece
molded gasket

Oil Rasarvair far Iha High

Prassura pump 0-ring seal
As of engine serial number 187100 the
reservoir has been cast and drilled to include ,_____ f l~•'---0-_r_in_g_s_eal_
------
the standpipe and is drilled, tapped and
Standpipe location
spotfaced to use both a straight thread, o ring
sealed engine oil pressure sensor and
inspection plug as sealing enhancements.

1997 Pre 1997

Model year Model year

Oil Pan
Due to the relocation of the pickup tube the
oil pan baffle was redesigned to allow the
pickup tube to pass through it to the bottom
of the pan. This was done as of engine serial
number 375549.

40
□
 7.3L DIT ANTHOLOGY

Fual Injectors Part Numbers

Navistar lnjaclar Part Numhar
On lap al On gald scr■w Canvarlad la
injaclar salanaid raplai:amanl units Fard numhar
FEDERAL 1816187C3 1821836C2 F7TZ9E527 ARM
PRIME 1822803C1 1825125C1 F7TZ9E527 BRM

lnjectars
California calibration, model year 1996- 1997,
utilized a "Split Shot" injector that in
conjunction with the proper PCM calibration
provides rate shaping capabilities. Our rate
shaping provides an initial charge of fuel
early in the injection cycle, followed by a
larger quantity of fuel to complete the
injection cycle. During the 1997 model year
Econoline utilized the "Split Shot" injectors in
all Federal and California calibrations.

• Rate shaping of injection provides for a

longer duration of the injection process,
providing a cleaner, quieter burn.

• Federal "F" Series (49 State and Canada)

injectors were unchanged through the 1997
model year
Note: Injector solenoids are now white in
color instead of the prior black units. No
functional change exists in the solenoids.

All '97 "E" series and Federal "F" series

California "F'' series 1997 Model Fuel System
• The fuel system has been improved by new
fuel supply pipe assembly and banjo fitting.
The new fitting on 1997 Econoline and 1997
California "F" series incorporates an
accumulator to steady fuel pressure for the
"Split Shot'' injection system.

..,
41
7.3L DIT ANTHOLOGY

High Pressure Oil Pump

The high pressure pump has had the drain
check valve deleted. This brings the variation of
high pressure pumps used on the DIT to three. Check valve No check valve
The pumps may be identified by the absence
or presence of the anti drain check valve.

• On 1994 1/2 and 1995 model year engines

up to serial number 187099, the initial high
pressure pump did have a drain check
valve but did not have an edge filter. The
edge filter was part of the injection
1994 1/ 2 1995 1996
pressure regulator.

• On 1995 model year engines starting with

serial number 187100, up to serial number
201680, the high pressure pump did have
a drain check valve and an integral edge
filter. The edge filter was deleted from the
injection pressure regulator.
• On 1996 model year engines starting with
serial number 201681, the high pressure
pump does not have a drain check valve,
but continues to have an integral edge filter. Edge filter and plug No edge filter or plug

Seal added

High Pressure Pump Gasket

• The high pressure pump gasket has been
modified to seal the standpipe between the
pump and front cover.
Note: The correct gasket must be used to
prevent internal and external oil leaks.

:--,
42
 7.3L DIT ANTHOLOGY

lnjaclion Prassura Regulator (IPR)

• On all engines starting with engine serial
number 187100 and above, the injection
pressure regulator does not have an edge
□-ring locations filter, but the high pressure pump does.
Note: There is now a service package for
the IPR o-rings that allow you to replace
them separately if needed.

Oil Pump
The engine lube oil pump has been modified
to include the words "out" or "damper'' on its
face, this is to insure that the pump is
installed correctly and no damage occurs to
the front cover due to incorrect installation.

Wiring Harnass and Glow Plug Ralay

• The wiring harness was redesigned starting
"F" Series "E" Series and
with serial number 375549 to incorporate gold
49 State "F" Series
Calliornia plated terminal pins to increase reliability and
meet OBD II standards.
• The sensors and connectors that received the
gold pins were CMP, EBP, ECT and ICP.
• The UVC harness now incorporates a wire clip
instead of plastic tabs to attach to the injectors
for improved reliability and ease of removal.
• The redesigned glow plug relay system is not
affected by high operating temperatures. This
redesign includes a new relay, relay cover, and
mounting brackets.
• The 1997 Econoline and 1997 California
models also include a new housing post (GPC
sensing) in the redesign.

43
 7.3L DIT ANTHO LOGY

1996 Model Year Pre 1996

Model Year
Tharmasla l
• The thermostat, along with being longer to
seal the lower bypass seat, opens at a
lower coolant temperature, 89° C (192° F)
from 96° C (205° F) to allow the engine to
operate at lower temperatures.

1994 - 1995

Waler Pump
The water pump has evolved since 1994
model year. Currently there are two part
1996 - 1997
numbers to service the Pre January 1998
engines. The F?TZ-8501-ARM pump is to be
used on all 1996 and 1997 model year
engines with serial numbers starting with
201681 through January 1998 production. The
F5TZ-8501 ARM is to be used on all engines
from the 1994 model year serial number
000501 through 1995 model year serial
number 201681. The F5 pump comes with a
bolt package that is to be used to mount the
Either
replacement pump. The F5 pump also pump
incorporates a larger bearing than the 1994 maybe ,_
1996 - 1997
pump, all pumps, new and remanufactured, usad
have an improved silicon carbide seal.

44
 7.3L DIT ANTHOLOGY

Parts Suffix Summary

Camshaft Position S ■nsor (CMP)
Suffix Kay Pin L ■nglh • The CMP sensor has also been changed to
F■ alur ■ s Mal ■ rial
incorporate gold plated pins. There has also
C96* CMP sensor at job 1 94.5 Tin Plated 1.152 ±0.006" been changes in length and circuitry since
C97* Tin Plated 1.152 ±0.006" 1994. To identify each CMP sensor there is
cse· Tin Plated 1.142 ±0.004" a part number suffix located on the top of
C99 Improved Circuitry Tin Plated 1.142 ±0.004" the sensor near the sensor wiring connector.
The CMP with a part number suffix of C96
est· Gold Plated 1.152 ±0.006"
is 1.152" ± 0.006" in length and has tin pins,
C92* Gold Plated 1.142 ±0.004"
this sensor was used in engines with serial
C93 Improved Circuitry Gold Plated 1.142 ±0.004" numbers between 000501 and 033780. A
* No longer availab le as service parts C96 sensor should not be installed as a
replacement sensor. The sensor with a C97
suffix is tin plated and 1.152" ± 0.006" in
length. This sensor has improved circuitry
over the C96 sensor. The C98 sensor is
identical to the C97 except for the length, it
is 1.142" ±0.004" in length.
• Due to the change in wiring harnesses three
new sensors were made with gold pins. The
C91 sensor is 1.152" ± 0.006" in length,
which was used in engine serial numbers
375549 through 408253, and the C92 is
1.142" ± 0.004" in length, which was used in
Part number suffix location engine serial numbers 408253
through 623916. A sensor with a part
number suffix of C93 has gold pins and a
length of 1.142" ±0.004", this sensor has
improved circuitry over the C91 and C92
sensors. The C93 sensor is being used as
of engine serial number 623916.
• The camshaft position sensor circuitry has
been updated to be less sensitive of
clearance to the trigger wheel.
• The part number suffix for the gold pl~ted
sensor is C93 and C99 for the tin plated sensor.

No wear sleeve
Crankshaft
The crankshaft's rear seal no longer utilizes a
wear sleeve on production DIT engines
beginning with engine serial number 201681 .
The service rear crankshaft seal does utilize
a wear sleeve, no change has been made to
the service seal package.

...,
45
 7.3L DIT ANTHO LOGY
I

Oil Caalar Haadar Prassura

Ragulatar and Filtar Bypass
Oil pressure
• As of engine serial number 286299 the oil
regulator with C-clip
pressure regulator and the oil filter bypass
is held in with a c-clip instead of staking.
Note: Bypass valves should be in place to
avoid engine damage.

"Staked" oil
pressure
regulator

46
□
 7.3L DIT ANTHOLOGY

Pre 1996 Model Year 1996 Model Year

Intake Hasas
The hoses connecting the turbocharger
discharge Y pipe to the intake manifolds have
been changed as of engine serial number
201681 to delete the humps and may be
used interchangeably.

Oil Pan Sealing

When resealing the oil pan, make sure that
the silicone is applied properly. Extra sealant
is required at the ends of the radius' on each
end of the pan. Make sure to avoid applying
too much sealant to pan rails since it can fall
off in the pan and plug the oil pick up tube.
Always use dowels (make locally), to locate
the pan during installation. Whenever the oil
pan is resealed, add a bottle of anti foam
Extra sealant required in these locations
concentrate to the oil available at Navistar
dealers (P/N CH1824392).

Fleetrite part number CH1824392

47
 7.3L DIT ANTHO LOGY

lnlaka Cavars
Intake Cover
The number of bolts holding the intake covers • T■ a Ball R ■ placas 8 Ball
in place went from eight (8) to ten (10) this
• l ■ rlal Num• ■ r 17411&
change was done at engine serial number
174666.

Flaxplata
The flywheel/flexplate, as of engine serial
Pl ■ t ■ Thhkna ■■
number 201681 , used in conjunction with
automatic transmissions has been changed • lafr ■ Y ■ • Dur ■ •ilily
for 1996. The flywheel/flexplate's thickness • l ■ rlal Num• ■ r 201181
has been increased to improve strength.

lnjaclar Tarqua
Injector Torque
Injector bolt torque is 120 lbf/in (13.6 Nm).
Failure to properly tighten the bolts may lead to • C ■ rr ■ cl T■ rqu ■ is 120 IH / in (13.& Nm )
engine damage if the copper washer at the
• ln ■ ullhl ■ nl Tarqu ■ Results in Engina

··-···
bottom of the injector burns away and the lower
0-ring melts, allowing fuel to pass the outside of
the injector into the combustion cylinder. It is • All ■ r ■ ngin ■ has •••n running, if tarqua is
common for relaxation to occur and torque ••• ■ uud ii will •• lass than 120 lbf / in
wrenches may indicate less than 120 lbf/in ( 13.8 Nna) - Shauld b ■ high ■ r than
10 1.. / ln (5 . 1 Nm).
(13.6 Nm) on the bolts. If less than 50 lbf/in is
measured with a wrench and an overfueling type
~ concern exists, such as a knock, smoke, or fuel
out the tailpipe, remove the loose injectors for
inspection, and repair as necessary. Remember
when servicing injectors to lubricate the bolt
threads to obtain the proper clamp load and
avoid overtightning the bolts since injector
damage can occur.

IOU CapacHy
The oil capacity on all DIT engines is 14 quarts
1114 •• 12 Guart Capacity
when changing the oil and filter. When released
in 1994, the oil level was described as 12 quarts • Dlp ■Hck R ■ cali•rat ■ d far 14 Guart Capacity
with filter change. The dipstick was changed at in 1111 Mad ■ I Year

the introduction of the 1995 model to indicate full • Ian•••••• Oil Laval Pravid ■ s Batter Oil
when 14 quarts were installed. The benefit of A ■ l' ■li ■ n Prat ■ clian

--,

48
en 7.3L Diesel Pin Out Values -1994 1/2
Cl

Pin# Name Circuit# Wire Color Key Off Key On Low Idle High Idle Operating Comments
Ranae
2 STO/M IL 658 PK-LG 0v B+ B+ B+ B+ 0v-Liaht On 12v-Liaht Off
4 PBA 977D P-W 0v 12v/0v 12v/0v 12v/0v 12v/0v Parkin □ Brake Aaalied Switch "Ua/Down"
5 IVS 308 R-O 0v/0v 0v/12v 0v 12v 0v/ 12v Idle Validation Switch PPS Pedal "Ua/Down"
13 FEPS 107 p N/A N/A N/A N/A N/A Flash EPROM Power Sunnlv
15 BUSI-\ 915 PK-LB N/A N/A N/A N/A N/A Not Used
16 BUSI+\ 914 T-O N/A N/A N/A N/A N/A Not Used
25 CASE GND 57Z BK 0v 0v 0v 0v 0v Case Ground
29 CPP 306 T-LB /0v 12v/0v 12v/0v 12v/0v 12v/0v Clutch Pedal Position Switch "Uo/Down"
30 EBP 553 P-LB 0v .8v-.95v .8v-.95v 1.25v-1.75v .8v-3v Exhaust Back Pressure Sensor
31 BPA 307 BK-Y 0v/0v 12v/0v 12v/0v 12v/0v 12v/0v Brake Pedal Annlied "Ua/Down"
33 VSS- 676 PK-O 0v 0v 0v 0v 0v Vehicle Saeed Sensor Ground
34 MAP 358 LG-BK .2-.5v 2.5v 2.5v 2.5v 110-186 Hz Manifold Pressure 110/ 113 Hz - At. Press.
38 EQT 354 LG-R 0v .35v-4.5v .35v-4.5v .35v-4.5v .75v - 212°F Ennine Oil Terna. 4.7v - -40°F/.68v - 230°F
39 IAT 743 GY 0v .35v-4.5v .35v-4.5v .35v-4.5v 3.07v - 68°F Intake Air Terna. 4.53v = -40°F/.358v - 230°F
40 SC GND 848 D-GO 0v 0v 0v 0v 0v Sneed Control Ground
42 EPA 318 GY-R 0v 6-8v 6-8v 0v 0v-10v Exhaust Back Pressure Volt. onlv when enabled
48 EF 818 GY-W 3-4 v/83 Hz .6v Electronic Feedback line diaital 12v freauencv
49 CMP 795 DG 0v 12v/2.5v 7v 7v 130-720 Hz Camshaft Position Sensor 650-3600 RPM
50 TAC 648 W-PK 0v 12v 6.5v/130 Hz 6.5v/660 Hz 130-720 Hz Tachometer Sianal Reflected CMP Sianal
51 PWR GND 570A BK-W 0v 0v 0v 0v 0v Power Ground
55 KAPWR 37E y B+ B+ B+ B+ B+ Keen Alive Power B+ - batterv voltaae
58 VSS+ 679 GY-BK Freauencv Sianal - Varies with Vehicle Sneed Vehicle Sneed Sinnal
61 SCCS 151 LB-BK 0v 0v to 12v 0v to 12v 0vto 12v 0v to 12v Sneed Control voltaae will varv w/ switch nosition
65 CMP GND 570 BK-W 0v 0v 0v 0v 0v Camshaft nosition sensor around
66 STI 209 W-P 0v 5v 5v 5v Self Test lnnut 0v
70 IDM EN 814 W-BK 0v 12V->0V 0v 0v 12v/0v IDM Relav 12v - IDM Off 0v - IDM On
71 VPWR 361B R 0v B+ B+ B+ B+ lnnition source nwr.
76 PWR GND 570B BK-W 0v 0v 0v 0v 0v Power Ground
77 PWRGND 570C BK-W 0v 0v 0v 0v 0v Power Ground
80 GPL 464 BK-PK 0v 0v/12v 12v 12v 0v/12v Glow Plun Lamn 0v - Linht On 12v - Liaht Off
83 IPR 552 Y-R 0v 12v 12v 12v 12v lniection Pressure Ren. Dutv Cvcle Controlled
84 BARO 356 DB-LG .75v-3v .75v-4.9v .75v-4.9v .75v-4.9v .75v-4.9v 4.64v at 100 kPa /sea level\ 2.6v at 60 kPa 110 000 ft.\
87 ICP 812 DB-LG 0v .25-.4v .75-1v 1.1-1 .5v .65-3.25v lniection Control Pressure lMin .83v rea. for startina\
89 AP 355 GY-W 0v .5-4v .5-.9v 3.8-4.2v Accelerator Pedal Sensor
90 V REF 351 BR-W .41v 5.0±.5v 5.0±.5v 5.0±.5V 5.0±.5v Voltaae Reference
91 SIG GAD 359 GY-R 0v 0v 0v 0v 0v Ground for all sensor sinnals
92 BOO 511 LG 0v/12v 0v/12v 0v/12v 0v/12v 0v/12v Brake On/Off Switch "Un/Down"
95 FDCS 821 BR-O 0v .5v 1v/49 Hz 2.7v/200 Hz 43/240 Hz Fuel Deliverv Control Sianal 650-3600 RPM
96 CID 817 Y-LB 0v .5v 6v/5 Hz 6v/720 Hz 5 Hz-720 Hz Cvlinder Identification
97 VPWR 361A R 0v B+ B+ B+ B+ lanition source nwr.
101 GPC 1090 P-O 0v 0v/12v 0v/12v 12v Glow Plua Cntrl. 0v...,/GP relav On\ 12v-,/GP relav off\
103 PWRGND 570D BK-W 0v 0v 0v 0v 0v Power Ground

D
l I

7.3b/T Electronic Engine Controls 1994 ½

Engine Mounted Components Truck Mounted Components Cab Mounted Components
PCM Connector

;
EOT ICP EBP MAP IAT Pin Numbers (104)

~ § ~ 42Way
Q .....~~ ......,
.•...I!!! . . . . •.
1• KAPWR

AP Sensor
B+

I
r-----
!
I 8
u. . V
AP
I
I
I

Ase l I ABC Connector

~,'-;' i
_ "lt,PJ,iQDaL
I
. .... ?.......
I· ....~~ ...... 1 IV..§ Sl9n.,!!I
I I IVS I

'I
------ 34
20 I -, EBP Sianal l · · · · ·30 ······ I

I 'II'----------i
'I 1::;r:
..
: ' """".:' .'"' ' ?-?-. • • ICP Sianal
:::::~::::::· """·~
•• • • •1!7'. •••••
!~~YPW~ _J
13 GPC IControll 101
··;;.••• EOTSignal • •• • •38··· ··
······· KEYPWR
:::::~~::::: IBAROSignal I SJ
.. ~?... -
r+-----------------------1 ...3.3••••,
.. ~ti ... __ __
CMPGround
.fMf Sjgn!J _ _ _ ]
J ___ I·.....~~ .....
- •• • • • •1!!.. . . .
••••••6.6• .•. • • 1 s11 E3I
~ ••• } Signal GND
2 6
.1!:'i!".:tor ~! .- ' - ' - ' - ' - ' - ' - ' - .- ' - .- .- .- .- . - .- .... 3. . . . . . STO/MIL 1,
I 1· - . - ' - . - . - ,·. ·;; ·.
15 BUS·
Injector #3 5 ,-·-·-·-··· ........ . ····•1s····· BUS+ ~
~ ; · · · · - · - · - · - · - 'j;,j1;""c_
iir.'i[s.':.':.':.':.':.':.': ............. \!
... 1... 1
·-·-·-·-·-1
_. _. _. _. _. ···ll···
7 • •• • •~~. .. . . VSS-
, , ; lniector #7 .. ?-9••• . . . . . .~~. . . . . vss +
CMP I~ ~ - • ·- · · · -·-· 16 CID
••••••9.6•• ••••
17 FDCS
••••••9.5•••• • •
A BC DE ABC DE 4 EF Feedback
• • • • ••4.8••••••
Glow Plug 120 volts 12 INJHI_R 24 29 I CPP (switch)
IDM
Relay
Connector .I
• •••••3.1•••• _ BPA (switch) d KEVPWR
KEYPWR

. .....~~ ..... ( BOO ( ..,,__,_KEYPWR

26 PWR GND (I• ,~ o sr'itch)
. ----,1,
120 volts 11 INJHI_L
B+ _ _ __,
23
ttciay • •• •• .~Q. • • • • r~rL. \ VUllu v ., ' ..,__KEYPWR

EDC BA E D C B A !07 1 .....7'.C! ••• ••

...... ~. . . . . . ( PBA ( ~ KEYPWR

~ ··1 , 1
Starter Motor ,-_!!'BA Switch)
Relay . . !~. 11 . ----,1, 0

~ n j e c t o r #8 , _, _
(Fusable Links)
l-·-·-·-·- ' 1.. ....~~. . . . I CASE GND (I·

t... ~. ...-.-'-'-.-I· ..
10 9 PCM PWR
Relay
. ~!! ' - ' - ' - . - ' -
'. - 'l!)i~.:t.o! 1.~ ••
'.. ,l,!:'i,e:~O!~! . _, _, _. _, _, _, _, _, _. _, _. _. _, ... 9•• , , _, _, _, _, _ 7
5.1;~~•??,1<!~.1 PWRGND
~ _1,n1e_c !~r!~_, _. _. _. _. _. _. _. _, _, _, _, _, _, _, _ ... ~... , _. _. _. _. _
. .

