ford e-series and f-series products - roush cleantech · troubleshooting page 5 diagnostic trouble...

DIAGNOSTIC MANUALP-01B101-AF

2011-2014

Ford E-Series and F-Series ProductsLiquid Propane Autogas Fuel System (3rd Generation)Includes:E-150/E-250/E-350 Cargo Van/WagonE-150/E-250/E-350 Extended Range Cargo Van/WagonE-450 Custom BodyF-250/F-350/F-450/F-550/F-650F-53/F-59

Revision History

-AA Initial Release 2/2013

-AB Revised 5/2013

-AC Revised 7/2013

-AD Revised 11/2013

-AE Revised 3/2014

-AF Revised 8/2014

TABLE OF CONTENTS

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SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Installation, Garaging and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Purging and Venting (Tanks and Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5About Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5System and Diagnostic Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Diagnostic Trouble Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Calibration Release OBD Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Flow Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Bleed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Tank Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Fuel Rail Pressure Control Module Supply Solenoid and Wiring . . . . . . . . . . . . . . . . . . . . . .12SRM, CAN Bus Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Electronic Fuel Pump Relay (A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Integrated Pressure Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

DIAGNOSTIC TESTS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21No Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Slow Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Over Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Engine Cranks, No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Engine Stumble, Stall, Rough Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Excess Flow Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Maximum Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Supply Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Fuel System Fails to Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Fuel Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Fuel Level Indication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Tank Solenoid Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Fuel Rail Pressure Control Module Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Integrated Pressure Temperature Sensor Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Fuel Pump Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Fuel Pump Control Module Electrical Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Smart Relay Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Fuel Level Sender Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Fuel Level Interface Module Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Manual Solenoid Activation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .52E-150/250/350 Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .53E-150/250/350 Extended Range Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .54E-450 Custom Body Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . .55

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TABLE OF CONTENTS

F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout . . . . . . . . . . . . . . .56F-650 Chassis Cab Wiring Harness and Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . .57F-450/550 Roush Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58F-650 Chassis Cab, Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59F-53/59 Roush Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60E-Series, Extended Range and E-450 Electrical Schematic — Underhood Harness . . . . . . . .61E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness . . . . . . . . .62E-Series, Extended Range and E-450 Electrical Schematic — Rear Frame Harness . . . . . . .63E-Series, Extended Range and E-450 Electrical Schematic — In-Tank Harness . . . . . . . . . .64E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness . . . . . . . . . .65E-450 Stripped Chassis CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66F-250/350 Pickup, CAN Bus Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . .67F-250/350 Pickup, F-450/550 and F-650, Tank Solenoid Harness Electrical Schematic . . . .68F-250/350 Pickup, In-Bed Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . .69F-250/350 Pickup, FTPT Jumper Harness Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . .70F-650 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71F-650 Fuel Tank Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72F-650 Underhood Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73F-53/59 CAN Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74F-53/59/250/350/450 Rear Frame Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .75F-53/59/250/350/450 Underhood Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . .76F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . .77

INTRODUCTION

Page 1

INTRODUCTION

INTRODUCTION

SAFETY INFORMATIONThe National Fire Protection Association (NFPA) publishes a code book of rules that apply to the storage, handling, transportation and use of liquefied petroleum gas (LP-Gas or LPG). The book is known as NFPA 58. It is revised as necessary and published every other year. This code is adopted as law in virtually every political subdivision in the United States. Check with your local authorities for regulations applicable to liquid propane.

Alert Messages

The following alert messages may appear from time to time in appropriate places in this manual. Ensure that all personnel read and adhere to these alert messages.

Although propane is nontoxic, nonpoisonous, has the lowest flammability range of any alternative fuel and dissipates quickly when released into the atmosphere, propane vapor is heavier than air and seeks the lowest point. When the ratio of propane to air is between 2.2% and 9.6%, propane will burn in the presence of an ignition source at 940°F (504°C) or hotter. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Failure to heed this danger may result in severe personal injury or death.

The fuel supply lines remain pressurized after engine shutdown. Keep away from heat, sparks, flames, static electricity or other sources of ignition. Do NOT enter storage areas or confined space unless they are adequately ventilated. Failure to heed this danger may result in severe personal injury or death.

Do NOT carry lighted smoking materials or smoke while working on fuel system components. Failure to heed this danger could result in severe personal injury or death.

Disconnect the battery ground at the battery to ensure that the vehicle electrical system has no current. Failure to heed this danger could result in severe personal injury or death.

Propane is heavier than air and seeks the lowest available level when released to the atmosphere. Keep heat, sparks, flames, static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank. Failure to heed this danger can result in severe personal injury or property damage.