71,97
IJ,
TAC

_______________ : :
24 VPWR
:~L ____ l~R ~ o!!_tr,W __ :::::.~Ci°::::· ,TAC (Control) I
OC)j"
1

1 ...............
83 .....
, •••1.6. • •
PWR GND I• FEPS
_ _ _ _ _ , ••• ~~... _ _ _ _ !iPRJ C~nt~ I)_
I::::::~~·:::::
IPR
en , ... . :~(! .. .. . SC GND
.... EPA (Dotted Lines = Frequency or Switch Functions) .• .... ~!. . . . . SCCS (to Speed Control Switches)

RED-12 VOLTS BLACK - GROUND CIRCUIT GREEN - SIGNAL CIRCUIT PURPLE= HIGH VOLTAGE BLUE-VREF 15 VOLTS)
 Power Stroke 1994 1/2
Fault J2012 Circuit Condition Probable
Code Code Index Descriotion Comments Causes
827 0107 BARO BARO circuit out of ranne low Defaults to 101 Koa Ooen/Grounded circuit biased sensor or PCM
864 0571 BPA Brake oedal aoc lied switch fail Switch Test - KOER /Code set if cruise not 0 resentl
828 0108 BARO BARO circuit out of ranne hinh Defaults to 101 Koa Circuit shorted to 5v, biased sensor or PCM
512 0603 PCED KAM memorv loss No historical faults outout durina a KOEO test Ooen PCM oin disconnected B+ faultv PCM
151 0112 IAT IAT circuit out of ran°e low Disables back oressure device Grounded circuit biased sensor or PCM
511 0605 PCED PCM ROM test failure Internal PCM failure
152 0113 IAT IAT circuit out of ranne hlnh Disables back oressure device Ooen circuit biased sensor or PCM short to 5V
523 0606 PCED PCM Inactive Backnround fault Internal PCM fault Internal PCM failure
122· 0122 AP/IVS AP Sensor Siona! ORL Enaine will idle onlv if hard fault Grounded circuit biased sensor or PCM
536 0703 BOO Brake On/Off switch circuit failure Switch Test - KOER activate switch KOER.
123• 0123 AP/IVS AP Sensor Siana! ORH Enaine will idle onlv if hard fault Ooen circuit biased sensor or PCM short to 5V
528 0704 CPP CPP switch circuit failure Switch Test - KOER Qnenfshort circuit Switch/ PCM failure failed to
116 0195 EOT EOT above/below KOER limits Aborts KOER test Enaine not uo to ooeratina temo., leakinn thermostat
675 0705 TR TR sensor circuit malfunction
117' 0197' EOT EOT circuit out of ranne low No cold adv. fast low idle EBP disabled Grounded circuit biased sensor or PCM
667 0707 TR TR sensor circuit low innut
118. 0198• EQT EOT circuit out of ranne hinh No cold adv. fast low idle EBP disabled Onen circuit biased sensor or PCM short to 5V
668 0708 TR TR sensor circuit hinh innut
815 0219 PCED Excessive Enaine RPM Transmission incorrectly downshifted or wronn near selected down hill
638 0712 TFT Trans fluid temp sensor ckt low innut
124· 0220· AP/IVS Idle validation switch fail Switch Test -KOER ShorUOnen circuit switch failure ooerator PCM
637 0713 TFT Trans fluid temo sensor ckt hinh inout
125• 0221· AP/IVS Idle validation switch fail Enc ine will idle onlv if hard fault Failed Pedal Assemblv
629 0741 TCC Converter Clutch Solenoid Failure
127' 0235• MAP MAP Inactive sinnal Uses Inferred MAP sianal Onen short to and or 5v faultv sensor
621 0750 SS1 Shift Solenoid 1 malfunction
128· 0236. MAP MAP ln-ranae failure Uses Inferred MAP sianal Restricted inlet/exhaust/suoolv hose tam 0 erina
622 0755 SS2 Shift Solenoid 2 malfunction
126· 0237" MAP MAP sianal out of ranne hi0 Mow Uses Inferred MAP sianal Noise faultv sensor Intermittent ooen
617 0781 1-2 Shift Error
921· 0261· INJ Low side short to nrd. in•. crkt. #1 FMEM mode enaine will run on 4 C\JI. Harness short to around
618 0782 2-3 Shift Error
931 0262 INJ Low side short to bat. in•. crk1. #1 FMEM mode enoine will run on 4 c\JI. Miswired connector or harness
619 0783 3-4 Shift Error
941 0263 PCED C, linder fault #1 - CCT Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem
111 1111 N/A Svstem Pass No PCM svstem faults detected N/A
922· 0264. INJ Low side short to nrd. ini. crk1. #2 FMEM mode enaine will run on 4 cvl. Harness short to around
841 1211 IPR ICP oressure is Above/Below Desired Continuous & On Demand Test - KOER Failed/stuck IPR valve
932 0265 INJ Low side short to bat. ini. crkt. #2 FMEM mode ennine will run on 4 cvl. Miswired connector or harness
819 1212 ICP ICP hiaher than exnected KOEO Sensor volt not at exoected level with KOEO Biased sensor or circuit
942 0266 PCED Cslinder fault #2 - CCT Cslinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem
915 1218 PCM/IDM CID stuck hiah c,1. identification line stuck hiah (historical fault onlv\ CID circuit onen most /ikelv on intermittent basis
923• 0267" INJ Low side short to nrd. ini. crkt. #3 FMEM mode ennine will run on 4 cvl. Harness short to nround
916- 1219 PCM/IDM CID stuck low c,I. identification line stuck low (historical fault onlv\ CID circuit short to nround most likelv intermittent on1v
933 0268 INJ Low side short to bat. ini. crk1. #3 FMEM mode ennine will run on 4 cvl. Miswired connector or harness
961- 968 1261-12681NJ Hinh to low side short cvl#1 - #8 Bank with fault will be commanded off Short circuit shorted iniector failed IDM
943 0269 PCED Cslinder fault #3 • CCT Cslinder not contributin□ durina CCT test Power cvlinder valve train or inlector oroblem
971- 978 1271-12781NJ Hiah to low side ooen cvl#1 - #8 Bank with fault will be commanded off Onen circuit Onen iniector failed IDM
924• 0210· INJ Low side short to ord. ini. crkt. #4 FMEM mode en□ine will run on 4 cvl. Harness short to nround
153 1280 ICP ICP circuit out of ranoe low Uses inferred ICP strateav Onen/Grounded circuit biased sensor or PCM
934 0271 INJ Low side short to bat. in•. crkt. #4 FMEM mode, en□ine will run on 4 C"I. Miswired connector or harness
154 1281 ICP ICP circuit out of ranne hinh Uses inferred ICP strateov Circuit shorted to 5v biased sensor or PCM
944 0272 PCED Cvlinder fault #4 - CCT Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector oroblem
155 1282 IPR Excessive ICP oressure Svstem fault Faultv IPR reaulator lstickina\ IPR shorted to around
925• 0273' INJ Low side short to nrd. in•. crk1. #5 FMEM mode enaine will run on 4 c\11. Harness short to around
546 935 0274 INJ Low side short to bat. inj. crk1. #5 FMEM mode, engine will run on 4 cyl. :
Miswired connector or harness
945 0275 PCED Cvlinder fault #5 - CCT Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem
926. 0275• INJ Low side short to nrd. ini. crkt. #6 FMEM mode enc ine will run on 4 cvl. Harness short to around
992 936 0277 INJ Low side short to bat. inj. crkt. #6 FMEM mode, engine will run on 4 cyl.
Miswired connector or harness
946 0278 PCED Cvlinder fault #6 - CCT Cvlinder not contributina durina CCT test Power~ linder valve train or iniector nroblem
927' 0279• INJ Low side short to nrd. in;. crkt. #7 FMEM mode encine will run on 4 cvl. Harness short to around
995' 1295• INJ Multiole faults on bank #1 lrinhtl Fix low side short and rerun diaonostics Miswired connector or harness short to nround
937 0280 INJ Low side short to bat. ini. crkt. #7 FMEM mode enc ine will run on 4 cvl. Miswired connector or harness
947 0281 PCED Cvlinder fault #7 - CCT Cvlinder not contributina durina CCT test Power C\ linder valve train or iniector nroblem
997 1297 INJ Hiah sides shorted tonether Shorted wires faultv IDM
928· 0282' INJ Low side short to □rd. ini. crkt. #8 FMEM mode ennine will run on 4 cvl. Harness short to nround
938 0283 INJ Low side short to bat. ini. crkt. #8 FMEM mode ennine will run on 4 cvl. Miswired connector or harness
539 1464 N/A A/C on durina KOER Aborts KOER test N/A
948 0284 PCED Cvlinder fault #8 - CCT Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem
843 1501 N/A Vehicle moved durin□ KOER Aborts KOER Test N/A
818 0340 CMP Inactive CMP sensor No CMP sensor sianal detected durina crankinn Onen/nrounded circuiUsensor fault
844 1530 N/A Invalid CCT test - oedal movement Aborts KOER Test N/A
817 0341 CMP Noise Reiection Electrical Noise Detected Harness routinn charninn circuit oroblems sensor fault
863 1536 PBA PBA oarkina brake aoolied fail Switch Test - KOER Ooen/short circuit., Switch/PCM failure, failed to

52 ..
r7
 POWERTRAIN CONTROL SYSTEM
ELECTRONICS DIAGNOSTIC GUIDE
Fault J2012 Circuit Condition Probable
Code Code Index Descriotion Comments Causes
816 0344 CMP CMP/SYNC Counts Incorrect number of CMP transition counts CAMP Sensor fault Noise Couolinn
549 1662 PCED IDM EN circuit failure IDM Enable Relav OCC - KOEO onlv Qnen relav blown fuse ocen arounded circuit
515 0380 GP GP relav cutout circuit failure Glow Plun Relav OCC - KOEO onlv Onen/arounded crkt. solenoid ooen/shorted failed PCM
956 1663 PCM/IDM FDCS circuit failure Fuel demand command sianal - OCC check - KOEO Onen /arounded circuit faultv IDM
516 0381 GP GP Lame cutout circuit failure Glow Plun Lamp OCC - KOEO onlv Onen/nrounded circuit lamo ooen failed PCM
955 1667 PCM/IDM CID circuit failure Cvl. identification circuit -OCC check - KOEO onlv Onen /nrounded circuit faultv IDM
145 0472 EBP ESP circuit out of ranne low Disables back nressure device Onan/Grounded circuit biased sensor or PCM
983 1668 PCM/IDM PCM-IDM diaa. communicalion error Communication on EF (Electronic Feedback linel Onen/shorled EF or FDCS wire onen IDM nrd.
146 0473 EBP ESP circuil oul of ranne hinh Disables back nressure device Circuit shorted to 5v biased sensor o r PCM
654 1705 TR TR sensor out of self test ranne
514 0475 EPA EPA circuit failure Exhaust Back nressure Reaulator OCC Onen/nrounded crkt. solenoid ooen/shorted failed PCM
636 1706 Hinh vehicle speed in Park
842 0476 EPA ESP nressure Above/Below Desired On Demand Test - KOER Failed/stuck EPA valve
636 7 8 1711 TFT TFT sensor out of self test ranae
147 0478 EPA Excessive back n.ressure Disables back oressure device Plunned sensor line stuck butterllv restricted exhaust
628 1728 Trans. slio Iconverter clutch failed\
452 0500 vss Vehicle soeed sensor malfunction
691 1729 4x4L 4x4 Low Switch Error
845 0560 PCED B+. volt too low for CCT test Aborts KOER Test Charoina svstem oroblem/load nlow nluns still enabled
625 1746 EPC EPC solenoid onen circuit
518 0562 PCED Batterv voltaae below normal Mav be temoorarv condition at crank onl\f. Low Svst. Voltaae Charoina Svs. Internal PCM failure
624 1747 EPC EPC solenoid short circuit
517 0563 PCED Batterv voltaae above normal Mav be temoorarv condition - 24V iumn start Hiah Svst. Voltaae, Charoina Svs. Internal PCM failure
1748 EPC EPC malfunction
831 0565 PCED Spd Cntrl ON not pressed Switch Test - KOER (Code set if cruise not present) Open or short circuit, Switch failure,
PCM failure or failed
641 1754 ccs Coast Clutch Solenoid ckt. malfunction
832 0566 PCED Sod Cntrl OFF not nressed Switch Test - KOER (Code set if cruise not nresentl to activate switch durina the KOER test.
631 1779 TCIL TCIL circuit out of self test ranne
833 0567 PCED Snd Cntrl RESUME not nressed Switch Test - KOER (Code set if cruise not nresentl
632 1780 TCS TCS circuit out of self test ranne
834 0568 PCED Sod Cntrl SET not oressed Switch Test - KOER /Code set if cruise not nresentl Cruise control codes will be set on everv switch test
691 1781 4X4L 4X4L circuit out of self test ranne
835 0569 PCED Sod Cntrl COAST not nressed Switch Test • KOER /Code set if cruise not nresentl on vehicles not enuipped with cruise control.
657 1783 TFT Transmission Overtemperature Condition

• Indicate MIL lamp illuminated when fault present

PCEO "" Powertrain Control Emissions Diagnostic Manual

KOEO - Standard Test KOER Key On Engine Running -Standard Test

Turn all accessories off
• Turn all accessories off
' • Set STAR tester to Fast Code position
• Engine oil temperature must be up to a minimum of
• Latch STAR test button on (ground STI) 176°F (80°C)
• Turn key to ON position • Set Star tester to Fast Code position, latch Star test button on
• Unlatching the STAR tester during "fast'' code transmission will (ground STI), start engine
clear all codes in the PCM • After Code 50 is transmitted, depress and release the following
(They will be stored in the STAR tester for viewing) switches:
- Accelerator Pedal (must depress and release first)
- Cruise Control On, Off, Resume, Set/Accel, Coast
KOEO Key On Engine Off - Buzz Test
-Emergency Brake and Clutch Pedal
• Turn all accessories off - Brake Pedal (must depress and release last) - S'tab firmly to
• Latch STAR test button on (ground STI) activate brake pressure switch

• Turn key to ON position • At the end of the switch test the PCM will perform the ICP and
EBP step tests
• After "fast" code transmission depress and release brake to abort
slow codes • Depressing and releasing the brake pedal after the last test will
stop the CCT test and allow the PCM to transmit codes
• Depress and release accelerator pedal to start test
KOER Cylinder Contribution Test
• Codes wi ll be displayed at end of test
• This test will run automatically after a KOER test
(Test can be repeated by depressing and releasing accelerator • Codes 51 thru 58 will be transmitted to indicate the cylinder under
pedal twice) test

Note: The engine will run rough during the KOER • Pass or fail codes will be transmitted at end of test
Standard and Cylinder Contribution Tests!
• This test can be accessed directly by starting a KOER test
depressing and releasing the accelerator pedal once and the
brake pedal two times (Ignore resultant switch codes)

53
 7.3L Diesel Pin Out Values - 1996
UI
lllo Pin# Name Circuit# Wire Color Key Off Key On Low Idle Operating
High Idle Comments
Ranae
1a SS2 315 P-O 0v 12v 12v 12v 0v/12v Shift Solenoid #2 0v = "On" 12v = "Off"
2 Check 658 PK-LG 0v B+ B+ B+ B+ 0v=Light On, 12v=Light Off
Enaine Liaht
40 PBA 977D P-W 0v 12v/0v 12v/0v 12v/0v 12v/0v Parkin□ Brake Annlied Switch "Un/Down"
5 IVS 308 R-0 0v 0v/12v 0v 12v 0v/12v Idle Validation Switch "Un/Down"· Ooen at idle
13 FEPS 107 p N/A N/A N/A N/A N/A Flash EPROM Power Sunnlv
14a 4X4L 784 LB-BK 0v 12v/0v 12v/0v 12v/0v 12v/0v 4x4 Low Switch 12v = "Off" 0v = "On"
15 BUS/-) 915 PK-LB N/A N/A N/A N/A N/A Data Link Connector
16 BUS/+l 914 T-O N/A N/A N/A N/A N/A Data Link Connector
25 CASE GND 57Z BK 0v 0v 0v 0v 0v Case Ground
27a SS1 237 O-Y 0v 0v 0v 0v 0v/12v Shift Solenoid #1 0v = "On" 12v = "Off"
28a TCC 480 P-Y 0v 12v 12v 12v 0v/ 12v Converter Clutch Solenoid 0v = "On" 12v = "Off"
29 CPP(Manl) 306 T-LB 0v 12v/0v 12v/0v 12v/0v 12v/0v Clutch Pedal Position Switch (Manual)
TCS/Auto\ 224 T/W 0v 12v/0v 12v/0v 12v/0v 12v/0v Transmission Control Switch (Automatic\
30 EBP 553 P-LB 0v .8v-.95v .8v-.95v 1.25v-1.75v .8v-3v Exhaust Back Pressure Sensor
31c BPA 307 BK-Y 0v 12v/0v 12v/0v 12v/0v 12v/0v Brake Pedal Annlied "Uo/Down"
33 VSS/-l 676 PK-O 0v 0v 0v 0v 0v Vehicle Saeed Sensor Ground
34 MAP 358 LG-BK .2v-.5v 2.5v 2.5v 2.5v 110-186 Hz Manifold Pressure 110/1 13 Hz - At. Press.
37a TFT 923 O-BK 0v .3v-4.5v .3v-4.5v .3v-4.5v .46v-212°F Transmission Fluid Tern□. 4.5v--40°F/.3v-230°F
38 EOT 354 LG-R 0v .35v-4.5v .35v-4.5v .35v-4.5v .75v-212°F Ennine Oil Tern□. 4.7v--40°F/ .68v-230°F
39 IAT 743 GY 0v .35v-4.5v .35v-4.5v .35v-4.5v 3.07v=68°F Intake Air Terna. 4.53v--40°F/.358v-230°F
40d SCGND 848 DG-O 0v 0v 0v 0v 0v Sneed Control Ground
41a,e ACC 198 DG-O 0v 12v/0v 12v/Ov 12v/0v 12v/0v Air Conditionina Clutch 12v = "On" 0v = "Off"
42 EPR 318 GY-R 0v 6v-8v 6v-8v 0v 0v-1 0v Exhaust Back Pressure Volt. onlv when enabled
48 EF 818 GY-W 0v 3.3v ava. .4v-2.2v 1.9v-2.2v .4v-2.2v Electronic Feedback Line diaital 12v freauencv
49 CMP 795 DG 0v 12v/2.5v 7v 7v 130-720 Hz Camshaft Position Sensor 650-3600 RPM
509 TAC 648 W-PK 0v 12v 6.5v/130 Hz 6.5v/660 Hz 130-720 Hz Tachometer Sianal Reflected CMP Sianal
51 PWRGND 570A BK-W 0v 0v 0v 0v 0v Power Ground
53a ccs 924 BR-O Ov 0v 0v 0v 0v/12v Coast Clutch Solenoid 0v = "On" 12v = "Off"
55 KAPWR 37E y B+ B+ B+ B+ B+ Keen Alive Power B+ - batterv voltaae
58 VSS(+\ 679 GY-BK Frenuencv Sinnal - Varies with Vehicle Saeed Vehicle Saeed Sinnal
61 SCCS 151 LB-BK 0v 0v to 12v 0v to 12v 0v to 12v 0v to 12v Cruise Cntl. Voltaae will varv with switch oosition
54a TR 199 LB-Y 0v 4.5v 4.5v 4.5v 0v-4.5v Transmission Range Sensor P = 4.5v, R = 3.7v,
N = 2.9v D = 2.2v MAN2 = 1.4v MAN1 = .7v
65 CMP GND 796 LB 0v 0v 0v 0v 0v Camshaft oosition sensor around
70 IDM EN 814 W-BK 0v 12V·>0V 0v 0v 12v/0v IDM Relav 12v = IDM Off 0v = IDM On
71 VPW R 361B R 0v B+ B+ B+ B+ lonition source owr.
76 PWR GND 570B BK-W 0v 0v 0v 0v 0v Power Ground
77 PWR GND 570C BK-W 0v 0v 0v 0v 0v Power Ground
79a TCIL 911 W-LG 0v 12v/0v 12v/0v 12v/0v 12v/0v Trans Control Indicator Liaht 12v = "Off" 0v = "On"
80 GPL 464 BK-PK 0v 0v/12v 12v 12v 0v/12v Glow Plua Lam□ 0v = Liaht On 12v = Liaht Off
81a EPC 925 W-Y 0v 4.5v 7.5v 12v 7.5v-12v Electronic Pressure Control Solenoid
83 IPR 552 Y-R 0v 12v 12v 12v 12v lniection Pressure Reo. Dutv Cvcle Controlled
84 BARO 356 DB-LG .75v-3v .75v-4.9v .75v-4.9v .75v-4.9v .75v-4.9v 4.64v at 100 kPa /sea level) 2.6v at 60 kPa /10 000 ft.}
871 ICP 812 DB-LG 0v .25v-.4v .75v-1v 1.1v-1 .5v .65v-3.25v lniection Control Pressure /Min . .83v rea. for startina\
89 AP 355 GY-W 0v .5v-4v .5v-.9v 3.8v-4.2v .5v-4v Accelerator Pedal Sensor
90 V REF 351 BR-W .41v 5.0±.5v 5.0±.5v 5.0+.5v 5.0±.5v Voltaae Reference
91 SIG GRD 359 GY-R 0v 0v 0v 0v 0v Ground for all sensor sianals
92 BOO 511 LG 0v/12v 0v/12v 0v/ 12v 0v/12v 0v/12v Brake On/Off Switch "Uo/Down"
95 FDCS 821 BR-O 0v .5v 1v-49 Hz 2.7v/200 Hz 43-240 Hz Fuel Deliverv Control Sianal 650-3600 RPM
96 CID 817 Y-LB 0v .5v 6v/5 hZ 6v/720 hZ 5 Hz-720 Hz Cvlinder Identification
97 VPWR 361A R 0v B+ B+ B+ B+ lanition source owr.
101 GPC 1086 P-O 0v 0v/12v 0v/12v 12v 0v/12v Glow Plua Cntrl. 0v=/GP relav On) 12v=(GP rerlav off)
103 PWR GND 570D BK-W 0v 0v 0v 0v 0v Power Ground
a E40D transmission only d 563 (0/V) for Econoline applications g Not used on Econoline applications
b 162 (LG/R) for Econoline applications e 347 (BK/Y) for Econoline applications
c 81 o (R/LG) for Econoline applications f 535 (LB/R) for Econoline applications

□
L I

I
7.3L DI Turbo Diesel Powertrain Control System Schematic - 1995/1996
Engjne Mounted Vehicle Mounted Components Cab Mounted
Components PCM Connector
Components

n¥ ::::::r::::·
: : : :::.
CMP EOT ICP EBP MAP IAT TR Pin Numbers (104)

~ ~ ~
-----,
P11i A : : : : :al
I
I

ti; ~ ~ ~
AP

WLl T!I S! gn_:!I IV~ S!!Jn~

42 Way
= •... ·ss ....
33 vss-
VSS +
~
- - , ~ 1vs!
I I I
•, c Connector , c• IAT Signal •••••
39 · · · · ·
: ~{:{:~:ic : : : : :::::f::::
I I

20 - - - - -
I ~E~PWR- l
'-if-----<l.+-if-----<I~--------+:::: ~L::: Si nal Ground : : : : :i1: : : : : : Signal Ground!