Technicians working with, or around, fuel systems should be properly trained to utilize extreme care and caution at all times. Failure to exercise extreme caution and care may lead to serious accidents which can result in property damage, personal injury and/or death.

Liquid propane is cold. The temperature of propane in its liquid state at atmospheric pressure is −44°F (−42°C). Wear eye and ear protection during venting and repair operations. Keep moisture away from the valves. Failure to heed this warning can result in personal injury.

INTRODUCTION

Page 3

Installation, Garaging and Training

Chapter 11 of NFPA 58 applies to engine fuel systems using LP-Gas in internal combustion engines, including containers, container appurtenances, carburetion equipment, piping, hose and fittings and their installation. Additionally, this chapter applies to garaging of vehicles and to the training of personnel.

Paragraph 11.2 specifies that each person engaged in installing, repairing, filling or otherwise servicing an LP-Gas engine fuel system shall be trained. Contact the Propane Education and Research Council to learn more about their CETP E-Learning computer-based training program: [email protected], or [email protected].

Purging and Venting (Tanks and Lines)

Venting of LP-Gas to the atmosphere is covered by paragraphs 7.3.1, General, and 7.3.2, Purging of NFPA 58, 2008 edition. Refer to NFPA 58, Local Codes and Proper Training for specific information relating to safe venting of LPG.

TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING

Page 5

DIAGNOSTIC TROUBLE CODES

About Diagnostic Trouble Codes

All diagnostic trouble codes (DTCs) known to be affected by the liquid propane autogas (LPA) system are covered in this manual. For all other

DTCs, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.

System and Diagnostic Terminology

Acronym or Abbreviation Description

BS Bleed Solenoid

CAN Controller Area Network

DTC Diagnostic Trouble Code

EFPR Electronic Fuel Pump Relay

ERFS Electronic Returnless Fuel System

EVAP Evaporative

FCS Flow Control Solenoid

FLIM Fuel Level Interface Module

FLS Fuel Level Sender

FP Fuel Pump

FPCM Fuel Pump Control Module

FRP Fuel Rail Pressure

FRPCM Fuel Rail Pressure Control Module

FTS Fuel Temperature Sensor

GRD Ground

HEGO Heated Exhaust Gas Oxygen

IC Instrument Cluster

IPTS Integrated Pressure Temperature Sensor

KOEO Key On Engine Off

KOER Key On Engine Running

LPA Liquid Propane Autogas

MAF Mass Air Flow

OEM Original Equipment Manufacturer

OPD Overfill Protection Device

PCM Powertrain Control Module

PID Parameter Identification

PWR GND Power Ground

SIG RTN Signal Return

SRM Smart Relay Module

SS Supply Solenoid

TS Tank Solenoid

VMV Vapor Management Valve

VPWR Voltage Power

VREF Voltage Reference

WOT Wide Open Throttle

TROUBLESHOOTING

Diagnostic Trouble Code List

Code Description

P0005 Fuel Shutoff Valve A Control Circuit Open

P0090 Fuel Pressure Regulator Circuit Open

P009B Fuel Pressure Relief Control Circuit Open

P009E Fuel Pressure Relief Control Performance Stuck Off

P009F Fuel Pressure Relief Control Stuck On

P0148 Fuel Delivery Error

P0171 System Too Lean (Bank 1)

P0172 System Too Rich (Bank 1)

P0174 System Too Lean (Bank 2)

P0175 System Too Rich (Bank 2)

P0182 Fuel Temperature Sensor (A) Circuit Low

P0183 Fuel Temperature Sensor (A) Circuit High

P0190 Fuel Pressure Sensor A Circuit

P0192 Fuel Pressure Sensor A Circuit Low

P0193 Fuel Pressure Sensor A Circuit High

P025A Fuel Pump Control Module Circuit Range/Performance A

P027A Fuel Pump Control Module Circuit Range/Performance B

P03xx Misfire

P0460 Fuel Level Sender A Circuit

P0461 Fuel Level Sender A Circuit Range/Performance

P0462 Fuel Level Sender A Circuit Low

P0463 Fuel Level Sender A Circuit High

P0627 Fuel Pump A Control Circuit Open

P116E Exceeded Maximum Pressure

P2067 Fuel Level Sensor B Circuit Low

P2068 Fuel Level Sensor B Circuit High

P2195 Heated Exhaust Gas Oxygen Sensor Stuck

P2197 Heated Exhaust Gas Oxygen Sensor Stuck

P25B1 Fuel Level Sensor B Stuck

P2632 Fuel Pump B Control Circuit Open

P2665 Supply Solenoid Circuit Fault

P26B3 Fuel Shutoff Valve A Control Circuit Performance/Stuck Off

P26B5 Fuel Shutoff Valve B Function Check

U0108 Lost Communication with Alternative Fuel Control Module

U0109 Lost Communication with Fuel Pump Control Module A

U016C Lost Communication with Fuel Pump Control Module B

U0309 Alt Fuel Module-Wrong SRM

TROUBLESHOOTING

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Calibration Release OBD Summary Chart

OEM MY HDE MY Cert Calibration OBD Class Detail Chart Comments

Vehicle (03P150)

E-Series 2011 N/A Fed Only PBGD-Ax & Bx OBD II E-Series 5.4L Group

FED OBD Identifier

2012 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group

2013 N/A Fed PBGD-Ax & Bx OBD II E-Series 5.4L Group

FED OBD Identifier

2013 N/A 50S PBGD-Cx & Dx OBD II E-Series 5.4L Group

Fuel Pump Codes Added

F-250/F-350 2012 N/A 50S Only PCDH-Ax & Bx OBD II F-Series 6.2L Group

2013 N/A Fed PCDH-Cx & Dx OBD II F-Series 6.2L Group


2013 N/A 50S PCDH-Ax & Bx OBD II F-Series 6.2L Group


E-450 2011 2011 Fed PBJC-Bx & Dx Non-OBD (EMD)

E-Series 6.8L HDE

OBD I / EMD Level

2012 2012 50S PBJC-Ax & Cx Non-OBD (EMD)

E-Series 6.8L HDE

OBD I / EMD Level

2013 2013 50S PDJC-Ax & Bx EMD+ E-Series 6.8L HDE

Cat Monitor Added

F-450/F-550 2012 2011 Fed PCEB-Ax Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2012 2012 Fed PCEB-Ax Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2013 2012 Fed PCEB-Ax Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2013 2013 50S PDEB-Ax EMD+ F-Series 6.8L HDE

Cat Monitor Added

F-59 (Step Van)

2013 2012 Fed PCEB-Sx Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2013 2013 50S PDEB-Sx EMD+ F-Series 6.8L HDE

Cat Monitor Added

F-53 (Motorhome)

2013 2012 Fed PCEB-Mx Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2013 2013 50S PDEB-Mx EMD+ F-Series 6.8L HDE

Cat Monitor Added

F-650 2012 2012 Fed PCFB-Ax Non-OBD (EMD)

F-Series 6.8L HDE

OBD I / EMD Level

2013 2013 50S PDFB-Ax EMD+ F-Series 6.8L HDE

Cat Monitor Added

Note: HDE MY - Heavy Duty Engine Model Year (Some HD products have different engine certifications within the vehicle model year.)