~
I • ••. ~) . • • • • VREF •••• .!!Q • • • • • VREF
I L--------------+··· ·??... .. ICPSi nal ••• ••1!7'. •••••
I '-------------------! .... )?. . . . . EQT Si nal • • •••~I!._._.
I 84 BA_8Q _S_ignal
I 33 CMP Ground ••• • • 65 .... .
I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ::: j~::::: __________ _ _£M.f S.!_g"!I _ _ _ __ _ :::: :-ii::::· BARO

. - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ •••••1_3. .. . . GPC Control • • • • 1~1 . ___

r--------------------------1 .... ?~... .. KEYPWR
IDM
37
·····s:i· ····1 SCAN TOOL

1119
r i : ~fi:=~·1,
Connector

Injector #1
1•-·-·-·-·-·-·-·-·-·-
lnjector#3 ·-·- ·-·-·· ······ ·-· 2
5
/•••• .~6 .... \ __ E40D
SOLENOID
ASSEMBLY
r,. -:::Jf::::l
u-- -,. .....8.1•••••
_1"-11-....::!::::::..J 1
21
··- ·-·-·- ·-·-·-·- ·-·-·-·-·-·-·-·- ·-· •••••·•·•·.1j.·.·.·.·..l.F!:!E:!P::.::_S~ ~ l -+--t__.
7
I ~n!:C,t~r,"._5, • ' - ' • ' - ' -
I ' . -. -...... . 8 16 i-:B
: :U
::S::..+
.:.....--11--•
Injector#? 4 20 :::::~~::::: BUS· KEYPWR
I •• • • • • • • • • • • • • • •

A B C D E ABCDE
• •• ••1.6•• ••• 1- - -
CID
- - - - - ---- •••••9.6•••••

·····Y···••I- - ------
FDCS
---- - - •••••9.5•••••
Glow Plug
Relay ('1?'1'J) ~
~II)) High Voltage
.... ~~..... I INJHI_R I ,... 2.4•••••
EF Feedback
------ •••••4.a•• • • •
51,76,77,103 PWR GND
•••• •••••••• I•
APC MODULE

~.1. .... +-A_c_c_ _ _ _

~
26 PWR GND •••• - -...., KEYPWR
High Voltage ~I• 14 4X4L KEYPWR
• • • • •1~ •••• • 1 I .. .2.3• ••••
ld;Jll) INJHI L IDMPWR · · •• • •••• •• •

B+ ~ ~
Starter Motor {!I I I I I
16 1
f{i i i I I IJ}
Relay
IDM
IDM_EN 70
• • • • •~~ • • • •• TCS (Automatic
~I•
KEYPWR
Relay EDCBA 14 PWR •••.·29 .. .. . CPP (Manual) KEYPWR
(Fusable Links) ,
E D C B A
...... ... .. ............
10
~- !~':"!~':.~8-. - . -

~◄•-1•__
I 9

~ ~~j~~t~'. ~~ -
~ Injector #4

~~ : : : : : : : : : : : :
'- '- '- '-
···
8
········
..... ......
6 ,. :::::::::r·.........
n B+ ~....,-,,1• : : : :; : : : : ~;(Coo,011 ; ;;;;
: ;';.;..;..
~-" R
:
W.;..;
; _l~j~§t~~ : : : : :: : : : : : : : : : : : : . . ...~ ..... ' - ' -' -' -' - ..... 4..... +-P_B_A...;.._ _ _ ® KEYPWR
.. ..... .. .. . @ -----"-,;.;._
I- - - - ------
. - - - - - - - - - - - - - - - - -, : : :: ;;: : : : : _ _ _ _ _ _ _ _ _ _ _ _ __ 11; ~ : ~ro!) _ .:: : :~f::: '---ii,
•l
•I - __ - j ....
....)!>... .. I•
~?..... __________________
PWR GND KEYPWR
E!:!,R ~ o!!tr~ )
•• • ••~~ • • • • • CASE GND
..... ~?-.. ...
I•
TAC

~
\.. ~ 50 TAC (Control)

en IPR EPA
J •····3;- ····
.. ........ ..
•••• • ~. • • • •
BPA

Check Engine Light ll'i\--- KEYPWR

KEYPWR

en 61 SCCS ~
.....40 ... .. SC GND (to Speed Control Switches]
(Dotted Lines= Frequency or Switch Functions) (Orientation = Looking into harness side of connector) \:_· ... ... ·_:;,
REP= 12 VOLTS BLACK - GROUND CIRCUIT GREEN = SIGNAL CIRCUIT PURPLE= HIGH VOLTAGE BLUE - VBEE ts VOLTS)
Faull : 1rcuit
Power Stroke I 99511996
Code ndex Co nd ition Descriptio n Comments Probable Causes
0107 ~ARO Barometric nress sensor circuit low input Defaults to 100 kPa Ooen/orounded circuit biased sensor PCM
0108 ~ARO Barometric nress sensor circuit hinh inout Defaults to 100 kPa Circuit shorted to 5V biased sensor PCM
0112 AT Intake air temn sensor circuit low innut Defaults to 15'C Grounded circuit biased sensor PCM
01 13 AT Intake air temn sensor circuit hlnh innut Defaults to 15'C Ooen circuit biased sensor PCM short to 5V
0122 p Accelerator nedal sensor circuit low innut EnQine will onlv idle if hard fault Grounded circuit biased sensor PCM
0123 p Accelerator nedal sensor circuit hinh lnout EnQine will onlv idle if hard fault Ooen circuit biased sensor PCM short to 5V
0195 OT EQT Sensor ckt malfunction 195 MY\ Aborts KOER CCT test Enc ine not uo to ooeratina temo. leakinn thermostat
0 196 OT EOT Sensor ckt malfunction 196 MY\ Aborts KOER CCT test Enc ine not uo to ooeratina temo, 1eakinn thermostat
0197 OT Ennine oil temn sensor circuit low inout No cold adv. fast low idle Grounded circuit biased sensor PCM
0198 OT Enaine oil temn sensor circuit hioh inout No cold adv. fast low idle Ooen circuit biased sensor PCM short to SV
0220 VS Throttle switch B circuit malfunction Switch test - KOER Short/ooen circuit switch failure ooerator PCM
0221 P/ IVS Throttle switch B circuit oerformance AP/IVS disanree - Enoine will onlv idle if hard fault Failed oedal assemblv
0235 MAP Turbo boost sensor A circuit oerformance Uses Inferred MAP sianal Ooen short to around or 5v faultv sensor
0236 MAP Turbo boost sensor A circuit oerformance Uses Inferred MAP sinnal Restricted inleVexhausVsuoolv hose
0237 MAP Turbo boost sensor A circuit low inout Uses Inferred MAP sinnal Sensor PCM <95MY) Ooen short sensor PCM 196MY\
0238 MAP Turbo boost sensor A circuit hiah inaut Uses Inferred MAP sinnal Noise faultv sensor
0261 NJ lniector circuit low - C, linder 1 FMEM mode enr ine will run on 4 cvl. Harness short to around
0262 NJ lniector circuit hiah - Cvlinder 1 FMEM mode enrine will run on 4 cvl. Miswired connector or harness
0263 NJ C, linder 1 contribution/balance fault Cvlinder not contributinn durinn CCT test Power C'i linder valve train or iniector oroblem circuit
0264 NJ lniector circuit lw - Cvlinder 2 FMEM mode ennine will run on 4 cvl. Harness short to around
0265 NJ lniector circuit hiah - Cvlinder 2 FMEM mode ennine will run on 4 co l. Miswired connector or harness
0266 NJ Cvlinder 2 contribution/balance fault Cvlinder not contributinn durinn CCT test Power cvlinder valve train or iniector problem circuit
0267 NJ lniector circuit low - Cvlinder 3 FMEM mode ennine will run on 4 C11i. Harness short to around
0268 NJ lniector circuit hiah - Cvlinder 3 FMEM mode ennine will run on 4 co l. Miswired connector or harness
0269 NJ Cvlinder 3 contribution/balance fault Cvlinder not contributinn durinn CCT test Power cvlinder valve train or injector problem circuit
0270 NJ lniector circuit low - Cvlinder 4 FMEM mode ennine will run on 4 cvl. Harness short to around
0271 NJ lniector circuit hl□h • Cvlinder 4 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0272 NJ Cvlinder 4 contribution/balance fault Cylinder not contributina durinn CCT test Power cvlinder valve train or iniector problem circuit
0273 NJ lniector circuit low - Cvlinder 5 FMEM mode enaine will run on 4 cvl. Harness short to around
0274 NJ lniector circuit hiah - C1w linder 5 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0275 NJ Cvlinder 5 contribution/balance fault Cylinder not contributina durina CCT test Power cvlinder valve train or iniector oroblem circuit
0276 NJ lniector circuit low - Cvlinder 6 FMEM mode enaine will run on 4 cvl. Harness short to around
0277 NJ lniector circuit hioh - C, linder 6 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0278 NJ Cvlinder 6 contribution/balance fault Cvlinder not contributin° durina CCT test Power cvlinder valve train or iniector oroblem circuit
0279 NJ lniector circuit low - Cvlinder 7 FMEM mode ennine will run on 4 cvl. Harness short to around
0280 NJ lniector circuit hiah - C-.. linder 7 FMEM mode ennine will run on 4 c, 1. Miswired connector or harness
0281 NJ Cvlinder 7 contribution/balance fault Cvlinder not contributinn durinn CCT test Power cvlinder valve train or iniector oroblem circuit
0282 NJ lniector circuit low - Cvlinder 8 FMEM mode en nine will run on 4 c, I. Harness short to around
0283 NJ lniector circuit hiah - C,linder 8 FMEM mode ennine will run on 4 c, I. Miswired connector or harness
0284 NJ Cvlinder 8 contribution/balance fault Cvlinder not contributinn durinn CCT test Power cvlinder valve train or iniector oroblem circuit
0340 CMP Camshaft oosition sensor ckt malfunction No CMP sensor sinnal detected durinn crank Ooen/arounded circuit sensor fault short to nower
0341 CMP Camshaft oosition sensor ckt oertormance Electrical noise detected Harness routine. charalna circuit sensor
0344 CMP Camshaft oosition sensor ckt intermittent Incorrect number of CMP transition counts Harness routina. charcina ckt sensor int ckt imnroner nan
038()._ GPC Glow olua circuit malfunction Continuous and KOEO on-demand test Ooen/orounded ckt solenoid ooen/shorted failed PCM
0381 GPL Glow olua indicator clrcuit malfunction Continuous and KOEO on-demand test O oen/orounded circuit lamp ooen failed PCM
0470 EBP Exhaust oress sensor circuit malfunction No-start or crank mode Biased sensor open sional return
0471 EBP Exhaust oress sensor circuit oerformance Continuous Plunned stuck or leakina hose
0472 e sp Exhaust oress sensor circuit low inout Disables back nressure device O oen/arounded circuit biased sensor PCM
0473 "BP Exhaust oress sensor circuit hiah inout Disables back nressure device Circuit shorted to 5V biased sensor PCM
0475 "PR Exhaust oress control valve malfunction Continuous & KOEO on-demand test O nen/nrounded ckt solenoid open/shorted failed PCM
0476 PR Exhaust oress control valve performance KOER on-demand test Failed/stuck EPR EBP fault EPR circuit
0478 PR Exhaust nress control valve hiah inout Excessive back nressure - Continuous Plunaed sensor line stuck butterfly, restricted exhaust
0500 l!ss Vehicle sneed sensor malfunction Continuous Sensor circuit, PCM PSOM low trans fluid
0560 "CED Svstem voltane malfunction B+ too low for KOER on-demand or CCT test • aborts test Charaina svstem oroblem/load qlow pluas still enabled
0562 °CED Svstem voltane low Mav be temoorarv condition at crank onlv Low svs voltaae charaino svs internal PCM failure
0563 bCED Svstem voltane hinh Mav be temoorarv condition - 24V iumo start Hiah svs voltaoe char□ina svs internal PCM failure
0565 bCED Cruise On sinnal malfunction KOER switch test /Code set if cruise not oresentl Ooen or short circuit switch failure PCM failure or failed
0566 bCED Cruise Off sinnal malfunction KOER switch test /Code set if cruise not oresentl to activate switch durina KOER switch test
0567 bCED Cruise Resume sianal malfunction KOER switch test /Code set if c ruise not oresentl
0568 bCED Cruise Set sianal malfunction KOER switch test 'Code set if cruise not oresentl Cruise control and BPA codes will be set on everv switch
0569 DCED Cruise Coast sianal malfunction KOER switch test tCode set if cruise not oresentl test on vehicles not eauiooed with cruise control.
0571 ilPA Brake switch A circuit malfunction KOER switch test ICode set if cruise not oresentl
0603 bCED Powertrain Control Module KAM test error No historical faults outnut durina self test Ooen PCM oin disconnected B+ faultv PCM
0605 bCED Powertrain Control Module ROM test error Internal PCM failure Internal PCM failure
0606 DCED PCM orocessor fault PCM inactive backnround fault Internal PCM failure
0703 llOO Brake switch B circuit malfunction KOER switch test Ooen/short circuit switch PCM failed to activate
0704 CPP Clutch switch inout circuit malfunction KOER switch test switch durino KOER switch test
0707 RS Trans ranoe sensor circuit low inout Continuous Short to around Analoa TRS
0708 RS Trans ranae sensor circuit hioh inout Continuous Ooen analoa TRS onArl oin 64 diaital TR S
0712 FT Trans fluid temo sensor ckt low inout KOEOKOER and Continuous Short to around biased sensor PCM
0713 FT Trans fluid temo sensor ckt hioh inout KOEOKOER and Continuous Ooen circuit biased sensor PCM short to nower
0741 cc Toraue converter clutch ckt □erform ance Continuous Faultv solenoid PCM converter hvdraulic svstem
0750 SS1 Shift solenoid A malfunction KOEO and Continuous Circuit failure faultv solenoid PCM
0755 SS2 Shift solenoi d B malfunction KOEO and Continuous Circuit failure faultv solenoid PCM
0781 l,J1A 1-2 shift error Continuous Circuit failure faulty solenoid faultv clutch PCM
0782 NIA 2-3 shift error Continuous Circuit failure, faulty solenoid, faulty clutch, PCM

56
 POWERTRAIN CONTROL SYSTEM
ELECTRONICS DIAGNOSTIC GUIDE
Fault Circuit
Code Index Condition Description Comments Probable Causes
0783 NIA 3-4 shift error Continuous Circuit failure fauttv solenoid faultv clutch PCM
1111 NIA Svstem Pass No PCM svstem faults N/A
1211 IPR ICP nressure above/below desired Continuous and KOER on-demand test IPR valve failed stuck or shorted to nround
1212 ICP ICP nress not detected durino crank Crank or KOEO Biased sensor or ckt onen sional return low oil in reservoir
1218 PCM/IDM Cl stuck hinh Cvlinder identification line stuck hinh Cl circuit onen nrobablv intermittent
1219 PCM/IDM Cl stuck low Cvlinder identification line stuck low Cl circuit short to nround . nrobablv intermittent
1261- INJ High to low side short cyl#1 - #8 Cylinder with fault will not operate Short ci rcuit, shorted injector, failed IDM
1268
1271- INJ High to low side open cyl#1 - #8 Cylinder with fault will not operate Open circuit, open injector, failed IDM
1278
1280 ICP ICP circuit out of ran□e low Uses inferred ICP strateov Onen/orounded circuit biased sensor PCM
1281 ICP ICP circuit out of ranoe hi□h Uses inferred ICP strateov Circuit shorted to 5V biased sensor PCM
1282 IPR Excessive ICP oressure Svstem fault Faultv IPR re□ulator lstickinnl, IPR shorted to around
1283 IPR IPR circuit failure Continuous & KOEO on-demand test Ooerv'arounded circuit stuck IPR loose connection
1284 N/A ICP failure - aborts KOER test Aborts KOER CCT and on-demand tests Sensor circuit fault
See codes 1280 1281 1282 1283 1211
1291 INJ Hioh side short to □rd or B+ bank #1 'ri 0 ht' lni oower suoolv circuit short (ooerates on 4 cvlinders\ Shorted circuit faultv IDM
1292 INJ Hiah side short to □rd or B+ bank #2 !left\ lni oower suoolv circuit short /ooerates on 4 cvlinders' Shorted circuit faultv IDM
1293 INJ Hiah side ooen bank #1 /riahtl lni newer suoolv circuit ooen (ooerates on 4 cvlindersl O°en circuit faultv IDM
1294 INJ Hioh side ooen bank #2 1left) lni newer SU"'11V circuit ooen (ooerates on 4 cvlindersl Ooen circuit faultv IDM
1295 INJ Multicle faults on bank #1 /rinhtl with low side sh rt Fix low side short and rerun diaanostics Miswired connector or harness short to nround
1296 INJ Multic le faults on bank #2 /leftl with low side sho Fix low side short and rerun diaanostics Miswired connector or harness short to nround
1297 INJ Hioh sides shorted toaether Fix shorts and rerun diaanostics Shorted wires faultv IDM
1298 PCED IDM failure Internal IDM failure Internal IDM failure
1464 NIA A/C demand out of self test ranne Aborts KOER CCT test Onerator error A/C circuit shorted to nower
1531 N/ A Invalid test - accelerator cedal movement Aborts test - KOER on-demand or CCT test Onerator error
1536 PBA Parkinn brake switch circuit failure KOER switch test Failed to activate switch durina test circuit switch PCM
1660 PCED OCC sinnal hinh Aborts KOEO on-demand test Hinh svstem voltane internal PCM fault
1661 PCED OCC sinnal low Aborts KOEO on-demand test Low svstem voltane. internal PCM fault
1662 PCED IDM EN circuit failure Continuous & KOEO on-demand test Onen IDM relav blown fuse onen/arounded circuit
1663 PCM/IDM FDCS circuit failure Fuel demand command si□nal - KOEO on-demand test Onen/□rounded circuit faultv IDM
1667 PCM/IDM Cl circuit failure Cvlinder identification circuit • KOEO on-demand test Onen/□rounded circuit faultv IDM
1668 PCM/IDM PCM-IDM dia□nostic communication error Electronic feedback line • KOEO on-demand test Onan/shorted EF or FDCS open IDM around
1705 TRS TR sensor out of self test ranne Not in PARK durin□ KOEO or KOER Ooerator error circuit failure faultv sensor PCM
1711 TFT TFT sensor out of self test range Transmission fluid temp too high or low for KOEO or KOER t st Transmission too hot or cold,
circuit failure faultv sensor PCM
1728 TCC Transmission slio error Continuous Solenoid failure or mechanical failure
1729 4x4L 4x4 Low switch error Continuous Circuit failure faultv switch, PCM
1746 EPC EPC solenoid ooen circuit Continuous Ooen circuit faultv solenoid PCM
1747 EPC EPC solenoid short circuit Continuous Short circuit fau ltv solenoid PCM shorted to nround
1748 EPC EPC malfunction Circuit failure PCM
1754 ccs Coast clutch solenoid circuit malfunction Continuous & KOEO on-demand test Circuit failure faultv solenoid PCM
1779 TC IL TCIL circuit malfunction KOEO OCC test Sort to around, PCM
1i'80 TCS TCS circuit out of self test ranne KOER switch test Circuit switch PCM failed to activate switch
1781 4X4L 4X4L circuit out of self test ranne In 4X4L durino KOEO Ooerator error short to around, PCM
1783 TFT Transmission overtemperature condition Continuous Internal transmission failure, circuit failure, sensor, PCM

Indicates Check Engine Light illuminated when fault present

Indicates Transmission Control Indicator Light (TCIL flashes when fault present
PCED = Powertrain Control Emissions Diagnostics Manual

57
 7.3L Diesel Pin Out Values 1997 - ALL Econoline (49 state and California) adn F-250/ F-350 (California only)