TROUBLESHOOTING


E-Series 5.4L GroupE-150/E-250/E-350

F-Series 6.2L GroupF-250/F-350

Code Descriptions 2012 50S

2013 Fed

2013 50S

2012 50S

2013 Fed

2013 50S

P0005 Fuel Shutoff Valve A Control Circuit Open 1 1 1 1 1 1

P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1 1 1

P009B Fuel Pressure Relief Control Circuit Open 2 2 2 2 2 2

P009E Fuel Pressure Relief Control Performance Stuck Off 2 2 2 2 2 2

P009F Fuel Pressure Relief Control Stuck On 2 2 2 2 2 2

P0148 Fuel Delivery Error 1 1 1 1 1 1

P0171 System Too Lean (Bank 1) 2 2 2 2 2 2

P0172 System Too Rich (Bank 1) 2 2 2 2 2 2

P0174 System Too Lean (Bank 2) 2 2 2 2 2 2

P0175 System Too Rich (Bank 2) 2 2 2 2 2 2

P0182 Fuel Temperature Sensor (A) Circuit Low 2 2 2 2 2 2

P0183 Fuel Temperature Sensor (A) Circuit High 2 2 2 2 2 2

P0190 Fuel Pressure Sensor A Circuit 2 2 2 2 2 2

P0192 Fuel Pressure Sensor A Circuit Low 2 2 2 2 2 2

P0193 Fuel Pressure Sensor A Circuit High 2 2 2 2 2 2

P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 2 1 2 2

P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2

P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 2 1 2 2

P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 2 1 2 2

P03xx Misfire 2 2 2 2 2 2

P0460 Fuel Level Sender A Circuit 2 2 2 2 2 2

P0461 Fuel Level Sender A Circuit Range/Performance 2 2 2 2 2 2

P0462 Fuel Level Sender A Circuit Low 2 2 2 2 2 2

P0463 Fuel Level Sender A Circuit High 2 2 2 2 2 2

P0627 Fuel Pump A Control Circuit Open 1 1 2 1 2 2

P116E Exceeded Maximum Pressure 1 1 1 1 1 1

P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2

P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2 2 2

P2632 Fuel Pump B Control Circuit Open 1 1 2 1 2 2

P2665 Supply Solenoid Circuit Fault 1 1 1 1 1 1


1 1 1 1 1 1

P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1 1 1

U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2 2 2

U016C Lost Communication with Fuel Pump Control Module B 1 1 2 1 2 2

U0309 Alt Fuel Module-Wrong SRM 2 2 2 2 2 2

0 Code not present

1 DTC – non MIL

2 DTC – MIL (two trips)

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E-Series 6.8L HDE GroupE-450

F-Series 6.8L HDE GroupF-450/550/650/53/59

Code Descriptions 2012 50S 2013+ 50S 2012 50S 2013+ 50S

P0005 Fuel Shutoff Valve A Control Circuit Open 1 1 1 1

P0090 Fuel Pressure Regulator Circuit Open 1 1 1 1

P009B Fuel Pressure Relief Control Circuit Open 1 2 2 2

P009E Fuel Pressure Relief Control Performance Stuck Off 1 2 2 2

P009F Fuel Pressure Relief Control Stuck On 0 0 0 0

P0148 Fuel Delivery Error 1 1 1 1

P0171 System Too Lean (Bank 1) 2 2 2 2

P0172 System Too Rich (Bank 1) 2 2 2 2

P0174 System Too Lean (Bank 2) 2 2 2 2

P0175 System Too Rich (Bank 2) 2 2 2 2

P0182 Fuel Temperature Sensor (A) Circuit Low 1 2 2 2

P0183 Fuel Temperature Sensor (A) Circuit High 1 2 2 2

P0190 Fuel Pressure Sensor A Circuit 1 2 2 2

P0192 Fuel Pressure Sensor A Circuit Low 1 2 2 2

P0193 Fuel Pressure Sensor A Circuit High 1 2 2 2

P025A Fuel Pump Control Module Circuit Range/Performance A 1 1 1 1

P025B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1

P027A Fuel Pump Control Module Circuit Range/Performance B 1 1 1 1

P027B Electronic Fuel Pump Relay Invalid Control Data 1 1 1 1

P03xx Misfire 1 1 1 1

P0460 Fuel Level Sender A Circuit 1 1 1 1

P0461 Fuel Level Sender A Circuit Range/Performance 0 0 0 0

P0462 Fuel Level Sender A Circuit Low 1 1 1 1

P0463 Fuel Level Sender A Circuit High 1 1 1 1

P0627 Fuel Pump A Control Circuit Open 1 1 1 1

P116E Exceeded Maximum Pressure 1 1 1 1

P2195 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2

P2197 Heated Exhaust Gas Oxygen Sensor Stuck 2 2 2 2

P2632 Fuel Pump B Control Circuit Open 1 1 1 1

P2665 Supply Solenoid Circuit Fault 1 1 1 1


1 1 1 1

P26B5 Fuel Shutoff Valve B Function Check 1 1 1 1

U0108 Lost Communication with Alternative Fuel Control Module 2 2 2 2

U016C Lost Communication with Fuel Pump Control Module B 1 1 1 1

U0309 Alt Fuel Module-Wrong SRM 2 2 2 2

0 Code not present

1 DTC – non MIL

2 DTC – MIL (two trips)

TROUBLESHOOTING

Flow Control Solenoid

P0090 — Fuel Pressure Regulator Circuit Open

Bleed Solenoid

P009E/P26B3 — Fuel Pressure Relief Control Performance Stuck Off

P009F — Fuel Pressure Relief Control Stuck On

Description FCS circuit fault. SRM monitors FCS circuit for open and short circuit faults.

Possible Causes � Short to voltage

� Water in the harness connector

� Open power circuit

� GND circuit

� Low battery voltage

� Corrosion

� Incorrect connections

� Damaged FCS coil

� Blown fuse

Symptom Fuel pressure in the rail does not change when commanded. Extended fuel rail flush time.

Diagnostic Aid Check the FRPCM and SRM electrical connector for damage, corrosion and water intrusion.

Action Refer to the Fuel Rail Pressure Control Module Electrical Check procedure in Diagnostic Tests and Procedures.

Description Fuel rail failed to bleed. The PCM measures fuel rail pressure on key-up to determine if fuel rail has been properly bled.

Possible Causes � BS did not open

� FRPCM check valve leaked (P26B3)

� FRPCM supply solenoid leaked (P26B3)

� Bleed port (bleed rate restrictor in outlet to VMV) clogged

� EVAP line kinked

� Blown fuse

Symptom Fuel pressure present in the fuel rail after bleed event should have occurred; this may result in hard starts.

Diagnostic Aid Check that FRPCM bleeds fuel from rail. Leaks to FRPCM can also trigger a fault.

Action Refer to the Fuel System Fails to Bleed procedure in Diagnostic Tests and Procedures.

Description Bleed solenoid stuck open. While the engine is running, the PCM seals the EVAP system and checks for a rise in pressure. If pressure in the EVAP system exceeds the threshold, a fault is set.

Possible Causes � Short to GRD

� Armature stuck in post

� Solenoid seal compromised

Symptom There is a potential for fuel odor.

Diagnostic Aid —


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P009B — Fuel Pressure Relief Control Circuit Open

Tank Solenoid

P0005 — Fuel Shutoff Valve A Control Circuit Open

Description Bleed solenoid circuit fault. The SRM monitors bleed solenoid circuit for open and short circuit faults.




� Open GND circuit


� Corrosion


� Damaged BS coil

Symptom Fuel rail bleed system does not operate correctly. There is a potential for fuel odor or hard start.

Diagnostic Aid Check the FRPCM and SRM electrical for damage, corrosion and water intrusion.


Description TS circuit fault. The SRM monitors tank solenoid circuit for open and short circuit faults.






� Corrosion


� Damaged TS coil

� Blown fuse

Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail.

Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion.

Action Refer to the Tank Solenoid Electrical Check procedure in Diagnostic Tests and Procedures.

TROUBLESHOOTING

Fuel Rail Pressure Control Module Supply Solenoid and Wiring

P26B5 — Fuel Shutoff Valve B Function Check

P2665 — Supply Solenoid Circuit Fault

Description Fuel supply solenoid stuck. The SRM monitors fuel rail pressure before and after the solenoid was commanded open. If the pressure rise is below a threshold, the fault is set.

Possible Causes � Electrical fault

� Damaged SS coil

� Damaged SS armature

� Excess flow valve tripped

� Tank solenoid stuck closed

� Tank manual valve closed

� Fuel pumps not powering on

� Blown fuse

Symptom Vehicle does not start. The pumps run (or may not) but no pressure builds in the fuel rail.


Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.

Description FRPCM supply solenoid circuit fault. SRM monitors supply solenoid circuit for open and short circuit faults.






� Corrosion


� Damaged SS coil

� Blown fuse

Symptom Vehicle does not start. The pumps run but no pressure builds in the fuel rail.



TROUBLESHOOTING

Page 13

SRM, CAN Bus Circuit Wiring

U0108 — Lost Communication with Alternative Fuel Control Module

U0309 — Alternate Fuel Module-Wrong SRM

Fuel System

P0148 — Fuel Delivery Error

Description Lost communication with SRM. The PCM monitors CAN bus communication for missing messages from the SRM. If the messages are continuously missing, a fault is set.

Possible Causes � Wiring between the SRM and PCM

� SRM lacks power

� Blown fuse

Symptom Rough idle.

Diagnostic Aid Check the FRPCM and SRM electrical connectors for damage, corrosion and water intrusion. Check for power at the SRM.

Action Refer to the Smart Relay Module Electrical Check procedure in Diagnostic Tests and Procedures.

Description Alternate Fuel Module (SRM) is not broadcasting over vehicle communication link the expected SRM module identifier. A U0309 code should only be expected during initial build or during service replacement of the SRM module.

Possible Causes � Incorrect SRM was installed into the vehicle for initial build or during service of the SRM

� Loss of CAN communications between the SRM and PCM

Symptom � MIL light

� Fuel gage may not read full or empty correctly

Diagnostic Aid � Verify to latest calibration

� Verify SRM part number is correct for vehicle type and tank

� Verify that no other DTCs are set related to CAN communications

� Inspect CAN harness for connection issues and integrity

Action Replace SRM to correct type or fix any CAN communication DTCs or wiring/connection concerns.

Description LPA system is operating in vapor space. At least one bank is lean at WOT.

Possible Causes � Severely restricted fuel filter

� Severely restricted fuel supply line

� Damaged or worn fuel pump

� Damaged or contaminated MAF sensor

� Excess flow valve tripped

� TS or SS closed

� Tank manual shutoff valve not completely open

Symptom Vehicle hesitation or stall condition.