Pin # Name Circuit # Wire Color Key Off Key On , Operating

Low Idle High Idle Comments
en Ranae
m 2 Check 658 PK-LG 0v 0v/12v 0v/12v 0v/12v 0v/12v 0v=Light On, 12v=Light Off
Ennine Linht
5 PBA 162 LG-R 0v 0v/12v 0v/12v 0v/12v 0v/12v Parkinn Brake Annlied Switch 12v - Brake off 0v - Brake on
6· SS1 237 O-Y 0v 0v 0v Ov 0v/12v Shift Solenoid #1 · 0v - "On" 12v - "Off"
8 GPMH 339 GY 0v 0v/12v 0v/12v 0v/12v 0v/12v Glow Plun Monitor Hinh Side· 0v - Plues off 12v - Pluns on
9 GPMR 1087 0 0v 0v/12v 0v/12v 0v/12v 0v/12v Glow Plue Monitor Rinht Bank· 0v - Plues off 12v = Plues on
10 IVS 308 R-O 0v 0v 0v 12v 0v/12v Idle Validation Switch· 0v - At idle 12v = Off idle
11• SS2 315 P-O 0v 12v 12v 12v 0v/12v Shift Solenoid #2· 0v - "On" 12v - "Off"
12• TCIL 911 W-LG 0v 0v/12v 0v/12v 0v/12v 0v/12v Trans Control Indicator Linht· 0v - Linht on 12v = Licht off
13 FEPS 107 p N/A N/A N/A N/A N/A Flash EPROM Power Sunnlv
14a,b 4X4L 784 LB-BK 0v 0v/12v 0v/12v 0v/12v 0v/12v 4x4 Low Switch 0v - On 12v - Off
15 BUSI-\ 915 PK-LB N/A N/A N/A N/A N/A Data Link Connector
16 BUSI+\ 914 T-O N/A N/A N/A N/A N/A Data Link Connector
17a,c TR1 1012 O-BK 0v Varies w ith aear 0v/10.7v P-Ov R-0v D-10.7v MAN2-10.7v MAN1-10.7v
19 TAC 648 W-PK 0v 12v 6.5v/130 Hz 6.5v/660 Hz 130/720 Hz Tachometer Sinnal Reflected CMP sinnal
20• ccs 924 BR-O 0v 0v 0v 0v 0v/12v Coast Clutch Solenoid· Ov - "On" 12v - "Off"
21 CMP 795 DG Ov 0.8v 7v 7v 130/720 Hz Camshaft Position Sensor· 650-3600 RPM
24 APGND 837 Y-BK Ov 0v 0v 0v 0v Accelerator Pedal Sensor Ground
25 CASE GND 875 BK-LB Ov 0v 0v 0v 0v Case Ground
29 (Mani) 306 T-LB 0v Ov/12v 0v/12v 0v/12v 0v/12v Clutch Pedal Position Switch (Manual)
TCSIAuto\ 224 T/W 0v Ov/12v 0v/12v 0v/12v 0v/12v Transmission Control Switch /Automatic\
30 EBP 553 R-LB 0v 0.9v 0.9v 1.2v 0.9v-3v Exhaust Back Pressure Sensor
31 BPA 810 R-LG 0v/12v Ov/12v Ov/12v 0v/12v 0v/12v Brake Pedal Aoolied Switch· 0v - Brake on 12v - Brake off
33 vssT-l 676 PK-O 0v 0v 0v 0v 0v Vehicle Sneed Sensor Ground
34 GPML 466 PK-O 0v Ov/12v Ov/12v 0v/12v 0v/12v Glow Plun Monitor Left Bank· 0v - Pluns off 12v = Pluas on
37• TFT 923 O-BK 0.2v-0.5v 0.3v-4.5v 0.3v-4.5v 0.3v-4.5v 0.3v-4.5v Transmission Fluid Temn. 4.5v--40°C/.3v-130°C
38 EOT 354 LG-R 0.2v-0.5v 0.3v-4.7v 0.3v-4.7v 0.3v-4.7v 0.3v-4.7v Ennine Oil Temn. 4.7v- -40°C/.3v- 150°F
39 IAT 743 GY 0.2v-0.5v 0.2v-4.5v 0.2v-4.5v 0.2v-4.5v 0.2v-4.5v Intake Air Temn. 4.5v--40°C/.2v-130°F
40 SC GND 563 O-Y 0v 0v 0v 0v 0v Sneed Control Ground
41 ACC 347 BK-Y 0v 0v/12v Ov/12v 0v/12v 0v/12v Air Conditioninn Clutch· Ov - NC off 12v - N C on
42 EPR 3 18 GY-R 0v Ov Ov/12v 0v/12v 0v/12v Exhaust Back Pressure Renulator· Dutv cvcled 0v - Off
48 EF 818 GY-W 0v 3v 1v 0.9v-3v 0.9v-3v Electronic Feedback Line dinital 12v frenuencv
49a,c TR2 146 W-PK 0v Varies with oear 0v/10.7v P-0v R- 0v N-10.7v D-10.7v MAN2-0v MAN1-10.7v
5oa,c TR4 145 GY-BK 0v Varies with near 0v/10.7v P-Ov R-10.7v N-0v D-10.7v MAN2-10.7v MAN1 -0v
51 PWR GND 570A BK-O 0v Ov Ov I 0v 0v Power Ground
54• TCC 480 P-Y 0v 12v 12v I 12v 0v/1 2v Tornue Converter Clutch Solenoid· Ov - "On" 12v - "Off"
55 KAPWR 37E y B+ B+ I B+ I B+ B+ Keen Alive Power· B+ - batterv voltaae
58 VSSI+\ 679 GY-BK Freauenc, Sianal - Varies with Vehicle Sneed Vehicle Soeed Sianal
61 SCCS 151 LB-BK 0v 6.6v 6.6v 6.6v 0v-12v Cruise Control Command Switch; On=12v, Off=0v, Set=2.8v,
Resume-4.7v Coast-0.8v Hold-6.6v
63 BARO 356 DB-LG 0v 2v-4.9v 2v-4.9v 2v-4.9v 2v-4.9v Barometric Pressure Sensor; 4.6v @ 100 kPa (sea level),
2.6v @ 60 kPa 11O 000 ft.\
64 3 TR3A 199 LB-Y Ov 0.7v-4.5v F-Series: P=4.5v, R=3.7v, N=2.9v, D=2.2v, MAN2=1.4v, MAN1=0.7v
IE Series\ Varies with aear 0v/1 .6v E-Series: P-Ov R- 1.6v N-1.6v D=1.6v MAN2-0v MAN1=0v
65 CMPGND 796 LB 0v 0v 0v Ov Ov Camshaft nosition sensor nround
70 GPL 464 BK-PK 0v 0v/12v 12v 12v 0v/ 12v Glow Plun Lamn 0v - Linht on 12v - Linht off
71 VPWR 361B R 0v B+ B+ B+ B+ lnnition source nower
76 PWR GND 570B BK-O 0v 0v Ov Ov Ov Power Ground
77 PWR GND 570C BK-O 0v 0v Ov 0v 0v Power Ground
80 IDM EN 814 W-BK 0v 12V->0V 0v 0v 0v-12v IDM Relav· 0v - Relav On 12v - Relav Off
81° EPC 925 W-O 0v 8v 10v 12v 8v-12v Electronic Pressure Control Solenoid
83 IPR 552 Y-R Ov 12v 12v 12v 12v lniection Pressure Renulator· Dutv Cvcle Controlled
87 ICP 535 LB-R Ov 0 .2v-0.4v 0.7v-1v 1.1v-1.5v 0.6v-3.2v lniection Control P ressure Sensor /Min 0.83v reo. for startina\
88 MAP 358 LG-BK 0.2v-0.5v 2.5v 2.5v 2 .5v 110-190 Hz Manifold Absolute Pressure· 11 0 Hz - Atmosoheric Pressure
89 AP 355 GY-W Ov 0.5v-4v 0.5v-0.8v 3.4v-4.2v 0.5v-4v Accelerator Pedal Sensor
90 V REF 351 BR-W 0.2v-0.5v 5.0±0.5v 5.0±0.5v 5.0±0.5v 5.0±0.5v Voltane Reference
91 SIG GRD 359 GY-R 0v 0v 0v Ov 0v Ground for all sensor sinnals
92 BOO 511 LG 0v/12v 0v/12v Ov/12v 0v/12v 0v/12v Brake On/Off Switch· ov - Brake off 12v - Brake on
95 FDCS 821 BR-O 0v 0v 1v/49 Hz 4v/200 Hz 40 Hz-240 Hz Fuel Deliverv Control Sinnal· 650-3600 RPM
96 CID 817 Y-LB 0v 0v 6v/5 Hz 7v/30 Hz 5 Hz-30 Hz Cvlinder Identification
97 VPWR 361A R 0v B+ B+ B+ B+ lnnition source newer
101 GPC 1086 P-O 0v 0v/12v Ov/12v 0v/12v 0v/12v Glow Plun Control· 0v - IRelav On\ 12v - IRelav off\
103 PWR GND 570D BK-O 0v Ov 0v 0v 0v Power Ground

a E40D transmission only b Not used in 1997 Econoline c Not used on 1997 F-Series
 7.3L DI Turl}Q Diesel Powertrain Control System - 1997 E-Series and California F-Series

nV ,~:~,
PC~,.i,ww.::'
Engine Mounted Components Vehicle Mounted Components .........as......... .-= . .:.:.:.-=- -
J_
CMP

A /Bi, A ~ ,,o;.:-~~
i !~
s ): ~ : : : : :: :: Ei :;;-:,~ API
I

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.........rn...... IVS Si nal
.........~.~......... vss- ..
........!ii!......... VSS + ..
r •[;i~~Jf~J!"'J l..:~.11--l~'F 42 Way Connector ~ -1---t--' L!±::::::!::!:l --+-- ~ ~ ~!!....- - ---1-- - -1.........;l.~......... I
I "+-- - - - - -+....... i!l.........
1
- - - - - - - - - ::::::::!~:::::::::
I L . . - -1-+.L..---l-. . . . , - - - - - - - 1......... rn......... Si nal Ground ........ al.. ....... Si nal Ground - . K.EYP.W!!_ I
'-+-- --+----+I---_._______ ........ 21.......... VREF ........ i!A......... l-'-
VR:.:;E
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~ - - - - - - - - - - -1.........17..........
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. ........ ,U!.. .......
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1-1-
EOT Si nal
CAMP Ground
_ _ _ _ _ _ _ _ _ -l _ _C~MP_Sil!_na.!_
ICP Si nal

GPC Control
GPML
_ _ _
........117. ........ .
.........3/l....... ..
....... ..'$.!i....... ..
_ _ .........21.. ...... .
....... J.0.1....... .
........ il~ ....... ..
~
1~============--=---=----==-==---==----==::::::::!J:::::::::1
,. 40
GPMH
GPMR
......... 11 ........ ..
......... lL ...... ..
~ ARO

- - - - - - - - - - - - - - - - - - - - - - - - - .....................

. - - - - - - - - - - - - - - - - - - - - - ........ J:i ......... ◄ l ------..

KEYPWR IDM Connector
.::~
.. ....... ><>< ...... ..
BARO Signal

J
&~:::::--;:..----'~ - , .........a1....... .. SCAN TOOL -ii•
.........f.......... ~ - - -, ......... io....... ..
l~ector#1 _________________ .........~.......... - - - - - .........~.......... E OD Q-f-ff----'~"- ......... :i\\ ...... .. 1al!laotiaaaa
I
I I
lnj!ctor#3
_ lnjector#5 ____
......... :i..........
.........
n.........
- - - - - .. ......
7.......... _____ .........~.........
4
SOLENOID
ASSEMBLY
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....... ~1. ........
I 90 DDD DIJ16
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KEYPWR
I t I lnll!!_ctor#7 .........~.......... ._____ ........ ~!>......... ......... l!L ......
I I I 1--- - - - - ....... Jli......... _ _ CL ____ - - - - - - ........ Ji!i ...... ..

lL
O

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A B C '
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==:': ==== : : : : :
.. ...... ..1~ ........t..2.l""""'--+-....1
AeC MOOOU'

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l f ==s:::i=======i:=;~=i-- v~ol~ta~g!'.:e-l ....... J.1.........
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t. .
... .. ...... .......... ....----t .........~.Q......... ,__,,
- ..=1-lc::::;::::;::;:::;;;::~ r:-+-- 1--+---' ..~.,.Zli,i:7.,1.Q~. PWR GND I•
-((I • • • • I)) {(I E• D• C• B• AIJ) 41 ACC -., KEYPWR

E_____
Grow Plug E D C B A
.........i9 ......... TCS (Automatic) -., KEYPWR

,. I . . . . . . .
Relay
I I I
I lnjec~_!:8_ _ _] .........111......... l ........ . .... ................. KEYPWR
I I I lnjecioril6 ____ ......... !!.......... _____ ....... J.11......... ..... ....~~.. ....... CPP (Manual)
Starter Relay I I _____ ........ ..<..........

[
Injector#4_______________ .........IL........ PCM Pwr Relay
........ J.L ...... TCIL
® -~:::::
.........1......... _____ ........i?. ....._J
fit
Fusible Links
BAT+
!J!!iector#2 _____________ _ ___ B+ D ......... ~~ ........ 1-.1a.t:r...- - --em BAT+

, - - - - - - - - - - - - - - - - - -~ ........?.4......... VPWR ::: ::z;:;z::::::1------,,----,

...........L ....... @
-,----
PBA KEYPWR
JPll.(C.12nt.CPI)_
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- -~ ~ - ~ - 1-13(8)=_=
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.) !!I 19
en IPR
KEYPWR :::::::::ji:::::::: KEYPWR
CD EPA
.......... L ...... i..::::=!.!:!.=::..:::.ll!!!. KEYPWR
(Dotted Lines= Frequency or Switch Functions) (Orientation = Looking Into harness side of connector)
.........li.1.. ........~ ~- -.
~.....~.Q.. .... (to Speed Control Switches)
RED - 12 VOLTS BLACK= GROUND CIRCUIT GREEN = SIGNAL CIRCUIT PURPLE= HIGH VOLTAGE BLUE = YREF 15 VOLTS}
 Fault Circuit
Power Stroke 1997 Econoline (ALL)
F-250/F-350 (California only)
Code Index Condition Descriotion Comments Probable Causes
0107' BARO Barometric press sensor circuit low inout Defaults to 100 kPa Ooen/arounded circuit biased sensor PCM
0108· BARO Barometric press sensor circuit hiah inout Defaults to 100 kPa Circuit shorted to 5V biased sensor PCM
0112· IAT Intake air temo sensor circuit low inout Defaults to 15' C Grounded circuit, biased sensor PCM
0113• IAT Intake air temo sensor circuit hiah inout Defaults to 15' C Ooen circuit biased sensor PCM, short to 5V
0122· AP Accelerator pedal sensor circuit low inout Erigine will onlv idle if hard fault Grounded circuit biased sensor PCM
0123• AP Accelerator pedal sensor circuit hiah inout Engine will onlv idle if hard fault Ooen circuit biased sensor PCM short to 5V
0197" EQT EQgine oil temo sensor circuit low inout No cold adv. fast low idle Grounded circuit biased sensor PCM
0198• EQT EQQine oil temo sensor circuit hiah inout No cold adv. fast low idle Ooen circuit biased sensor PCM short to 5V
0220 IVS Throttle switch B circuit malfunction Switch test - KOER Short/ooen circuit switch failure O_l)_erator PCM
0221· AP/IVS Throttle switch B circuit oerformance AP/IVS disaaree - Enaine will onlv idle if hard fault Failed oedal assemblv
0236' MAP Turbo boost sensor A circuit oerformance Uses Inferred MAP sianal Restricted inlet/exhaust/suoolv hose
0237" MAP Turbo boost sensor A circuit low inout Uses Inferred MAP sianal Ooen short to around or 5V faultv sensor
0238• MAP Turbo boost sensor A circuit hiah inout Uses Inferred MAP sianal Noise faultv sensor
0261 INJ lniector circuit low - Cvllnder 1 FMEM mode enqine will run on 4 cyl. Harness short to Qround
0262 INJ lniector circuit hiah - Cvlinder 1 FMEM mode ennine will run on 4 cvl. Miswired connector or harness
0263 INJ Cylinder 1 contribution/balance fault Cylinder not contributino durina CCT test Power cylinder valve train or injector problem circu it
0264 INJ Injector circuit lw - Cvlinder 2 FMEM mode enaine will run on 4 cyl. Harness short to ground
0265 INJ Injector circuit hiah - Cvlinder 2 FMEM mode enaine will run on 4 cyl. Miswired connector or harness
0266 INJ Cvlinder 2 contribution/balance fault Cylinder not contributino durinq CCT test Power cvlinder valve train or injector problem circuit
0267 INJ Injector circuit low - C\ linder 3 FMEM mode enc ine will run on 4 cyl. Harness short to around
0268 INJ Injector circuit hiah - Cvlinder 3 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0269 INJ Cylinder 3 contribution/balance fault Cylinder not contributina durina CCT test Power C\llinder valve train or ir}i_ector_moblem circuit
0270 INJ Injector circuit low - Cvlinder 4 FMEM mode enoine will run on 4 cyl. Harness short to around
0271 INJ Injector circuit hiah - Cvlinder 4 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0272 INJ Cylinder 4 contribution/balance fault Qy_linder not contributina durina CCT test Power C1Jlinder valve train or iniector_Qroble m circuit
0273 INJ Injector circuit low - Cvlinder 5 FMEM mode enaine will run on 4 cvl. Harness short to around
0274 INJ lrJ.iector circuit hiah - Cvlinder 5 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0275 INJ ~linder 5 contribution/balance fault Cvlinder not contributina durina CCT test Power ci, linder valve train or iniector_Qroblem circuit
0276 INJ IQj_ector circuit low - C1Jlinder 6 FMEM mode enaine will run on 4 cvl. Harness short to around
0277 INJ lniector circuit hiah - C, linder 6 FMEM mode enaine will run on 4 cyl. Miswired connector or harness
0278 INJ C, linder 6 contribution/balance fault Cvlinder not contributina durina CCT test Power C\linder valve train or injector problem circuit
0279 INJ lniector circuit low - C~ linder 7 FMEM mode enoine will run on 4 cvl. Harness short to qround
0280 INJ lniector circuit hiah - c, linder 7 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0281 INJ C~linder 7 contribution/balance fault Cylinder not contributina d urina CCT test Power c~ linder valve train or injector problem circuit
0282 INJ Injector circuit low - CvHnder 8 FMEM mode ennine will run on 4 cyl. Harness short to Qround
0283 INJ Injector circuit hiah - Cvlinder 8 FMEM mode ennine will run on 4 cyl. Miswired connector or harness
0284 INJ Cvlinder 8 contribution/balance fault Cylinder not contributina durina CCT test Power cvlinder valve train or injector problem circuit
0340 CMP Camshaft position sensor ckt malfunction No CMP sensor sional detected during crank Ooen/arounded circuit sensor fault short to oower
0341 ' CMP Camshaft position sensor ckt performance Electrical noise detected Harness routina charaing circuit sensor
0344' CMP Camshaft position sensor ckt intermittent Incorrect number of CMP transition counts Harness routina charail"l9 ckt sensor int ckt imorooer aao
0380" GPC Glow pluq circuit malfunction Continuous and KOEO on-demand test Oaen/arounded ck! solenoid Qll_en/shorted failed PCM
0381" GPL Glow p!uQ indicator circuit malfunction Continuous and KOEO on-demand test Ooen/arounded circuit lamo Qll_en failed PCM
0470 EBP Exhaust press sensor circuit malfunction No-start or crank mode Biased sensor ooen sianal return
047t' EBP Exhaust press sensor circuit performance Continuous Pluoaed stuck or leakina hose
0472• EBP Exhaust press sensor circuit low in□ut Disables back oressure device Ooen/arounded circuit biased sensor PCM
0473" EBP Exhaust press sensor circuit hiah inout Disables back oressure device Circuit shorted to sv biased sensor PCM
0475" EPA Exhaust press control valve malfunction Continuous & KOEO on-demand test Ocen/arounded ck! solenoid ooen/shorted failed PCM
0476 EPA Exhaust press control valve oerformance KOER on-demand test Failed/stuck EPA, EBP fault EPA circuit
0478" EPA Exhaust press control valve hioh inout Excessive back oressure - Continuous Pluaaed sensor line stuck butterflv. restricted exhaust
0500• vss Vehicle speed sensor malfunction Continuous Sensor circuit PCM PSOM low trans fluid
0560 N/A S__y_stem voltaae malfunction B+ too low for KOEA on-demand or CCT test - aborts test Charoinq svstem oroblem/load qlow cluns still enabled
0562" VPWR S_ystem voltaae low Mav be temporarv condition at crank onlv Low svs voltaae charoina svs internal PCM failure
0563 VPWR S_ystem voltaae hioh Mav be temoorarv condition - 24V iumo start Hiah svs voltaae charaina svs internal PCM failure
0565 SCCS Cruise On sianal malfunction KOER switch test (Code set if cruise not oresent) Open or short circuit, switch failure, PCM failure or failed
0566 secs Cruise Off sianal malfunction KOEA switch test (Code set if cruise not oresent) to activate switch during KOER switch test
0567 SCCS Cruise Resume sianal malfunction KOER switch test (Code set if cruise not oresent)
0568 SCCS Cruise Set sianal malfunction KOER switch test fCode set if cruise not present) Cruise control and BPA codes will be set on every switch
0569 SCCS Cruise Coast sional malfunction KOEA switch test fCode set if cruise not present) test on vehicles not equipped with cruise control.
0571 BPA Brake switch A circuit malfunction KOER switch test fCode set if cruise not present)
0603 PCM Powertrain Control Module KAM test error No historical faults outaut durina self test Oaen PCM pin disconnected B+ faultv PCM
0605 PCM Powertrain Control Module ROM test error Internal PCM failure Internal PCM failure
0606 PCM PCM processor fault PCM inactive backoround fault Internal PCM failure
0703 BOO Brake switch B circuit malfunction KOER switch test Open/short circuit, switch, PCM, failed to activate
0704 CPP Clutch switch inout circuit malfunction KOER switch test switch durina KOER switch test
0705" TRS Trans ranqe sensor circuit malfunction Continuous Short or nnon diaital TRS loin 64 short onlvl
0707' TRS Trans ranoe sensor circuit low inout Continuous Short to around Anafoa TRS
0708' TRS Trans range sensor circuit hiah inout Continuous Onon analoa TRS ooen cin 64 diaital TRS
0712 TFT Trans fluid tame sensor ck! low inout KOEOKOER and Continuous Short to around biased sensor PCM
0713 TFT Trans fluid temo sensor ckt hiah inout KOEO KOER and Continuous Onon circutt biased sensor PCM short to oower
0741 TCC Torque converter clutch ckt oerformance Continuous Faultv solenoid PCM convertor t,y_draulic svstem
0743' TCC Tg_rque converter clutch svstem electrical KOEO and Continuous Faultv solenoid PCM
0750" SS1 Shift solenoid A malfunction KOEO and Continuous Circuit failure faultv solenoid PCM
0755' SS2 Shift solenoid B malfunction KOEO and Continuous Circuit !allure faultv solenoid PCM
0782 NIA 2-3 shift error Continuous Circuit failure faultv solenoid faultv clutch PCM
0783 NIA 3-4 shift e rror Co ntinuous Circuit failure, faulty solenoid, faulty dutch, PCM