Diagnostic Aid —

Action Refer to the Engine Cranks, No Start procedure in Diagnostic Tests and Procedures.

TROUBLESHOOTING

P116E — Maximum Pressure

P0171, P0174 — System Too Lean (Bank 1 and Bank 2 respectively)

P0172, P0175 — System Too Rich (Bank 1 and Bank 2 respectively)

P03xx — Misfire

Description Maximum injection pressure reached. The PCM monitors fuel rail pressure and battery voltage. Based on these measurements, the PCM adjusts fuel pump speed to stay below the maximum operating pressure of the injectors.

Possible Causes � Operating the vehicle in high ambient conditions

� Vehicle operated in a low voltage condition

Symptom Vehicle hesitation, stall, rough idle, misfire or no start.

Diagnostic Aid The P116E code is meant as an indication that the fuel system was operated at the limits of the system. The customer may have experienced drive issues although the system is performing as expected.

Action Refer to the Maximum Pressure Check procedure in Diagnostic Tests and Procedures.

Description Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for more descriptive information.

Possible Causes � The LPA system was operated in the vapor region

� Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.

Symptom —

Diagnostic Aid Verify that no LPA system faults are present and then follow the Ford service manual procedure.

Action Refer to the Fuel Pressure Drop Check procedure in Diagnostic Tests and Procedures.




Symptom —






Symptom —



TROUBLESHOOTING

Page 15

Heated Exhaust Gas Oxygen Sensor

P2195, P2197 — Heated Exhaust Gas Oxygen Sensor Stuck

Electronic Fuel Pump Relay (A/B)

U0109, U016C — Lost Communication with Fuel Pump Control Module A/B

P025A, P027A — Fuel Pump Control Module Circuit Range/Performance




Symptom —



Description The SRM repeats the signal from the second EFPR to the PCM over the CAN bus. The PCM monitors this communication. If there is a lack of communication for a long enough period of time, a fault is set.

Possible Causes � Wire fault between the EFPR and SRM

� Wire fault between SRM and PCM

� No power to the EFPR

� SRM fault

� CAN bus fault

� Blown fuse


Symptom —

Diagnostic Aid —

Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure and also the Smart Relay Module Electrical Test procedure in Diagnostic Tests and Procedures.

Description The SRM receives the output of the second fuel pump monitor line and repeats the output over the CAN bus to the PCM. The PCM monitors the commanded output versus the monitor’s feedback. If the monitor is out-of-range, a fault is set.

Possible Causes Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for a list of other causes.

Symptom Poor starts, rough idle, hesitation/surge.

Diagnostic Aid —

Action Refer to the Fuel Pump Control Module Electrical Continuity Test procedure in Diagnostic Tests and Procedures.

TROUBLESHOOTING

Integrated Pressure Temperature Sensor

P0182 — Fuel Temperature Sensor (A) Circuit Low

P0183 — Fuel Temperature Sensor (A) Circuit High

Description The SRM reads the IPTS and passes the voltage reading over the CAN to the PCM monitors the voltage as if the sensor were plugged into the vehicle.

Possible Causes � CAN bus fault between the SRM and PCM

� Wiring fault between IPTS and SRM

� Short in harness

� VREF open or short

� Low ambient temperature operation

� Incorrect harness connection

� Damaged IPTS (or FTS)

� IPTS failure

� SRM failure

Symptom —

Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short.

Action Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure in Diagnostic Tests and Procedures.

Description The SRM reads the IPTS and passes the voltage reading over the CAN bus to the PCM. The PCM monitors the voltage as if the sensor were plugged into the vehicle.



� Open circuit

� Open or short to voltage in harness

� Incorrect harness connection

� Damaged IPTS (FTS)

� IPTS failure

� SRM failure

Symptom —

Diagnostic Aid Verify the fuel rail temperature PID value to determine open or short.


TROUBLESHOOTING

Page 17

P0190 — Fuel Pressure Sensor A Circuit

P0192 — Fuel Pressure Sensor A Circuit Low

P0193 — Fuel Pressure Sensor A Circuit High




� VREF open in harness

� VREF open in sensor

� Vacuum leaks

� IPTS failure

� SRM failure

Symptom —

Diagnostic Aid VREF should be between 4–6 volts.





� IPTS FRP signal short to SIG RTN or PWR GND

� Damaged IPTS (or FRP)

� IPTS failure

� SRM failure

Symptom —

Diagnostic Aid A FRP PID value during ignition ON, engine OFF, or ignition ON, engine running is less than 0.3 volt. This indicates a concern is present.





� IPTS FRP signal short to VREF or VPWR

� IPTS (or FRP) open signal

� Damaged IPTS (or FRP)

� IPTS failure

� SRM failure

Symptom —

Diagnostic Aid Verify the FRP PID value to determine open or short.


TROUBLESHOOTING

Fuel Level Sender

P0460 — Fuel Level Sender A Circuit

P0461 — Fuel Level Sender A Circuit Range/Performance

P0462 (P2067) — Fuel Level Sender A (B) Circuit Low


Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the FLS and the SRM and not the IC.

Symptom —

Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM.

Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.


Possible Causes Refer to the Ford service manual. Causes are the same except that communication is between the sender and the SRM and not the IC.

Symptom —

Diagnostic Aid The SRM reads fuel level sender input and broadcasts it to the IC and PCM.

Action Refer to the Fuel Level Indication System Check procedure in Diagnostic Tests and Procedures.

Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value.

Possible Causes � Fuel level sender wiring shorted to ground

� Damaged Fuel Level Sender

� Smart Relay Module

Symptom P0462 — Fuel gauge may read empty all the timeP2067 — Fuel gauge will only show primary tank

Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster.

Action Refer to the following tests located later in this manual.� SRM Electrical Test

� Fuel Level Sender Test

� Fuel Level Interface Module

TROUBLESHOOTING

Page 19

P0463 (P2068) — Fuel Level Sender A (B) Circuit High

P25B1 — Fuel Level Sensor B Stuck

Description This DTC sets when the Fuel Level Gauge signal is electrically less than the minimum allowable sender value.

Possible Causes � Fuel level sender wiring is disconnected or shorted to above 5 volts

� Damaged Fuel Level Sender

� Smart Relay Module

Symptom P0463 — Fuel gauge may read full all the time

P2068 — Fuel gauge will only show primary tank

Diagnostic Aid Smart Relay Module (SRM) reads fuel level sender and broadcasts to the PCM and Instrument Cluster.

Action Refer to the following tests located later in this manual.

� SRM Electrical Test

� Fuel Level Sender Test

� Fuel Level Interface Module

Description Failed transfer of fuel from secondary tank B to primary tank A. Failure code sets if a transfer is not detected by sender movement in 3 transfer attempts.

Possible Causes Secondary tank transfer failure causes:� Tank supply solenoid did not open

� Manual valve closed

� Excess flow valve trips on transfer attempts

� Blown fuse

� Electrical fault or relay failure that supplies the tank solenoid or pumps

� SRM hardware failure

� Sender arm stuck

� Sender signal out of range

� Fuel transfer line between secondary and primary tank kinked or plugged

� High differential of pressure when the primary tank greater than ~60 psi over secondary tank (typically caused by higher temperatures in the primary tank)

Primary tank transfer failure causes:� Faulty transfer OPD connected to transfer line

Symptom � Fuel indication is only based on primary tank sender

� Customer does not achieve expected driving range

� Short fuel fills (only adds fuel to primary tank)

� Cluster fuel gauge may indicate inconsistent behavior

Diagnostic Aid Check all electrical connectors and voltage supply to the secondary tank valve and fuel pumps. Verify that the secondary tank sender voltages (or resistances) are in the expected range. Verify that no other primary or secondary tank out-of-range codes are set (P0462, P0463, P2067, P2068).

Action Refer to the Secondary Tank – Fuel Will Not Transfer Troubleshooting.

TROUBLESHOOTING

Secondary Tank – Fuel Will Not Transfer

F-650 vehicles can be equipped with a unique ROUSH CleanTech liquid propane autogas storage system which includes two fuel tanks. The system operates as if it were just one large tank. A few key points about the system:

• The engine is always running from the driver's side tank. All fuel to the engine, and the excess fuel returning to the tank, is only connected to this tank.

• The passenger's side tank is used to store extra fuel only. When the driver's side tank fuel level drops, the system will activate fuel pumps in passenger's side tank to transfer fuel automatically.

• Both tanks are filled at the same time from the single fuel filler located on the driver's side. There is a ball valve on the fill line for the right-hand tank, which is used for periodic inspections only. It should always be open during normal operation in order to use the full system capacity.

The ROUSH CleanTech control system reads the usable fuel level in each tank and adds them together to provide a single reading for the instrument cluster. However, if the system detects a failure in the fuel transfer system which may interfere with the ability to transfer fuel, it will provide a reading based on the driver's side tank only. This ensures that the driver is warned before the vehicle runs out of fuel. If this occurs, the vehicle is fully usable, but should be serviced in order to restore full function and use of the full system fuel capacity.