60
□
 POWERTRAIN CONTROL SYSTEM
ELECTRONICS DIAGNOSTIC GUIDE
Fa ult Circuit
Code Index Condition Description Comments Probable Causes
1000 NIA Check of all O8D11 svstems not complete
1184 EOT Ennine oil temn sensor out of self test ranne Ennine not warm enouqh to run KOER CCT - aborts test Enaine not warm enouoh leakina thermostat ckt failure
1209• IPR lniection control nressure svstem fault IPR valve stuck
1210· IPR lniection control pressure above expected level No-start mode and KOEO on-demand test
1211 · IPR ICP nressure above/below desired Continuous and KOER on-demand test IPR valve failed stuck or shorted to around
1212 ICP ICP nress not detected durinn crank Crank only Biased sensor or ckt ooen sianal return low oil in reservoir
1218 Cl Cl stuck hinh Cvlinder identification line stuck hioh Cl circuit open probably intermittent
121 9 Cl Cl stuck low Cvllnder identification line stuck low Cl circuit short to oround probably intermittent
1247• M AP Turbo boost nressure low
1248· MAP Turbo boost nressure not detected Hose disconnected
1261- INJ High to low side short cyl#1 - #8 Cylinder with fault will not operate Short circuit, shorted injector, failed IDM
1268
1271- INJ High to low side open cyl#1 - #8 Cylinder with fault will not operate Open circuit, open injector, failed IDM
1278
12ao• ICP ICP circuit out of ranae low Uses inferred ICP strateav Open/grounded circuit biased sensor PCM
123 1• ICP ICP circuit out of ranae hiah Uses inferred ICP strateav Circuit shorted to SV biased sensor PCM
1232• IPR Excessive ICP oressure Svstem fault Faultv IPR reaulator (sticking), IPR shorted to around
1283 IPR IPR circuit failure Continuous & KOEO on-demand test Ocen/arounded circuit stuck IPR loose connection
1284 N/A ICP failure - aborts KOER test Aborts KOER CCT and on-demand tests Sensor circuit fault
See codes 1280 1281 1282, 1283 1211
1291 INJ Hiah side short to ardor B+ bank #1 /riaht\ lni oower suooly circuit short (ooerates on 4 cylinders) Shorted circuit faultv IDM
1292 INJ Hiah side short to ard or B+ bank #2 /left\ lni oower supply circuit short (ooerates on 4 cylinders) Shorted circuit faultv IDM
1293 INJ Hiah side ooen bank #1 (riaht\ lni oower supply circuit open (operates on 4 C'i linders) Open circuit, faultv IDM
1294 INJ Hiah side open bank #2 (left\ lni oower supply circuit ooen (operates on 4 C'i linders) Open circuit faultv IDM
1295 INJ Multiple faults on bank #1 (riaht\ with low side she rt Fix low side short and rerun diaqnostics Miswired connector or harness short to around
1296 INJ Multinle faults on bank #2 /left\ with low side shor Fix low side short and rerun diagnostics Miswired connector or harness short to around
1297 INJ Hinh sides shorted toaether Fix shorts and rerun diannostics Shorted wires faultv IDM
1298 IDM IDM failure Internal IDM failure Internal IDM failure
1316· IDM lniector circuiVIDM codes detected Run KOEO on-demand test to retrieve codes Injector circuiVIDM codes detected
1391• GPM Glow nlun circuit low inout bank #1 lriaht\ Aborts alow olua monitorina Open circuit short to power or qround, fau ltv relav
1393• GPM Glow nlun circuit low inout bank #2 /left\ Aborts alow olua monitorina Open circuit short to power or ground faultv relav
1395• GPM Glow olua monitor fault bank #1 Continuous & KOER alow olua monitor test One or more ~ low i lugs failed
1395• GPM Glow olua monitor fault bank #2 Continuous & KOER alow olua monitor test One or more Qlow i lugs failed
1397 VPWR Svstem voltaae out of self test ranae Aborts KOER c low olua monitor test System voltage too high or low for glow olua monitor test
1464 N/A A/C demand out of self test ranae Aborts KOER CCT test Qperator error AfC circuit shorted to power
1501 N/A VSS out of self test ranae Aborts test - KOER on-demand CCT or switch test Ooerator error
1502 N/A Invalid test • APCM functionino Aborts test - KOER on-demand CCT. or switch test APCM active while KOER test is runnina
1531 N/A Invalid test - accelerator oedal movement Aborts test - KOER on -demand or CCT test Ooerator error
1536 PBA Parkina brake switch circuit failure KOER switch test Failed to activate switch durina test circuit switch PCM
1660 occ OCC sianal hiah Aborts KOEO on-demand test Hiah svstem voltaae internal PCM fault
1661 occ OCC sianal low Aborts KOEO on-demand test Low svstem voltaae internal PCM fault
1662 IDM El IDM EN circuit failure Continuous & KOEO on-demand test Open IDM relav blown fuse ooen/arounded circuit
1663 FDCS FDCS circuit failure Fuel demand command sianal - KOEO on-demand test Open/arounded circuit laultv IDM
1667 Cl Cl circuit failure Cvlinder identification circuit - KOEO on-demand test Ooen/arounded circuit faultv IDM
1668 EF PCM-IDM diaanostic communication error Electronic feedback line - KOEO on-demand test Open/shorted EF or FDCS ooen IDM nround
1670· EF EF sicnal not detected Continuous Open/shorted EF circuit
1704 TRS Dic ital TRS failed to transition state KOEO only Sensor wirlnq PCM mechanical alianment
1705 TRS TR sensor out of self test ranae Not in PARK durina KOEO or KOER Operator error ci rcuit failure faultv sensor, PCM
1711 TFT TFT sensor out of self test range Transmission fluid temp too high or low for KOEO or KOER Transmission too hot or cold,
testcircuit failure faulty sensor PCM
1114• S$1 Shift Solenoid 1 inductive sianature malfunction Continuous Solenoid or PCM
1715• SS2 Shift Solenoid 2 inductive sianature malfunction Continuous Solenoid or PCM
1728 TCC Transmission silo error Continuous Solenoid failure or mechanical failure
1729 4x4L 4x4 Low switch error Continuous Circuit failure faulty switch PCM
1140• TCC Toraue converter clutch inductive sia malfunction Continuous Solenoid or PCM
1746 EPC EPC solenoid ooen circuit Continuous l'lnan circuit laultv solenoid PCM
1747' EPC EPC solenoid short circuit Continuous Short circuit faultv solenoid PCM shorted to around
1754 ccs Coast clutch solenoid circuit malfunction Continuous & KOEO on-demand test Circuit failure faulty solenoid PCM
1780 TCS TCS circuit out of self test range KOER switch test Circuit, switch, PCM, failed to activate switch
or switch alwavs active during KOER
1781 4X4 L 4X4L circuit out of self test ranae In 4X4L durina KOEO Ooerator error short to around PCM
1783 TFT Transmission overtemperature condition Continuous Internal transmission failure, circuit failure, sensor, PCM

• (OBDII) MIL illumination occurs after 2nd consecutive fault

(FMEM) MIL illumination occu rs after 1st fault
Transmission Co ntrol Indicator Light (TCIL) flashes when fault is present.
TCIL Illuminates on 49 state a !!cations on

For F-250/F-350 (49 state) and F-Super Duty (ALL)

refer to Diagnostic Guide #FCS-70230208

FCS-70230207

61
 7.3L Diesel Pin Out Values - 1997
F-250/F-350 (49 state only) and ALL F-Super Duty (49 state and California)
r
a, Pin# Name Circuit# Wire Color Key Off Key On Low Idle High Idle
Operating
Comments
~ Ranae
1a 882 315 P-O 0v 12v 12v 12v 0v/12v Shift Solenoid #2 0v - "On" 12v - "Off"
2 Check 658 PK-LG 0v B+ B+ B+ B+ 0v=Light On, 12v=Light Off
Ennine Liaht
,i6 PBA 977D P-W 0v 12v/0v 12v/0v 12v/0v 12v/0v Parkinn Brake Annlied Switch "Uo/Down"
5 IVS 308 R-O 0v 0v/12v 0v 12v 0v/12v Idle Validation Switch "Uo/Down"· Ooen at idle
13 FEPS 107 p N/A N/A N/A N/A N/A Flash EPROM Power Sunnlv
148 4X4L 784 LB-BK 0v 12v/0v 12v/0v 12v/0v 12v/0v 4x4 Low Switch 12v - "Off" 0v - "On"
15 BUS!-\ 915 PK-LB N/A N/A N/A N/A N/A Data Link Connector
16 BUS!+\ 914 T-O N/A N/A N/A N/A N/A Data Link Connector
25 CASE GND 57Z BK 0v 0v 0v 0v 0v Case Ground
278 881 237 O-Y 0v 0v 0v Ov 0v/12v Shift Solenoid #1 0v = "On" 12v - "Off"
288 TCC 480 P-Y 0v 12v 12v 12v 0v/12v Converter Clutch Solenoid 0v - "On" 12v - "Off"
29 (Mani) 306 T-LB 0v 12v/0v 12v/0v 12v/0v 12v/0v Clutch Pedal Position Switch (Manual)
TCS!Auto\ 224 T/W 0v 12v/0v 12v/0v 12v/0v 12v/0v Transmission Control Switch !Automatic\
30 EBP 553 P-LB 0v .8v-.95v .8v-.95v 1.25v-1.75v .8v-3v Exhaust Back Pressure Sensor
31c BPA 307 BK-Y 0v 12v/0v 12v/0v 12v/0v 12v/0v Brake Pedal AnnJied "Ua/Down"
33 VSS(-\ 676 PK-O 0v 0v 0v 0v 0v Vehicle Saeed Sensor Ground
34 MAP 358 LG-BK 0v .2v-.5v 2.5v 2.5v 110-186 Hz Manifold Pressure 110/113 Hz - At. Press.
378 TFT 923 O-BK 0v .3v-4.5v .3v-4.5v .3v-4.5v .46v-212°F Transmission Fluid Terna. 4.5v--40°F/.3v-230°F
38 EOT 354 LG-R 0v .35v-4.5v .35v-4.5v .35v-4.5v .75v- 212°F Enaine Oil Terna. 4.7v--40°F/.68v-230°F
39 !AT 743 GY 0v .35v-4.5v .35v-4.5v .35v-4.5v 3.07v-68°F Intake Air Terna. 4.53v--40°F/.358v-230°F
40° SCGND 848 DG-O 0v 0v 0v 0v 0v Sneed Control Ground
41a,e ACC 198 DG-O 0v 12v/0v 12v/0v 12v/0v 12v/0v Air Conditionina Clutch 12v - "On" 0v - "Off"
42 EPR 318 GY-R 0v 6v-8v 6v-8v 0v 0v-10v Exhaust Back Pressure Volt. onlv when enabled
48 EF 818 GY-W 0v 3.3v av□. .4v-2.2v 1.9v-2.2v .4v-2.2v Electronic Feedback Line diaital 12v freauencv
49 CMP 795 DG 0v 12v/2.5v 7v 7v 130-720 Hz Camshaft Position Sensor 650-3600 RPM
509 TAC 648 W-PK 0v 12v 6.5v/130 Hz 6.5v/660 Hz 130-720 Hz Tachometer Sianal Reflected CMP Siana!
51 PWR GND 570A BK-W 0v 0v 0v 0v Ov Power Ground
538 ccs 924 BR-O 0v 0v Ov 0v 0v/12v Coast Clutch Solenoid 0v - "On" 12v - "Off"
55 KAPWR 37E y B+ B+ B+ B+ B+ Keen Alive Power B+ - batterv voltaae
58 VSSI+\ 679 GY-BK Frenuencv Siana! - Varies with Vehicle Sneed Vehicle Sneed Sianal
61 SCCS 151 LB-BK 0v 0v to 12v 0v to 12v 0v to 12v 0v to 12v Cruise Cntl. Voltaae will varv with switch nosition
648 TR 199 LB-Y 0v 4.5v 4.5v 4.5v 0v-4.5v Transmission Range Sensor P = 4.5v, R = 3.7v,
N - 2.9v D - 2.2v MAN2 - 1.4v MAN1 - .7v
65 CMP GND 796 LB 0v 0v 0v 0v 0v Camshaft nosition sensor around
70 IDM EN 814 W-BK 0v 12V->0V 0v 0v 12v/0v IDM Relav 12v - IDM Off 0v - IDM On
71 VPWR 361B R 0v B+ B+ B+ B+ lnnition source nwr.
76 PWR GND 570B BK-W 0v 0v 0v 0v 0v Power Ground
77 PWR GND 570C BK-W 0v 0v 0v 0v Ov Power Ground
79• TCIL 911 W-LG 0v 12v/0v 12v/0v 12v/0v 12v/0v Trans Control Indicator Liaht 12v - "Off" 0v - "On"
80 GPL 464 BK-PK 0v 0v/12v 12v 12v 0v/12v Glow Plun Lamn 0v - Liaht On 12v - Liaht Off
81 8 EPC 925 W-Y 0v 4.5v 7.5v 12v 7.5v-12v Electronic Pressure Control Solenoid
83 IPR 552 Y-R 0v 0v 12v 12v 12v lniection Pressure Rea. Dutv Cvcle Controlled
84 BARO 356 DB-LG .75v-3v .75v-4.9v .75v-4.9v .75v-4.9v .75v-4.9v 4.64v at 100 kPa /sea level\ 2.6v at 60 kPa 110 000 ft.\
871 ICP 812 DB-LG 0v .25v-.4v .75v-1v 1.1v-1.5v .65v-3.25v lniection Control Pressure /Min ..83v rea. for startinnl
89 AP 355 GY-W 0v .5v-4v .5v-.9v 3.8v-4.2v .5v-4v Accelerator Pedal Sensor
90 V REF 351 BR-W .41v 5.0±.5v 5.0+.5v 5.0±.5v 5.0±.5v Voltaae Reference
91 SIG GRD 359 GY-R 0v 0v 0v 0v 0v Ground for all sensor sianals
92 BOO 511 LG 0v/12v 0v/12v 0v/12v 0v/12v 0v/12v Brake On/Off Switch "Un/Down"
95 FDCS 821 BR-O 0v .5v 1v-49 Hz 2.7v/200 Hz 43/240 Hz Fuel Deliverv Control Sinnal 650-3600 RPM
96 CID 817 Y-LB 0v .5v 6v/5 hZ 6v/720 hZ 5 Hz-720 Hz Cvlinder Identification
97 VPWR 361A R 0v B+ B+ B+ B+ lnnition source nwr.
101 GPC 1086 P-O 0v 0v/12v 0v/12v 12v 0v/12v Glow Plua Cntrl. ov~IGP relay On) 12v~(GP relav off\
103 PWR GND 570D BK-W 0v 0v 0v 0v 0v Power Ground
a E40D transmission only d 563 (O/Y) for Econoline applications g Not used on Econoline applications
b 162 (LG/R) for Econoline applications e 347 (BK/Y) for Econoline applications
c 810 (R/LG) for Econoline applications I 535 (LB/R) for Econoline applications

l
 7.3L DI Turbo Diesel Powertrain Control System -A/11997 F-series except California
Engine Mounted Components Vehicle Mounted Components Cab Mounted Components
PCM Connector
-,

I !p~~~:~ I ---:-ittt!
-
CAMP EQT ICP EBP MAP IAT TRS

~
?,~
r::i
(Il[Jti§~
n~r n n
AP .
·:·:·:·:·:·:·:·:·:;f_:.:.:.:.:..
TRS Signfil_ ........ .64... .... ..
..........?. ......... 1••->->1y11a, 1·
42Way
Connector
~
:::::::::::::::::::: 1-1->'~.;;.u;.
: _: . ~ IVS I
_r ______ MA.f I - 11-\1 .;;;,IU!lc:11 ......... ~ ~ ' " " " "
Sj,gnJ!.! _ ,_ _ _ _ _ ......... ;JL .......1

II l. . . . .
........ ~9.......... ~~~ . .. .......~.Q.........
I L--...j Ir l• rn........ l Sianal Return .........~t. ....... lSignal Return i
'------~---+1._.-_-_-_-_-_-_"°'._►::::::::::::::·.·.· ·.·.·.·.·.·~;.·.·.-.·.·.·.·.·. ~:~:~:II ::::::::::~:::::: .. VREF JR
....- - -- - - - - - - - - - -- ..........17.......... .. .......;ia ........ ,
......... aL ...... j BARO Signal "i!!j
I ,..........~;!......... CAMP Grnund ...... ... 6:i ...... .. BARO
. ........ ;li! ......... 1- _ _ _ _ _ _ _ _ _ _ _ i;A,MP.§igoal_ _ _ _ _ _ .........~\!........ ,,
-------------------------1......... J.L ...... GPC /Control\ .........1lll........,
I ------------------------1 ........;lli......... ◄KEYPWR IDM conff91or
Data Link
11·
Connector I G _ L_

..........?........ .. G...l;G~ii---I~.,:g.-=€,.:-ji..........L ....... ..

E400
lnjector#1 - - - - - - - - - - - - - - - - - ~ ..........?.......... - - - - - ......... .6 ....... .. SOLENOID .. .......BL ..... .
I lnjectar#3 _ _ _ _ _ _ _ _ _ _ ......... :\........ ..
- - - - - ..........:1....... ,, ASSEMBLY .. ........1,:1......... FEPS I I
I ,---- lnjector#5
I I i----~cto7"#1-- ......... : ..........
1 - - - - - ..........8 ...... . ........ J.e.........,1-"-
BU ~S
"'-'-
+- -+-- KEYPWR
I I I , - - - - - - - - .................... . - - - - - ........ 20 ....... .
......... ~:i........ BUS· J
1
I I I I ......... ).9........ . _ C!Q - _ .........ae.........
......... ).?........ . !:_0<2_5 - _ .........l!L .... .
------
i - I. . . . ......... ~ ......... EF Feedback

l
- ....... All........ .
..:;,1,ze,7.7.,1!!~.. - PWRGND
~ I ~ I ~ JL...... INJHI R .........:1........ . .. ....... M....... IACC • -. KEYPWR
~ ~:
I
........ ~9......... 1-1 P:..:Wa.:.R.:..:G=N=D__,II•
~~ : High voltage ........ J.1......... INJHI_L ......... n ...... .. ......... H ...... l4X4L @ KEYPWR
1 1 ---ii,
,,.. ,,.,.~-~········•1.:.::
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m..:,.
n:.:,;
•n~ - - IDM-EN , ........ .?.Q........ .
......... ~!!.. ...... TCS (Automatic) -_.__ __KEYPWR
_

1. . . . . -----,
Starter Motor KEYPWR
Relay E DCB A ......... .f.~......... CPP (Manual)
(Fusable Links)
I
II I Injector #8
lnjecloi'116"' _ _ _ _ _
11! ........ ,
8 .........~..........
1. ..... ... !!?....... 1Boo , _• BAT+

- - - - - ........ J.11.. ...... . 11•

I 1njector#4_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ........ 6 ........ . .. .......7.~............T_C_IL_ _ _ _ _-lo!,t,/ KEYPWR
- - - - - ..........1........ .. l<l=VPWR
!Jnjector #2 __________________ ......... 3........ ..
----- ........ ~~ ........J
. ........ ~9......... GPL Control "c"
..........~.......... PBA KEYPWR
..---- - --------------1.........?.4......... .__
........ 2:i. ........ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
VPWR ....... 7.1.il7....... .
,. lf RJ.Co_!!tr~ ) _ . .. ...... 83........ ..
.... .... i?;l........ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ E_!'RJ C~ tr~ I) _ .........~.~........ .

m
~ IPR
C EPR
........ rn ........

(Dotted Lines= Frequency or Switch Functions)

P I•

(Orientation = Looking into harness side of connector)

KEYl>WR
.........~......... CASE GND
.........?.0......... : iA Control ~ KEYPWR
..........~L ........I,!:!::=...._ __ _ _ _ _ __
..........;( ......... Check En ine Li ht@. _ KEYPWR
......... 6L ....... SCCS
,.........~O.........
I•

t o Speed Control Switches)

TAC

w REP - 12 VOLTS BLACK =GROUND CIRCUIT GREEN =SIGNAL CIRCUIT PURPLE= HIGH VOLTAGE BLUE - VREF (5 VOLTS\
 Fault
Power Stroke I 997 F-250/F-350 (49 state)
F-Super Duty (ALL)
Circuit
Code Index Condition Oesc riotion Comments Probable Causes
0107 BARO Barometric oress sensor circuit low inout Defaults to 100 kPa Ooen/arounded circuit biased sensor PCM
0108 BARO Barometric oress sensor circuit hiah inout Defaults to 100 kPa Circuit shorted to 5V biased sensor PCM
0112 IAT Intake air temo sensor circuit low inout Defaults to 15•C Grounded circuit biased sensor PCM
0113 IAT Intake air temo sensor circuit hiah inout Defaults to 15•c Ooen circuit. biased sensor PCM short to 5V
0122 AP Accelerator nA<ial sensor circutt low Inout Enaine WIii onlv Idle if hard fault Grounded circurt. biased sensor PCM
0123 AP Accelerator nA<ial sensor circurt hinh Inout Ennine WIii onlv idle ii hard fautt Ooen cucuit biased sensor PCM short to 5V
0196 EOT Enaine oil temo sensor circuit oerformance Enaine not warm enouah to run KOER CCT • aborts test Enaine not warm enouah leakina thermostat ckt failure
0197 EOT Enaine oil temo sensor circuit low inout No cold adv. fast low idle Grounded circuit biased sensor PCM
0198 EOT Enaine oil temn sensor circuit hinh inout No cold adv. fast low idle Ooen circuit biased sensor PCM short to 5V
0220 IVS Throttle switch B circuit malfunction Switch test • KOER Short/nnAn circuit switch failure ooerator PCM
0221 APnvs Throttle switch B circuit nerformance AP/IVS disanree • Ennine will onlv idle if hard fault Failed oedal assemblv
0236 MAP Turbo boost sensor A circuit oerformance Uses Inferred MAP si□nal Restricted inletlexhaustlsuoolv hose or missina hose
0237 MAP Turbo boost sensor A circuit low inout Uses Inferred MAP si□nal Open short to around or 5V faultv sensor
0238 MAP Turbo boost sensor A circuit hi□h in□ut Uses Inferred MAP si□nal Noise faultv sensor
0261 INJ lniector circuit low - Cvlinder ~ FMEM mode en□ine will run on 4 cvl. Harness short to nround
0262 INJ lniector circuit hioh • Cvlinder 1 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0263 INJ Cvlinder 1 contribution/balance fault Cvlinder not contributino durino CCT test Power cvlinder valve train or iniector nroblem circuit
0264 INJ lniector circuit low • Cvlinder 2 FMEM mode enolne will run on 4 cvl. Harness short to around
0265 INJ lniector circuit hiah • Cvlinder 2 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0266 INJ Cvlinder 2 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector oroblem circuit
0267 INJ lniector circuit low • Cvlinder 3 FMEM mode enaine will run on 4 cvl. Harness short to around
0268 INJ lniector circuit hiah • Cvlinder 3 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0269 INJ Cvlinder 3 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector orobtem circuit
0270 INJ lniector circuit low - Cvlinder 4 FMEM mode enaine will run on 4 cvl. Harness short to around
0271 INJ lniector circuit hiah - Cvlinder 4 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0272 INJ Cvlinder 4 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector oroblem circuit
0273 INJ lniector circuit low • Cvlinder 5 FMEM mode ennlne will run on 4 ""I. Harness short to around
0274 INJ lniector circuit hinh • Cvlinder 5 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0275 INJ Cvlinder 5 contribution/balance fault Cvlinder not contributinn durinn CCT test Power cvlinder valve train or iniector oroblem circuit
0276 INJ lniector circuit low • Cvlinder 6 FMEM mode enoine will run on 4 cvl. Harness short to around
0277 INJ lniector circuit hiah • Cvlinder 6 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0278 INJ Cvlinder 6 contribution/balance fault Cvlinder not contributino durino CCT test Power cvlinder valve train or injector nroblem circuit
0279 INJ lniector circuit low • Cvlinder 7 FMEM mode enoine will run on 4 cvl. Harness short to around
0280 INJ lniector circuit hioh • Cvlinder 7 FMEM mode enoine will run on 4 cvl. Miswired connector or harness
0281 INJ Cvlinder 7 contribution/balance fault Cvlinder not contributino durino CCT test Power cvlinder valve train or iniector oroblem circuit
0282 INJ lniector circuit low - Cvlinder 8 FMEM mode enaine will run on 4 cvl. Harness short to around
0283 INJ lniector circuit hiah - Cvlinder 8 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0284 INJ Cvlinder 8 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder, valve train or iniector oroblem circuit
0340 CMP Camshaft oosition sensor ckt malfunction No CMP sensor sianal detected durino crank Ooen/arounded circuit. sensor fault. short to oower
0341 CMP Camshaft oosition sensor ckt oertormance Electrical noise detected Harness routina. charaino circuit sensor
0344 CMP Camshaft POSition sensor ckt intermittent Incorrect number of CMP transition counts Harness routine. charaina ckt sensor int ckt imorooer aao
0380 GPC Glow olua circuit malfunction Glow Piua Relav • KOEO on-demand test OPeniarounded ckt solenoid ooen/shorted failed PCM
0381 GPL Glow olua indicator circuit malfunction Glow Plua Lamo • KO EO on-demand test nn..n1arounded circuit lamP ooen failed PCM
0470 EBP Exhaust oress sensor circuit malfunction Kev•on or crank mode Biased sensor ooen sianal return
0471 EBP Exhaust oress sensor circuit oertormance Continuous Pluaaed stuck or leakina hose
0472 EBP Exhaust oress sensor circuit low inout Disables back pressure device OPen/arounded circuit biased sensor PCM
0473 EBP Exhaust cress sensor circuit hinh incut Disables back nressure device Circuit shorted to 5V biased sensor PCM
0475 EPA Exhaust cress control valve malfunction Exhaust back press reo • KOEO on-demand test Ooen/arounded ckt solenoid ooen/shorted failed PCM
0476 EPA Exhaust oress control valve oerformance KOER on-demand test Failed/stuck EPA EBP fault EPA circuit
0478 EPA Exhaust nress control valve hinh inout Excessive back nressure • Continuous Pluaaed sensor line stuck butterflv. restricted exhaust
0500 vss Vehicle s,,....,. sensor malfunction Continuous Sensor circutt PCM PSOM low trans fluid
0560 N/A Svstem voltaae malfunction B+ too low for KOER on-demand or CCT test • aborts test Chaminn svstem nroblemnoad alow pluas still enabled
0562 VPWA Svstem voltaae low Mav be temoorarv condition at crank onlv Low svs vo1tane charninn svs internal PCM failure
0563 VPWA Svstem voitaoe hiah Mav be temoorarv condition - 24V iumo start Hinh svs voltaae charaina svs Internal PCM failure
0565 s ecs Cruise On sional malfunction KOER switch test /Cede set if cruise not oresent\ Open or short circuit, switch failure, PCM failure or failed
0566 sec s Cruise Off sianal malfunction KOER switch test /Code set if cruise not oresent\ to activate switch during KOER switch tesr
0567 secs Cruise Resume sianal malfunction KOER switch test /Code set if cruise not oresent\
0568 SCCS Cruise Set sianal malfunction KOER switch test /Code set if cruise not oresent\ Cruise control and BPA codes will be set on every switch
0569 SCCS Cruise Coast sianal malfunction KOER switch test /Code set if cruise not oresent\ test on vehicles not equipped with cruise control.
0571 BPA Brake switch A circuit malfunction KOER switch test /Code set if cruise not Present\
0603 PCM Powertrain Control Module KAM test error No historical faults outPut durina self test Ooen PCM oin disconnected B+ faultv PCM
0605 PCM Powertrain Control Module ROM test error Internal PCM failure Internal PCM failure
0606 PCM PCM processor fault PCM inactive backaround fault Internal PCM failure
0703 BOO Brake switch B circuit malfunction KOER switch test Open/short circuit, switch, PCM, failed to activate
0704 CPP Clutch switch incut circuit malfunction KOER switch test switch durino KOER switch test
0707 TRS Trans ranee sensor circuit low incut Continuous Short to around in circuit biased sensor PCM
0708 TRS Trans ranee sensor circuit hinh inout Continuous Ooen In circuit biased sensor PCM short to Power
0712 TFT Trans fluid temp sensor ckt low inout KOEO KOER and Continuous Short to around. biased sensor PCM
071 3 TFT Trans fluid temo sensor ckt hiah inout KOEO KOER and Continuous Ooen circuit biased sensor PCM short to oower
0741 TCC Toraue converter clutch ckt performance KOEO onlv Circuit failure faultv solenoid PCM
0750 SS1 Shift solenoid A malfunction KOEO onlv Circuit failure faultv solenoid PCM
0755 SS2 Shift solenoid B malfunction KOEO onlv Circuit failure. faultv solenoid PCM
0782 NIA 2-3 shift error Continuous Circuit failure faultv solenoid fauttv clutch PCM
0783 NIA 3-4 shift error Continuous Circuit failure faultv solenoid faultv clutch PCM
1111 N/A Svstem nass No PCM svstem faults detected N/A
1211 IPA ICP oressure above/below desired Continuous and KOER on-demand test IPR valve failed stuck or shorted to around
1212 ICP ICP volt not at expected level Crank mode and KOEO on-demand test Biased sensor or ckt, open signal return, low oil in reservoir
64
□
 POWERTRAIN CONTROL SYSTEM
ELECTRONICS DIAGNOSTIC GUIDE
Fault Circuit
Code Index Condition Oescriotion Comments Probable Causes
1218 Cl Cl stuck hinh Cvlinder identification line stuck hinh C l circuit onen nrobablv intermittent
1219 Cl Cl stuck low Cvlinder identification line stuck low Cl circuit short to nround nrobablv intermittent
1261- INJ High lo low side short cyl#1 • #8 Cylinder with fault will not operate Short circuit, shorted injector, failed IDM
1268
1271- INJ High to low side open cyl#1 • #8 Cylinder with fault will not operate Open circuit, open injector, failed IDM
1278
1280 ICP ICP circuit out of ranoe low Uses inferred ICP strateov Onen/arounded circuit biased sensor PCM
1281 ICP ICP circuit out of ranoe hioh Uses inferred ICP strateov Circuit shorted to SV biased sensor PCM
1282 IPR Excessive ICP oressure Svstem fault Faultv IPR reoulator lstickinn\ IPR shorted to around
1283 IPR IPR circuit failure KOEO on-demand test Ooen/arounded circuit stuck IPR loose connection
1284 NIA ICP failure • aborts KOER test Aborts KOER CCT lest Sensor circuit fault
See codes 1280 1281 1282 1283 121 1
1291 INJ Hioh side short to ord or B+ bank #1 irinhtl lni cower suoolv circuit short looerates on 4 cvlinders) Shorted circuit, faultv IDM
1292 INJ Hioh side short to ord or B+, bank #2 /left\ lni cower suoo!v circuit short (ooerates on 4 cvlinders' Shorted circuit, faultv IDM
1293 INJ Hiah side ooen bank #1 /riahtl lni newer sucolv circuit ooen {ooerates on 4 cvlinders' Ooen circuit faultv IDM
1294 INJ Hiah side ooen bank #2 /left\ lni newer sunnJv circuit ooen (ooerates on 4 ~linders' Qnen circuit faultv IDM
1295 INJ Multiple faults on bank #1 (right) with Fix low side short and rerun diagnostics Miswired connector or harness, short to ground
low side short
1296 INJ Multiple faults on bank #2 (left) with Fix low side short and rerun diagnostics Miswired connector or harness, short to ground
low side short
1297 INJ Hinh sides shorted toaether Fix shorts and rerun diannostics Shorted wires, faultv IDM
1298 IDM IDM failure Internal IDM failure Internal IDM failure
1464 N/A NC demand out ol self test ranne Aborts test • KOER on-demand CCT or switch test Onerator error, A/C circuit shorted to oow er
1501 N/A VSS out of self test ranae Aborts test • KOER on-demand CCT or switch test Onerator error
1502 N/A Invalid test • APCM functioninq Aborts test • KOER on-demand CCT. or switch test APCM active wh ile KOER test is runninn
1531 N/A Invalid test - accelerator nedal movement Aborts test • KOER on-demand or CCT test Onerator error
1536 PBA Parkinn brake switch circuit failure KOER switch test Failed to activate switch durina test circuit. switch PCM
1660 occ OCC sinnal hiah Aborts KOEO on-demand test Hinh svstem voltaae internal PCM fault
1661 occ OCC sianal low Aborts KOEO on-demand test Low svstem valtaae, internal PCM fault
1662 IDM EN IDM EN circuit failure KOEO on -demand test Ooen IOM relav, blown fuse, ooen/arounded circuit
1663 FDCS FDCS circuit failure Fuel demand command sianal • KOEO on-demand test Ooen/arounded circuit. faultv IDM
1667 Cl Cl circuit failure Cvlinder identification circuit - KOEO on-demand test Ooen/arounded circuit faultv IDM
1668 EF PCM-IOM di aanostic communication error Electronic feedback line - KOEO on-demand test Ooen/shorted EF or FDCS ooen IDM nround
1705 TRS TR sensor out of self test ranae Not in PARK durina KOEO or KOER Ooerator error, circuit failure faultv sensor PCM
1711 TFT TFT sensor out of self test range Transmission fluid temp too high for KOEO or KOER test Transmission too hot or cold, circuit failure,
faultv sensor. PCM
1728 TCC Transmission slio error Continuous Solenoid failure or mechanical failure
1729 4x4L 4x4 Low switch error Continuous Circuit failure, faultv switch PCM
1746 EPC EPC solenoid ooen circuit KOEO onlv Onen circuit faultv solenoid PCM
1747 EPC EPC solenoid short circuit KOEOonlv Short circuit, faultv solenoid PCM shorted to nround
1748 EPC EPC malfunction Continuous Circuit failure PCM
1754 ccs Coast clutch solenoid circuit malfunction KOEO on-demand test C ircuit failure faultv solenoid PCM
1779 TCIL TCIL circuit malfunction KOEO on-demand test Short to around PCM
1760 TCS TCS ci rcuit out of self test ranne KOER switch test Circuit switch, PCM failed to activate switch KOER
1781 4X4L 4X4L circuit out of self test ranne In 4X4L durinn KOEO Onerator error short to nround PCM
1783 TFT Transmission OV11rtamr>Arature condition Continuous Internal transmission failure, circuit failure, sensor, PCM

(FMEM) MIL illumination occurs after 1st fault

TransmisslQn Control Indicator Light (TCIL) flashes when fault Is p,-rt.
(FMEM) M IL and TCIL illuminate when fault is present

For Econoline (ALL) and F-250/F-350 (California only)

refer to Diagnostic Guide #FCS-70230207

FCS-70230208

65
 F-Series
PCM Connector Cab Mounted Components

Vehicle Mounted Components

.... . .4 ... .. , ....D""D""
s _ _ _.,. --.., GRD I
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BATT Light ®KEYPWR I
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KAPWR ••• •• PP••••••
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•.• . . fill•.•.•• AP Si nal
50 . . .•.
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option only
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19 Signal Return 91 Si nal Return I_
. .......... ~i1· . . VREF •.• •• 90...... VREF KEYPWR
.••... . .. 22· ..1-- - + - - - - - --1---......:..:..:.::.;__ _➔------1 •.·.·.·.·:~t.·::.·.•.l--...,_;.;...._ '-.i - - - - - , __
· · · · · · · · · · · 1'/ · ·1-- - - - - - - --1-- - - -~!--"IJ~I.L...-1- - - - --t · . ... 3a .... .
. • . . . . . •. ;37... . . . . . ~?.... . .
•• •• ••••••• )~... • •• •• f>?••••• •
- ;3;3 CAMP Ground ••• • J>P... •. •
. • ••••••• ;3~· . . _ _ _ _ _ _ _ _ _ _ _ _ _ .QAft1P_Sig,naj_ _ _ _ _ _ _ _ 21 BARO
••••••••••• ••• ••••• 6:3° ••••• BARO Si nal
..•. •.•.. J;3.. . 1----------l----la.t:.I. .U. :I.U.l lL.1.!1.1. - f-- - - --+ :::::i<ii ::: : :
. . ......... 27... . ... . ;3~•• • •••
.. ....... M... . .. . . Jl .... . .

· · · · · · · · · ~P. · · IDM Connector rr===.. ~~:.:.:.!~:::::::::::f...::::..j1::::::

fl...... .
~ -- E~onolin:
Only
~
. . ... .?. . . .. . . ... . ;3;3• ••••• VSS- J Data Link

........... ... 2
·-·-· 6
r-
•••. • ~~...... Y$St ►
..... ~?.. .. ..
1
-______
- •,:.:.:.,==---11,
...,
5 21 1 Not used on ' 20
7 8 I Econoline • • • • • 5;1 · · · · ·
4
·-·-· ............ 20
. nt--...:;f';'-•::: :::t :: ::: B+

ll'--..a:;.:;:'""-• · · ··· J.1 . . ... .

. . . . . .2.~..... PWR GND II• / ~-""'-"""-L • • • • • ?.1 ••....
16 CID
:::::fr::::
4
: FflC§ : : : : : : . : . _ -
EF
96
::::J~::::::
.... . ~?.. . .. .
12
INJHI R ::::::~1:::::. - -, -- -- --=- r=~~4!f1D~M
!l.·;£EJ:N
: !h .. . .. J;3.... .........=--......
•• ••• Jf5.... . ..................,,..._ +-'
11 INJHI_L 23 APC MODULE
·········-··· ··· ·· ··· ······· · ••••• JP••••. •i...:.=......- -+-----'
. .... )~..... . t-=""""- --+-.... KEYPWR
.•••• f!P•••• ••
.~1.,?f,,??'19~ ·1--.;.;.;..;...;.;.;.=.-'-1(1
94
'----ii•
.•...•. •. ••)P•••
..............
8
6
...... .? ... . . . B+
3 22
24
VPWR
~ :: : : : : : : : ~~:::
25
1◄-111(1---- KEYPWR
••••••••• •2::i" •• _!PE!, ((2_on..!_ro!2_ _ _ _ _ _ _ _
. ........•2i,i" ". _EP_R ~O!!.trQJ) _ _ _ _ _ _ _
.•••••. •. 15" •. _W~CJ C2_nt!:S)I)_ _ ___ _

FPM

Fuel Pump GND I•

67
 Fault
Power Stroke 1999 1998 1/2 E-Series and
1999 F-Series
Circuit Condition
Code Index Description Comments Probable Causes
0107' BARO Barometric cress sensor circuit low innut Defaults lo 100 kPa Onen/arounded circuit biased sensor PCM
0108' BARO Barometric cress sensor circuit hioh innut Defaults lo 100 kPa Circuit shorted to 5V biased sensor PCM
0112' IATIntake air temo sensor circuit low innut Defaults to 15'C Grounded circuit biased sensor PCM
0113' IATIntake air temo sensor circuit hiah illDut Defaults to 15•c Onen circuit biased sensor PCM short to 5V
0122· AP Accelerator oedal sensor circuit low inout Enaine will onlv idle if hard fault Grounded circuit biased sensor PCM
0123' AP Accelerator oedal sensor circuit hinh innut Enaine will onlv idle if hard fault Ooen circuit biased sensor PCM short to 5V
0197' EOT Enaine oil temo sensor circuit low innut No cold adv. fast low idle Grounded circuit biased sensor PCM
0198' EOT Enaine oil temo sensor circuit hinh innut No cold adv. fast low idle Ooen circuit biased sensor PCM short to 5V
0220 IVS Throttle switch B circuit malfunction Switch test • KOER Short/ooen circuit switch failure ooerator PCM
0221' AP/IVS Throttle switch B circuit performance AP/IVS disaaree • Enaine will onlv idle if hard fault Failed nedal assemblv
0230 FP Fuel Pumo relav driver failure KOEO
0231' FP Fuel Puma relav driver failure numn ON KOEO
0232 FP Fuel Puma relav driver failure numn OFF KOEO
0236' MAP Turbo boost sensor A circuit nerformance Uses Inferred MAP sianal Restricted inlet/exhaust/suoolv hose
MAP

'";· ~,;.,,"lil'
0237' Turbo boost sensor A circuit low innut Uses Inferred MAP sianal Ooen short to around or 5V faultv sensor
0238' MAP Turbo boost sensor A circuit hiah innut Uses Inferred MAP sianal Noise faultv sensor
0261 INJ

I
lniector circuit low - Cvlinder 1 FMEM mode enaine will run on 4 cvl. Harness short to around
0262 INJ FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0263 INJ Cvlinder 1 contribu · ce fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector Droblem circuit
0264 INJ lniector circuit low - r2 mode enaine will run on 4 cvl. Harness short to around
0265 INJ lniector circuit hiah • 2 mode enaine will run on 4 cvl. Miswired connector or harness
0266 INJ Cvlinder 2 contribution a ance fault er not contributina durina CCT test Power cvlinder valve train or iniector nroblem circuit
0267 INJ lniector circuit low - Cvlinder 3 mode enaine will run on 4 cvl. Harness short to around
0268 INJ lniector circuit hiah • Cvlinder 3 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0269 INJ Cvlinder 3 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or injectorDroblem circuit
0270 INJ lniector circuit low - - 4 FMEM mode enaine will run on 4 cvl. Harness short to around
0271 INJ lniector circuit hiah - 4 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0272 INJ Cvfinder 4 contributio ce fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem circuit
0273 INJ lniector circuit low - Cylinder 5 FMEM mode enaine will run on 4 cvl. Harness short to around
0274 INJ lniector circuit hiah • Cylinder 5 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0275 INJ Cvlinder 5 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniectorDroblem circuit
0276 INJ lniector circuit low - Cvlinder 6 FMEM mode enaine will run on 4 cvl. Harness short to around
0277 INJ lniector circuit hiah - Cvlinder 6 FMEM mode encine will run on 4 cvl. Miswired connector or harness
0278 INJ Cvlinder 6 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem circuit
0279 INJ lniector circuit low - Cylinder 7 FMEM mode enaine will run on 4 cvl. Harness short to around
0280 INJ lniector circuit hiah • C~ finder 7 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0281 INJ Cvlinder 7 contribution/balance fault Cvlinder not contributina durina CCT test Power cvlinder valve train or injector aroblem circuit
0282 INJ lniector circuit low • Cvlinder 8 FMEM mode enaine will run on 4 cvl. Harness short to around
0283 INJ lniector circuit hiah - Cvlinder 8 FMEM mode enaine will run on 4 cvl. Miswired connector or harness
0284 INJ Cvlinder 8 contribution/balance fault Cvfinder not contributina durina CCT test Power cvlinder valve train or iniector nroblem circuit
0301' INJ Fault cvlinder 1 • Misfire Detected
0302' INJ Fault cvlinder 2 • Misfire Detected
0303' INJ Fault cvlinder 4 • Misfire Detected
0304' INJ Fault cvlinder 5 • Misfire Detected
0305' INJ Fault cvlinder 6 • Misfire Detected
0306' INJ Fault cvlinder 7 • Misfire Detected
0307' INJ Fault cvlinder 3 • Misfire Detected
0308' INJ Fault cvlinder 8 • Misfire Detected
0340 CMP Camshaft oosition sensor ckt malfunction No CMP sensor sianal detected durina crank Onen/orounded circuit sensor fault short to nower
0341' CMP Camshaft oosition sensor ckt oerformance Electrical noise detected Harness routina. charaina circ uit sensor
0344' CMP Camshaft position sensor ckt intermittent Incorrect number of CMP transition counts Harness routing, charging ckt, sensor, int ckt,
imnroner aan
0380' GPC Glow riJua circuit malfunction Continuous and KOEO on-demand test Onen/nrounded ckt solenoid ooen/shorted failed PCMz
0381 ' GPL Glow olua indicator circuit malfunction Continuous and KOEO on-demand test Ooen/arounded circuit lama open failed PCM
0460 FLI Fuel Level Sensor Circuit Malfunction
0470 EBP Exhaust cress sensor circuit malfunction No-start or crank mode Biased sensor ooen sianal return
0471' EBP Exhaust cress sensor circuit nerformance Continuous Pluaaed stuck or leakina hose
0472' EBP Exhaust cress sensor circuit low innut Disables back nressure device Qnen/nrounded circuit biased sensor PCM
0473' EBP Exhaust nress sensor circuit hiah innut Disables back nressure device Circuit shorted to 5V biased sensor PCM
0475' EPR Exhaust aress control valve malfunction Continuous & KOEO on-demand test Onen/arounded ckt solenoid open/shorted failed PCM
0476 EPR Exhaust aress control valve oerformance KOER on-demand test Failed/stuck EPR EBP fault EPR circuit
0478' EPR Exhaust cress control valve hinh innut Excessive back oressure - Continuous Pluaaed sensor line stuck butterflv restricted exhaust
0500' vss Vehicle soeed sensor malfunction Continuous Sensor circuit PCM PSOM low trans fluid
0560 N/A Svstem voltaae malfunction B+ too low for KOER on-demand or CCT test • aborts test Charaina svstem oroblem/load alow nluns still enabled
0562' VPWR Svstem voltane low Mav be temnorarv condition at crank onlv Low svs voltaae charaina svs internal PCM failure
0563 VPWR Svstem voltaae hiah Mav be temoorar• condition• 24V iumo start Hinh svs voltaae charaina svs internal PCM failure
0565 SCCS Cruise On sional malfunction KOER switch test Code set if cruise notDresent Onen or short circuit switch failure PCM failure or failed
0566 secs Cruise Off sianal malfunction KOER switch test Code set if cruise not oresent to activate switch durina KOER switch test
0567 secs Cruise Resume sianal malfunction KOER switch test Code set if cruise not nresent
0568 secs Cruise Set sianal malfunction KOER switch test Code set if cruise not nresent Cruise control and BPA codes will be set on everv switch
0569 secs Cruise Coast sianal malfunction KOER switch test Code set if cruise not nresent test on vehicles not eauiooed with cruise control.
0571 BPA Brake switch A circuit malfunction KOER switch test /Code set if cruise not nresentl
0603 PCM Powertrain Control Module KAM test error No historical faults output during self test
Ooen PCM oin disconnected B+ fault" PCM
0605 PCM Powertrain Control Module ROM test error Internal PCM failure Internal PCM failure
0606 PCM PCM orocessor fault PCM inactive backaround fault Internal PCM failure
0703 BOO Brake switch B c ircuit malfunction KOER switch test
Onen/short circuit switch PCM failed to activate
0704 CPP Clutch switch innut circuit malfunction KOER switch test switch durina KOER switch test
0705' TRS Trans range sensor circuit malfunction Continuous
Short or ooen diaital TRS loin 64 short onlvl
0707 TRS Trans ranae sensor circuit low innut Continuous Short to around Analon TRS
0708' TRS Trans range sensor circuit high input Continuous
Ooen analoa TRS ooen e in 64 diaital TRS
0712 TFT Trans fluid temo sensor ckt low innut KOEO KOER and Continuous Short to around biased sensor PCM
0713 TFT Trans fluid temp sensor ckt hiah innut KOEO KOER and Continuous Qnen circuit biased sensor PCM short to nower
0715' TSS sensor circuit malfunction fault
0720' OSS sensor circuit malfunction fault
0731 Gear #1 Ratio Error Continuous
732 Gear #2 Ratio Error Continuous
0733 Gear #3 Ratio Error Continuous
0741 TCC Toraue converter clutch ckt oerformance Continuous
0743' TCC Toraue converter clutch svstem electrical KOEO and Continuous Faultv solenoid PCM
0750' SS1 Shift solenoid A malfunction KOEO and Continuous Circuit failure faultv solenoid PCM
0751 CCM SSA Shilt solenoid #1 fault
0755' SS2 Shift solenoid B malfunction Continuous and KOEO Circuit failure faultv solenoid PCM
0756 CCM SSB Shift solenoid #2 fault
0760 CCM SSC Shift solenoid #3 fault
0781 N/A 1-2 shift error Continuous

68
□
 POWERTRAIN CONTROL SYSTEM
ELECTRONICS DIAGNOSTIC GUIDE
Fault Circuit Condition
Code Index Description Comments Probable Causes
0782 N/A 2-3 shift error Continuous Circuit failure faultv solenoid faulty clutch PCM
0783 NIA 3-4 shift error Continuous Circuit failure faultv solenoid faultv clutch PCM
1000 NIA Check of all OBDII svstems not comolete
1105 ALT Dual Alternator uooer fault
1106 ALT Dual alternator lower fault
1107' ALT Dual alternator lower circuit malfunction
1108 ALT Dual alternator batterv lamo circuit malfunction
1118' MAT Manifold Air Temo sensor out of ranae low KOEO
1119' MAT Manifold Air Temo sensor out of ranae hioh KOEO
1139 WIF Water•in-Fuel circuit malfunction KOEO
1140 WIF Water-in-Fuel condition failure
1184 EDT Enaine oil temo sensor out of self test ranae Enaine not warm enauah to run KOER CCT • aborts test Enaine not warm enouah leakina thermostat ckt failure
1209' IPR lniection control cressure svstem fault IPR valve stuck
1210· IPR lniection control cressure above exoected level No-start mode and KOEO on-demand test
1211· IPR ICP oressure above/below desired Continuous and KOER on-demand test IPR valve failed stuck or shorted to around
1212 ICP ICP press not detected during crank Crank only Biased sensor or ckt, open signal return,
low oll In reservoir
1218 Cl Cl stuck hiah Cylinder identification line stuck hiah Cl circuit ooen orobablv intermittent
1219 Cl Cl stuck low Cvlinder identification line stuck low Cl circuit short to around orobably intermittent
1247' MAP Turbo boost oressure low
1248' MAP Turbo boost oressure not detected
Hose disconnected
1249' WG Waste-aate failure steadv state
1261- INJ High to low side short cyl#1 • #8 Cylinder with fault will not operate
1268
Short circuit shorted iniector failed IDM
1271- INJ High to low side open cyl#1 • #8 Cylinder with fault will not operate
1278
Coen circuit ooen lniector failed IDM
1280' ICP ICP circuit out of ranQe low Uses inferred ICP strateav Ooen/arounded circuit biased sensor PCM
1281' ICP ICP circuit out of ranae hiah Uses inferred ICP strateav Circuit shorted to 5V biased sensor PCM
1282' IPR Excessive ICP oressure Svstem fault Faultv IPR reaulator rstickinal. IPR shorted to around
1283 IPR IPR circuit failure Continuous & KOEO on-demand test Ooen/arounded circuit stuck IPR loose connection
1284 N/A ICP failure • aborts KOER test Aborts KOER CCT and on-demand tests Sensor circuit fault
See codes 1280 1281 1282 1283 1211
1291 INJ Hlah side short to ard or B+ bank #1 lrlahtl lni cower suoolv circuit short fooerates on 4 cvlindersl Shorted circuit faultv IDM
1292 INJ Hiah side short to ard or B+ bank #2 (leftl lni cower suoolv circuit short Cooerates on 4 cvlindersl Shorted circuit faultv IDM
1293 INJ Hiah side ooen bank #1 lriahll lni oower suoolv circuit ooen looerates on 4 cvlindersl Coen circuit faultv IDM
1294 INJ Hiah side ooen bank #2 rleftl lnl oower suoolv circuit ooen looerates on 4 cvlindersl Coen circuit faultv IDM
1295 INJ Multiple faults on bank #1 (right) with Fix low side short and rerun diagnostics
low side short Mlswired connector or harness short to around
1296 INJ Multiple faults on bank #2 (left) with
Fix low side short and rerun diagnostics
low side short
Miswlred connector or harness short to around
1297 INJ Hiah sides shorted toaether Fix shorts and rerun diaanostics Shorted wires faultv IDM
1298 IDM IDM failure Internal IDM failure Internal IDM failure
1316' IDM lniector circuiVIDM codes detected Run KOEO on-demand test to retrieve codes lniector clrcuit/lDM codes detected
1389 GPM Glow Plua Hlah Side out of ranae low KOER
1391• GPM Glow olua circuit low inout bank #1 /rlahll Aborts Qlow oluQ monitorinQ Coen circuit short to oower or around faulty relay
1393' GPM Glow olua circuit low inout bank #2 (left\ Aborts Qlow olua monitorlna Onen circuit short to nower or arr,und faultv relay
1395' GPM Glow nlua monitor fault bank #1 Continuous & KOER alow olua monitor test One or more alow oluas failed
1395• GPM Glow nlua monitor fault bank #2 Continuous & KOER alow r>lua monitor test One or more alow r>luas failed
1397 VPWR Svstem voltaae out of self test ranae Aborts KOER alow olua monitor test Svstem voltaae too hiah or low for alow olua monitor test
1399 GPM Glow Plua Hiah Side out of ranae hiah
1464 NIA AJC demand out of self test ranae Aborts KOER CCT test Ooerator error AJC circuit shorted to oower
1501 NIA VSS out of self test ranqe Aborts test • KOER on-demand CCT or switch test Ooerator error
1502 N/A Invalid test • APCM functionina Aborts test • KOER on-demand CCT. or switch test APCM active while KOER test Is runnina
1531 N/A Invalid test - accelerator oedal movement Aborts test • KOER on-demand or CCT test Ooerator error
1536 PBA Parkina brake switch circuit failure KOER switch test Failed to activate switch durina test circuit switch PCM
1634 DOL Data Cutout Link failure
1660 DCC DCC sianal hiah Aborts KOEO on-demand test Hiah system voltaae internal PCM fault
1661 DCC DCC sianal low Aborts KOEO on-demand test Low system vollaQe internal PCM fault
1662 IDM E~ IDM EN circuit failure Continuous & KOEO on-demand test Oaen IDM relav. blown fuse oaen/arounded circuit
1663 FDCS FDCS circuit failure Fuel demand command sianal - KOEO on-demand test Ooen/arounded circuit faultv IDM
1667 Cl Cl circuit failure Cvlinder identification circuit • KOEO on-demand test Ooen/arounded circuit faultv IDM
1668 EF PCM•IOM diaanostic communication error Electronic feedback line • KOEO on-demand test Coen/shorted EF or FDCS ooen IDM around
1670' EF EF sianal not detected Continuous Coen/shorted EF circuit
1690' WG Waste-aate failure KOEO KOEO
1700 OSS sensor intermittent circuit malfunction
1701 TSS sensor Int ermittent circuit malfunction
1702 TRS sensor intermittent circuit malfunction
1704 TRS Diaital TRS failed to transition state KOEO onlv Sensor wirina. PCM mechanical alianmenl
1705 TRS TR sensor out of self test ranae Not in PARK durina KOEO or KOER Ooerator error circuit failure faultv sensor PCM
1706 E4OD fails - Vehicle soeed excessive In oark
1711 TFT TFT sensor out of self test range Transmission fluid temp too high or Transmission too hot or cold, circuit failure1
low for KOEO or KOER test faultv sensor PCM
1713 TOT stuck hlah in-ranae failure below S0"F
1714' SS1 Shift Solenoid 1 inductive sianature malfunction Continuous
Solenoid or PCM
1715' SS2 Shift Solenoid 2 inductive sianature malfunction Continuous
Solenoid ar PCM
1716 TOT stuck hlah in-ranae failure between 50-250' F
1718 TOT stuck hiah in-ranae failure above 250 "F
1727 CCS Inductive sianature malfunction
1728 TCC Transmission slio error Continuous Solenoid failure or mechanical failure
1729 4x4L 4x4 Low switch error Continuous Circuit failure faulty switch PCM
1740 TCC Toraue converter clutch Inductive sla malfunction Continuous
Solenoid or PCM
1741
1742 TCC TCC mechanical failure
1744• Solenoid stuck on
Excessive slio across converter clutch
1746 EPC EPC solenoid ooen circuit Continuous Coen circuit faultv solenoid PCM
1747• EPC EPC solenoid short circuit Continuous Short circuit faultv solenoid PCM shorted to around
1748 EPC EPC malfunction Continuous Circuit failure PCM
1751 SSB shift solenoid #1 fault
1754 ccs Coast clutch solenoid circuit malfunction Continuous & KOEO on-demand test Circuit failure faultv solenoid PCM
1756 SSB shift solenoid #2 fault
1779 TCIL Failure
1780 TCS TCS circuit out of self test range KOER switch test Circuit, switch1 PCM 1 failed to activate switch or
switch alwavs active durina KOER
1781 4X4L 4X4L circuit out of self test ranae In 4X4L durina KOEO Oaerator error short to around PCM
1783 TFT Transmission overtemperature condition Continuous Internal transmission failure1 circuit failure, sensor, PCM

• (OBDII) MIL illumination occurs after 2nd consecutive fault

(FMEM) MIL Illumination occurs after 1st fault
Transmission Control Indicator Light (TCIL) flashes when fault Is present.
TCIL illuminates on 49 state applications only

69
 1998 1/2 Econoline

Hard Start / No Start Diaanostics

NOTE: A hard start/ No start concern with EOT 7. Retrieve Continuous Trouble Codes SooFlg.E 10. Glow Pl ug Systom Operation SooFig. E&G
Temp. below 60F perform step 10 f irst. • ores retrieved during this test are hlstorlcal faults. Relay Operation
- - - - -- - - - - - -- - - - - --------i Note: IDAf historical DTCs can be cl.ar here GIOw Plug ON time is dependent on oli temperature
1. Visual Ennfne/Chassls lnsoectlon even If none are dis la.,ed. and altitude. The Glow Plug relay comes on between
Fuel OH COOiant Electrical Hoses Leaks Oiagnostlc 1 to 120 sec. and does not come on at all if oil Temp
Method I Check Trouble Codes is above 86 F
Visual I 8. KOEO Injector Electrical Self-Test SO&Rg. e Verily that 8+ Is being supplied on the large
• UsetheNGSTestElf. BKIW wire going to the Glow Plug relay.
2. Check Engine Oil Level SooF~ C • AH Injectors will momentarily buzz, Ihen individual Install a vo~meter to the glow plug feed terminal
, Check for contaminants (fuel, coolant) injectors will buzz in sequence 1 through a. (lerminal with two brown wires) or (center terminal on
• Correct Grade/Viscosity • IDM DTCs may be transmitted alter test is compteted. the shunt for California).
• Miles/Hours on oil ,correct level Note: IDM DTCs can be historical If not cleared above. • Turn key to run position, measure 'ON" time
• Check level in reservoir Injector • Using lhe NGS GPCTM and EQT pids, verily
I Method I Check I Troublo Codes suflicient glOw plug "ON" Ume and voltage.
Vlsual I 9. NGS Too l - Data LISI Monitoring SooFlg. E IDeMndent on oil temoera ture and attilude1
• NGS Tester may reset below 9.5 vOlts. I9 • 12 volts I SDec. I Measurement I
3. In take/Exhaust Restriction See FJg.B &l , Select the parameters indicated lrom the NGS Re~yOn 1 to 120
• Inspect air filter and ducts - exhaust system parameter list and monitor while crankin11 ennine. lime seconds
tnsnect exhaust back oressure device Parameter I S"""'C. I Measurement Hot•: W•lt to Sf4'rt L•mp #On'" tfm• (1 - 10 HC,J
Method I Checlc V PWA 7 volt min. Is lnd.,,..,.,dent lrom Glow Plug Relay " On" llm•
Visual
I You mav need to use a outside nnwer source for the NGS
Glow Plug Ooerauoo
Measure Glow Plug Resistance to Bat. Ground.
4. Sufficient Clean Fuel Seo Fig. A RPM 100 RPM Remove both 9 pin connectors from valve covers
• Check if the WATER IN FUEL tamp minimum Measure GP Harness Resistance to Retav
has been illuminated. ICP 500 PSI or Glow Glow Plug Connector
• Alter verifying that there Is tuet in the tank, drain a 3.4 mPa mln. Plug to Ground to Relay
sample trom luel f ilter housing by key on, engine ofl . FUEL PW 1 mSto Number .1 to2ohms Oto 1 ohms
NOTE: Fuel numn will on/v run for 20 sec. 6 ms #1
Method I Chcclcs A - V PWR - II indicating a low voltage condition, • 3
Visual check battery voltage, charging system or power • 5
I and ground circuit s to the PCM. #7
5 . Electric Fu el Pump Pressure GOTOPINPOINTTESTA #2
• Alter verifying that there is luel in the tank 8 - RPM • Low RPM could be an Indication or starting{ • 4
and the pump is being powered, charging system problems, No RPM indicated with the #6
Measure at the top ol !he rel! cylinder head with engine Ctanking • could be CMP circ1.Jit fault , check #8
a (0-160 PSI) gauge. lor Diagnostic Trouble Codes. 1'0
Ke11 on ennine off. - Pumn will run for about 20 sec. GOTO Pll'FOINTTEST DG ,,o [

Instrument I SfHM:. I Measuremsnt I C • ICP • A minimum of 500 PSI (3.4 mPa) Is required i

0-1!~::..s1 I 30 PSI min. I belore the injectors are enabled. No 0r low oil in the
reservoir, system leakage, Injector 0-Aings or faulty IPR
1ii'100 •

"8 ,o
~
If pressure tails low, Go to step Be on the Performance could cause pressure loss.
i 60
s;de of this sheet to alnaolnt the cause. Go to section <18 step 9c in the PC/ED Manual for a ;:: 40 '
6. Perform KOEO On Demand Test SoeFig. E delalled description on how to perform this test. ' '
• Use the NGS Tester Note: If a no RPM signal Is received, IPR duty-
20
'
• OTCs set during this test are current faults. cycle wltl default to 14" See Fig. E & F 0

Note: IDM DTCs dfspl•yed here could b B current

or historical faults.
D • FUEL PW· Even though a 1 to 6 ms FUEL PW
0
" 20 30 40 50
EOT(• F)
60 70 80 90 100

is sho,.,11 on the NG$ to be sent to the IDM, irs

Diagnostic I possible that the IOM dld not get the signal, due to a • Add 5 seconds to glow plug on lime when above
Trouble Codes laull oo ether CID or FDCS circuits or even the IDM. 7000 feet in altitude, but not to exceed 120 secoods.

See PC/ED manual, Section 4B for more detail on all of the above test steps.

70
□
 1998 1/2 Econoline
Performance Dia nostics
1. v I1uaI Engine/Chassi s Inspection 88. Fuel Pretture at the left head See Ag. I 10b. Low Idle Stablllty (ICP Pressure)
, Verity thal lhefe are no ttlMO Of pressure leaka. • Vlrit; cnat fuet Is in cne tank and lhe pomp Is being powered. • Check It 10w kle
• Inspect an wire connection tor damage • Meuore fuel pres.sure at 1he rear ot lett head • Monit0t ICP and RPM with the NGS Tost8f
, Ins MAP hOse and lntak IOf leaks. CAUTION: S.Cu,_ Inf hoH ,wq from tutDo .,,d • xhwtt.

.....
F,

Yl1u1I
ON Cool1nt Electrical Leaks , Road Tes!- with a lull IOad on thee lne.
M . . .u,em.,,t
30 PSI mkt
II .ngln• RPM Is unstable d lsconn«:t tht ICP Hnsor
2. SuHlclent Clean Fuel tull prn,u,.. t-11• low, Go to ,,.,, le.
If
NOTE; ICP wtll d.,eult to 73$ PSI wtt•n dl1conneeted.
• Check ii WATER IN FUEL lamp nu been ilumlntted.
, Crain sample lrom fuel lilter housing by key on, engine Oft.
NOTE: Pum .,,,, onl run for n H C.
··--·•If l!,..•~u,. 1, above mf.n. ,IP«, Go IOLlff~-- - - - - - -
8b. Fuel Pressure at the right head
• Measure fuel pressure 11 lhe front ot right head
• ...... ,
It RPM , , ,,111 un,,.,,,,, Cheng, the IPR and ,.,•• ,.
It RPM 1mootttH out. the ICP 1/gnel II flt I.ult
11. Crankcase Prasure THt S.Rg.J
Cllo<I< • Tut undet ful load, but doni bfake • Assure onglne ls at normal operating temp.
v1,u,1 IOn • Measure at oil !ill with adapter and oriflee
tool P.N. 5631 & 014•00743 installed.
3. Check Engine 011 Level
• Block breather tube on letc valve cover.
• Check to, contaminants (fuel, coolant).
• Mea..re at WOT under no IOad.
• Cofrect GtadeMscosity. If ,u., prn•ure I• t>.low min. •,,.c, ,..,,Jae• right ch«:lc 11al11• ln•trument
• Mfles/hours on oll correct level.
w
._: ....JULtt_tl!f~!!.~,.Jf.w'°1'v_,__m_,[f..w•¥.,C, G~.J-~-~,~~·•~ - -- - Maonenelic less 1nan
ec. Electric Fuel Pump Pruaure 0 10 60" HOO 4~ HOO
vr, ual
II more then 4" HOO Refer baM en Int In Sho M•nual
12. Cylinder Contribution Tut SNRg.E
4. Intake Restriction
• Ensure tnat EOT Is above 70 F nin.
• Check filter minder
• Turn NC and all accessories oll
or Measur at WOT w/ma eh le au e.
• Select Cylinder Contribution from the tos-t menu
Chock ff IIHI p,_.u,,. l•II• tow, Go to •lflf' Id. NOTE: T1re newly dnJgn«J t•t will run M • Idle fO< about
MagnehelicJ 2 " · 2 5" ......:_fi_/!!..flHUre I• aboNI ml ~ _ r . l « f l I.rt c"-ck IIM_vo._ _ _ _ 110 ch•n e lhro Hut,,.. Int.
-~-•~;•~••~•~"~'•~•=••-~-~H~•~o-~~-- ---~---l 8d. Electric Fuel Pump Inlet Restriction SoeA;.H
5. Perform KOEO On Demand Test ...... E , M aaura WOT at I
, UsettioNGSTester. tn,trum•nt 13. Exhaust Restrlcllon SooFlg.E,K & L
, OTCs $01 during this test ,re current lault.s, 0·30 .. Hg • Vbualy Inspect exhaust system tor dam11ge
Not•: IDM ore, dl1pl ~ ,,.,. could 1H current vacuumG • V8fly EBP device Is open at WOT In park 0t neutral
or hl•torlc•I teu1t1. It tu., llne Is r•trlctH •bove r Hg, ch«:k for • Monitor EBP with !he NGS Tester with the engine
Diagnostic Blockage bttw.tn pump end fuel tenk. raturo at 170 • F minimum at 3400 RPM.
Trouble Codn It tu•I line 1, not re,trlcted, ln,,,.ct reguMtor 11el111
e. Retrieve Continuo us Trouble Codes SN~ e condition ,nd tor debrl
OK r, fac9 um ff
34 PSI MAX
· UselheNGSTes•. 9. Perform KOER On D«nand TH 3400 RPM
, DTCs retrieved during this teat are historical faults. KOEII 14. Boost Pr111ure Test
Note: /OM hlttorlc•I ore, cen lH clHr her• OTQ1 • Verily that MAP nose Is nol opeo, ptugged o, pinched
•wwn II non• • dis I• 10a. Injection Control Pressure Testa See Fig.D&E • MonllOt MGP (~nilold oauge pressure) and
Diagnostic (011 Aeration • Poor ldlt quallty)

......
RPM with the NGS Testel.
Troubl• Cod. . • Al aoc. off, Monii>r ICP and RPM with NGS Tester • Road Test - select appropriate gear k> obtain
7. KOEO Injector Electrical Self-Test at 3400 RPM tor 3 minutes. desired englne speed at fuN load throttle position.
, Useltle NOS Tester.
Bos! aocom llshed cllmbln hill or truck lull loaded.
• AU infectors will momentarily buzz, then fndMdual
1250 PSI MAX .PS/G M•••ur•ment
Injectors wiUbuzz ill sequence 1 though 8. ~RPM MGP 13 PSI G MIN
Note: IOM OTC• un be h/1torlcel If not cl..-.d NONI. II ICP •lgnal lncrenn above 1ZS0 PSI .rt«
lnJ•ctor J minute, MIi-foam all Mldltlrn m•y heve
Measure between 2500 to 3000 RPM
Troubl• CodN become deplfled from oll, cllMJge oll Mid r•t•t.
See PC/ED manual, Section 48 for more deta/1 on all of the above test steps.

71
 1999 F-Series

Hard Start / No Start Diaanostics

7. Retrieve Continuous Trouble Codes SooRg.E 10. Glow Plug Syatem Operation See FIG. e & G
NOTE: A hard start/ No start concern with EOT
, DTCs retrieved during this test are historical faults. R1l1y Oper11100
Temp. below 60F perform step 10 first.
---------- - ---- ---------,
1. Visual Enalne/Chassls lnsoectlon
Nott: IDM historical DTCs can be clHr here
even If non& at• d/sn/aved.
• Glow Plug ON time Is dependent on oil temperature
and altitude. The Glow Plug te1ay comes on bet.Yecn
Fuel OH Coolant Elearkal Hoses Loo/ts Diagnostic 1 to 120 sec. and does not oomo on at all i1 oil Temp
Method I Check Trouble Codes is above 131 F
Visual I B, K0E0 Injector Electrlcal Seit-Test S.ORg.E , Verily that B+ is being supplied on the large

2, Check Engine OIi Level ...,..c • UseVleNGSTester.

• All Injectors will momentarily buzz, t hen lnelivldual
BKfW wire going to the Glow Plug relay.
• Install a voltmeter to the glow plug food termlnal
• Check tor contaminants (luel, coolant), injectors will buzz In sequence 1 through 8. (terminal with two brown wires) or (center terminal on
• Correct GradeNiscosity. • IDM DTCs may be transmitted after test is oompleted. the shunt tor CaUlornla).
• Mires/Hours on oil .correct level. Note: IDM DTCs can be hlstorlc•I ,, not CIHr«I abowt. • Turn key to run poSition, measure "ON~ time
• Check level In reservoir. Injector • Using fie NGS GPCTM and EQT plds, 't'8fify
I Method I Chock Trouble Codes sufficient glow plug ~oNH time and vottage.
Visual I 9. NGS Tool - Data List Monitoring See Ag. E (Oeoenclent on oil temoeraturo and altitude\
• NGS Tester may reset below 9.5 vOlts. I - t2 volt, I Sr-- I Measurement
3. Intake/Exhaust Restriction Sooflg. B&l • Select the parameters indicated from the NGS Relay On 1 to 120
, tns~ct afr litter and ducts - exhaust system aramcter list and monitor while cranklno enolne. time seconds
, lnsnect exhaust back messuro device Not•: W•ll '" :;,.rt t.mp "On" tlrM (t • ro He.)
I Method I Check V PWR 7 volt min. ,- ktff'IN(lffll from Glow Pfug RN y "On" lint•
Visual G!ow Plug OPtration
I You ma need 10 use a outs!de """'""" source for the NGS • Measure Glow Plug Reslstance to Bat. Ground.
4. Sufficient Clean Fuel ScoFig. A RPM 100 RPM • Remove both 9 pin connectors from valve covers
• Check ii the WATER IN FUEL lamp mi nimum • Measure GP Harness Resistance to Retav
h as been illuminated. ICP 500 PSI or Glow Glow Plug Connector
• Aft er verifying that there is f uel in the tank, drain a 3.4 mPa min. Plug to Ground to Rel ay
sample from luel filter housing by key on, engine off. FUEL PW 1 mSIO Number .1 to 2 ohms o to 1 ohms
NOTE: Fuel numn wlll onlv run for 20 sec. 6mS #,
Method I Check A - V PWR - It Indicating • low voltage condition, #3
Visual I check battery voltage, chargfng sysIom or power # 5
and ground circuits to the PCM. # 7
5. Electric Fuel Pump Pressure SooFlg.l GOTOPll',flQINTTESTA #2
• Alter verilying that there is fuel in the tank B - RPM - Low RPM could be an Indication of starting/ • 4
and the pump is being powered, ctiarging system problems, No RPM lndieated with the #6
Measure at the top of the right cylinder head with engine cranking - could be CMP circuit fault, check #8
a (0-160 PSI) gauge. tor Oiagnostrt Trouble Codes.
, Kev on enoine off. - Puma will run for about 20 sec. GOTOPINPOINT TEST 0G
Instrument I Snee. I Measurement I C - ICP - A minimum of 500 PSI {3.◄ mPa) is required
0-1!~.-':,Sl I 30 PSI min. I before the injectors are enabled. No or low oil lo the
reservoir. system leakage, injector 0-Rings or faulty IPA
If pressure fails low, Go to step Be on the Perlormallce could cause pressure loss.
side ot this shHt to oinoolnl the cause. Go to section 48 step 9c In the PC/ED Manual f or a
6. Perform KOEO On Demand Test Seo Fig. e detailed description on how lo perform this t est.
• UsetheNGSTes'CI' Note: It • no RPM signal Is received, IPR duty-
• OTCs sel during this test are current faults. cycle wl/1 default to 14'6 See Fig. E&.F
Note: IOM DTCs displayed here could be current 0 • FUEL PW - Even though a 1 to S ms FUEL PW 20 40 60 110 100
EOT 1•F)
or historical tau/ts. tS shown on the NGS to be sent to the IDM, it's
Diagnostic I possible that the IDM did not get the Signal, due to a , Add 5 seconds to glow plug on lime when above
Troub!e Codes fault on other CID or FDCS circuits or e ven the IOM. 7000 leot Jn altitude. but not to exceed 120 seoonds.
See PC/ED manual, Section 48 for more detail on all of the above test steps.

72 D
 1999 F-Series

Performance Dia nostics

1. Visual Engine/Chassis Inspection ea. Fuel Pressure at the right head 10b. Low Idle Stability (ICP Press ure) SooFig.E
, Verily that there are no fluid, vacuum o r pressure leaks. Verify that fuel is in the tank and the pump is being powered. Check at low tdle
• Inspect all wire connectfon for damage . Measure fuel pressure at the Front of right head MonitOf ICP and RPM 'Nith lhe NGS Tester
• Ins t MAP WGC hOses and Intake for leaks. Road Test- with a lull IOad on the en ine. Paramet er S ec. 650 RPM Measurement
Fuel Oil COOiant Elecffirul Hoses Leaks Instr ument s Measurement ICP 400 to 600 PSI
Method Check 0-160 PSI 30 PSl min. Take readin before d isconnectin ICP
Vis ual
II en gi ne RPM Is unstabl e disconnect the ICP sensor
If tu81 pressure t ails low, Go to step Be. NOTE! ICP will default to 72.5 PSI when dlsconnecred,
2. Sufficient Clean Fuel See Fig. A .. ..l(pr_~ s_ v__~_.f!IJl)~---~P&f:~ G.o_J~ S_lf!P.. Sb. -
u,:~ Is abg_ II RPM Is s till unstable, change lhe IPR Bnd re-l est.
• Cheek if WATER IN FUEL lamp has been illuminated. Sb. Fuel Pressure at 1he left head It RPM smoothes out, the ICP signal Is at fau /1.
• Drain sa mple lrom luel filte r housing by key on , e ngine oll, • Measure tuel pressure at the rear of lelt head 11. Crankcase Pressure Test
NOTE: Pum will onl run for 20 sec. CAUTION: s«ure test hose away from turbo and exhaust. • Assure engine is at normal operating temp.
MethOd Check Road Test- with a l ull IOad on the en ine. • Measure at o il fill with adapter and orifice
Visual Ins trument Measurement tool P.N. 5631 & 0 14-007 43 Insta lled.
0-1 60 PS I • Block breather tube on left valve cover.
3. Check Engine OIi Lev el SoeAg.C
• Measure at WOT under no IOad.
, Check for contaminants (fuel , coolant). II lu91 pressure Is below min. spec, r~laco left check valve Instrument Measurement
• Correct GradeN iscosi ty . ~ ure_Is above m)'!.!__sp~ , . Go to St!f)__9~.
• If. fuel,. pr~_ Magnehelic less than
Miles/hours on oi l correct leve l. Be. Electric Fuel Pump Pressure Soo Ag. I 0 to 6 0" HOO 4" H◊0
Mtlthod Check • Measure at fuel outlet fro m Electric f uel pump. If more then 4" HOO Refer base en l ne In Sho Man ual
Visu al , Road Te st- with a full load on the e n ine. 12. Cylinder Contribut ion Test SceAg. E
s Meas urement • Ensure that EOT is above 70 F min.
4. Intake Restriction Soo Flg. B 30 - 8 0 • Turn A/C and a ll accessories off.
. Check filter minder
PSI • Select Cylinder Contribution from the test menu.
or Measure at WOT w/ma nehellc au e. If fuel pressure falls l ow, Go to step Bel. NOTE: The newly designed test will run at a idle for about
Instrument s Check ....J.f_ P.'.~~ur~ _!s_ _,1.t)~ V.• .. tJ?.ln. sp~ l r ~pl ace right Cl!~k Vi!_[ve. ttO sec. and ou will not feel an chan e throu h·out th& test.
Ma gnehe l l c/ 2 " - 25 " Bd. Electric Fuel Pump Inlet Restriction SOOAg. 11 CCT
Fi lter Min der Ho o Measure WOT at f uel Inlet to Electric fue l for restriction Trouble Codes
5. Perform KOEO On Demand Test Soo Ro E Inst rument S ec. Measurement 13. Exhaust Restriction SooFig.E, K &L
• Use the NGS Tester. 0-30 " Hg 6" Hg MAX • Visually inspect exhaust system lor damage
• DTCs set during this test are current faults. vacuum G • 1/erify EBP device is open at WOT in park m ne utral
Note: /OM DTCs dlsplay6d h ers could b e current If fuel line Is ros lrlcted above 6" Hg, check tor • Monitor EBP with the NGS T esler with the engine
or historical faults. Blockage b9tween pump and fuel tank . tem rature at 170 • F minimum at 3400 RPM.
Diagnostic If fuel lln9 Is not restrlct&d, inspect regulator valve Parame ter s Measurement
Trouble Codes condition and tor debris If OK re lace um ESP 34 PSI MAX
6. Retrieve Continuous Trouble Codes Sce F,g. E 9. Perform K OER On Demand Test Soc Fig. E 3400 RPM
• UsetheNGS TeslQ'. • This will tes1 both ICP and ESP s stems for fault. 14. Boost Pressure Test SooFig. E&J
• DTCs relrieved during this 1est are historical faults. KOER • Verily that MAP hose is not open, plugged or pinched
Note: IDM h istorical DTCs can b e clear here OTC • Verify that inter coole r hoses o r intake are not leaking.
aven it none ar9 dis la ed. 10a. Injection Control Pressure Tests SeeFlg. E & O • Verify that the green Waste gate hose is not plugged.
Dlagnostic (OIi Aeration • Poor Id le quality) , Moni tOJ MGP (manifold gauge pressure) and
Trouble Cod es • All acc. o ff, Monitor ICP and RPM with NGS Tester RPM wilh the NGS Tester.
7, KOEO Injector Electrical Self-Test SeoFlg. E Ho ld en lne s 00 al 3400 RPM tor J minutes. • Road Test - select appropriate gear to obtain
, Use the NGS Tester. Paramett1r HI h RPM Maasurement desired engine speed at !ult load throttle position.
• All injectors wlll momen tarily bu zz, the n individual ICP 1250 PSI MAX Best accom llshed Climbin hill or truck full loaded.
injectors will buzz in sequence 1 though 8. 3400 RPM Pa ram tJter S c. PSI G Measurement
Note: IDM DTCs can ~ historic• ! II not cln red • bolfB. If ICP signal Increases above 12.50 PSI alter
MGP 16 PSI G MIN
Injector 3 minutes anti-loam oll Bdditives may ha ve
Trou bl e Codes becom• deplertd from oil, change oit and r6-t est. Measure between 2500 to 3000 RPM

See PC/ED manual, Section 48 for more detail on all of the above test steps.

73
 GLOSSARY

APS Accelerator Position Sensor Hall Effect Sensor

A potentiometer style sensor that indicates the operator's A Hall Effect sensor generates a digital on/off signal that
pedal position. indicates speed and also engine timing. The signal is
created by a switching action caused by the passing of a
vane thru a positive and negative voltage potential. When
Aclualor the vane is between this potential, a signal is c reated. When
A device which delivers motion in response to an electrical the gap in between this potential is open, no signal is
signal. generated. The wider the vane the longer the duty cycle of
the signal, the narrower the vane the shorter the duty cycle
of the signal. A narrow van is used ti indicate the position of
Analog #1 cylinder and a wide vane ti indicate the position of #8. A
A continuously variable voltage. Hall Effect sensor has three connections: ground, Vref, and
signal.

BARD Barometric Pressure Sensor

An analog device which indicates atmospheric pressure IAT Intake Air Temperature Sensor
which allows the PCM to compensate for altitude. A BARO A thermistor style sensor used to indicate air temperature.
sensor has three connections, signal return (gnd), BARO
signal, and Vref.
ICP Injector Control Pressure
A transducer style sensor used to indicate gallery pressure.
CAC Charge Air Cooling
A process of cooling the air coming out of the turbo before it
enters the engine. IPR Injection Control Regulator
Controls injection oil pressure. An electrical signal to a
solenoid creates a magnetic field which applies a variable
CMP Camshaft Position Sensor force on a poppet to control pressure. The quantity of fuel
A Hall effect sensor used to indicate engine speed and delivered to the combustion chamber is proportional to
camshaft position. Speed is indicated by the number of injection control pressure.
vanes counted per revolution. Camshaft position is indicated
by a single narrow vane which indicates #1 cylinder position
or a wide vane in dual sync application that indicates #6 IDM Injector Drive Module
cylinder. An electronic unit which has the primary function of an
electronic distributor for the injectors. It also is the power
supply for the injectors. It supplies 90v @ 7 amps to the
DVDM Digital Voll Ohm Meler injectors.
A meter that uses a digital display to indicate a measured
value. Preferred for use on microprocessor systems because
a DVOM has a very high internal impedance and will not IVS Idle Validation Switch
load down the circuit being measured. An on/off switch sensor that indicates when the accelerator
pedal is in the idle position.

EBP Exhaust Back Pressure Regulator

A pulse width modulated controlled butterfly valve mounted Impedance
on the exhaust side of the turbocharger used to create A form of opposition to AC current flow measured in Ohms.
exhaust back pressure to insure faster engine and cab
warmup.
KDED Key On Engine 011 Test
A self-test operation that is performed with the ignition
EBP Exhaust Back Pressure Sensor switch in the ON position with the engine off.
A transducer style sensor used to indicate exhaust back
pressure.
KDER Key On Engine Running Test
A self-test operation that is performed with the ignition
EDT Engine Oil Temperature switch in the ON position and the engine running.
A thermistor type sensor which indicates engine
temperature.

GPR Glow Plug Relay

Relay which supplies power to the glow plugs.

75
 GLOSSARY

MAP Manifold Absolute Pressure VBAT

A MAP sensor is a sensor that generates a digital frequency Battery voltage (see VPWR).
that indicates manifold boost pressure or vacuum. The signal
is created by switching action caused by manifold pressure
on a diaphragm connected to a capacitor circuit in the VPWR
sensor. The digital frequency increases as pressure Battery voltage (see VBAT).
increases. A MAP sensor has three connections: signal
return (gnd), MAP signal, and Vref.
VSS Vehicle Speed Sensor
Normally a magnetic pickup style sensor that is mounted on
MAT Manifold Air Temperature Sensor the tailshaft of the of the transmission to indicate ground
A thermistor style sensor used to indicate air temperature speed.
after passing through the charge air cooler.

Normally Closed
Refers to a switch or a solenoid that is closed when no
control or force is acting on it.

Normally Open
Refers to a switch or a solenoid that is open when no control
or force is acting on it.

PCM Powertrain Control Module

The housing which contains the micro computer, Vref
regulator, input conditioners and output drivers.

Potentiometer (Pol)
Converts a mechanical motion to a voltage value. Most often
used to sense the position of a component. This sensor
works as a variable voltage divider. The wiper arm is
~mechanically connected to the component desired to be
sensed. Potentiometers have three connections: Vref, signal
out, and ground.

Pulse Width
The length of time an actuator, such as an injector, remains
energized .

Split Shot Injector (Prime)

Split shot injectors provide improved exhaust emissions and
quiets engine operation by tailoring the injection of fuel,
without a decrease in performance.

Thermistor
Sensor used to determine temperature. A thermistor
changes it's resistance value in relation to temperature
change. Increasing temperature results in decreasing
resistance, decreasing temperature results in increasing
resistance. The thermistor in conjunction with a current
limiting resistor in the ECA forms a voltage divider that
provides a voltage signal that indicates temperature. Since
the top half of the voltage divider is the current limiting
resistor and is internal to the ECA, a thermistor sensor only
has two connections, signal return and ground.

76 D
'
INDEX

A Fuel inlet check valve, 27

Air cleaner, 12 Fuel supply lines, 27, 41
Air induction hose, 19 Fuel system diagram, 28
Antifoam concentrate, 47 G
C Glow plug relay, 43
Cam follower guide, 38 H
Camshaft, 6 High pressure oil pump, 42
Charge air cooler Horsepower, 5
housing, 15-16
piping, 18-19 Injector, 21-23, 41
Circuit diagrams, 51, 55, 59, 63, 66-67 torque, 48
Crankcase, 6, 38 o-rings, 23
pressure, 10 split shot (prime), 21-22, 41
Crankshaft, 6, 45 Injection control regulator, 43
wear sleeve, 45 o-rings, 43
Cylinder head gasket, 39 Intake cover, 16, 48
D Intake hoses, 16, 47
Diagnostic forms, 70 0
Diagnostic guide, 60-61, 64-65 Oil cooler header
Dipstick, 1O filter bypass valve, 46
E pressure regulator, 46
ECM pinouts, 50, 54, 58, 62 Oil fill, 10
Emission label, 5 Oil pan, 40
Engine harness, 8, 43 capacity, 48
,Engine mounts, 12 gasket, 42
Engine serial number, 4 resealing, 47
Engine torque, 5 Oil reservoir, 23, 40
Exhaust back pressure, 9, 13-15 p
Exhaust manifolds, 9 Pistons, 7
Exhaust pipe, 19 rings, 7
Exhaust up pipes, 8 Pressure check
F at pump, 29
Flexplate/Flywheel, 12, 48 left head, 28
Front cover, 39 right head, 28
Fuel filter assembly s
filter element, 25 Sensors
heater, 24-26,36 camshaft position (CMP) , 32, 43, 45
pressure regulator, 24, 35 engine coolant temperature (ECT), 43
restriction sensor, 35 exhaust back pressure (EBP) , 32, 43
service, 25-26, 35-37 injection control pressure (ICP), 43
standpipe, 26 manifold air temp (MAT), 31
water drain, 24-25, 37 manifold absolute pressure (MAP), 31
water sensor, 25, 36 Snap to connect ICP lines, 29

77
 connections, 29
tools, 30
Sound insulating material, 17
T
Thermostat, 44
Thermostat housing, 11
Torque data, 33
Turbine inlet and clamp, 10, 20
Turbo, 13-1 5, 20
Removal, 17-20
u
Under valve cover harness (UVC), 7, 43
V
Valve cover gasket, 7
Valve cover gasket breakout tool, 8
w
Waste gate
actuator, 16
control, 15
Water pump, 11 , 44
Water pump pulley, 11

78
7. 3 D I T Power Stroke
Direct Injection
Turbocharged Diesel Engine
FSC 12922JA