The fuel transfer line from the passenger's side tank is connected to a dedicated overfill prevention device (OPD) on the driver's side tank. This is a safety device which ensures that even if there is a fault in the control system, it is not possible for the driver's side tank to overfill during transfers.

TROUBLESHOOTING

Page 21

DIAGNOSTIC TESTS AND PROCEDURESGeneral InformationMeasuring Fuel Rail and Fuel Tank PressureMeasuring Fuel Tank Pressure — Fuel tank pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information regarding the tools required.

Method 1 — Install a 0–500 psi (0–3447 kPa) fuel pressure gauge on the bleeder valve at the tank, or to the remote bleeder valve location. Open the valve to monitor the fuel tank pressure. Record the value.

Method 2 — If a 0–500 psi (0–3447 kPa) fuel pressure gauge is not available, fuel rail pressure can be used to infer fuel tank pressure. Refer to Method 1 of Measuring Fuel Rail Pressure. Monitor fuel rail pressure with the engine running. Turn the engine off and continue to monitor fuel rail pressure. When the pressure has stabilized, record the value as fuel tank pressure.

Measuring Fuel Rail Pressure — Fuel rail pressure can be measured two ways: Refer to Tools and Equipment, Special Tools in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual for more information regarding the tools required.

Method 1 — Using the OBD-II scan tool, read the fuel rail pressure PID. If using the Ford IDS tool, it will be necessary to select the tool box tab, then select Powertrain near bottom of selection, OBD Test Modes, Mode 1 Powertrain Data. Then locate and select FRP (pressure) from PID selection table.

Method 2 — Empty the fuel rails and fuel lines. Refer to the Fuel Line Purging Procedure in the 2012 Ford E-150/250/350/450 or 2013 F-250/350 Liquid Propane Autogas Fuel System Service Manual Supplement for more information. Using the Jiffy-Tite disconnect tool, disconnect the fuel supply line at the rear of the RH fuel rail. Install the ROUSH service port adapter between the fuel line and the fuel rail. Attach 0–500 psi (0–3447 kPa) fuel pressure gauge to the service port on the adapter. Record the value.

Expected Fuel Tank Pressure — On a tank at ambient temperature conditions, the following pressures can be expected:

On vehicles that have been operated for extended periods of time, the tank (fuel) can be much warmer and so higher pressures are to be expected.

Expected Fuel Rail Pressure — Under normal operating conditions, the fuel pump has two operating speeds. The pump operates in low speed mode at idle and during moderate fuel flow/part throttle driving. Once a fuel demand threshold is met, typically during wide open throttle (WOT) operation, the pump is switched to high speed. The pump is also operated at high speed during the pre-start flush sequence.

Temperature (°F)

Pressure (psi)

Min. Nominal Max.

0 15 25 35

5 19 29 39

10 23 33 43

15 28 38 48

20 33 43 53

25 38 48 58

30 43 53 63

35 49 59 69

40 55 65 75

45 62 72 82

50 69 79 89

55 77 87 97

60 84 94 104

65 93 103 113

70 102 112 122

75 111 121 131

80 121 131 141

85 131 141 151

90 142 152 162

95 153 163 173

100 165 175 185

105 178 188 198

110 191 201 211

115 205 215 225

120 219 229 239

TROUBLESHOOTING

The fuel pressure controls are designed to keep the rails at a certain pressure over tank pressure, therefore, it is important to measure tank pressure prior to collecting fuel rail pressure data. For example, if the fuel tank is at 150 psi (1034 kPa) and pressure in the rail is measured at 200 psi (1379 kPa), the rail is running at 50 psi (345 kPa) over tank.

Under extreme operating conditions, there is a third pump mode. In the event that the fuel system has degraded and the sensor detects vapor, or if the fuel rail pressure is approaching the limit of the fuel system, the pump runs in a variable speed mode, controlling to a target pressure. In this mode there is no predicted rise over tank pressure. The fuel pump will adjust the pressure to maintain a required operating pressure. This condition will likely result in a P116E or P0148 code.

No Fill

Condition Pump SpeedPressure Over Tank

Engine Off Off <10

Idle Low >30

Part Throttle Low <25

Part Throttle High >25

WOT High >25

Step Procedure Action

1 Inspect vehicle to check for kinked fill lines.Are fill lines kinked?

Yes — Replaced kinked fill lines.

No — Go to Step 2.

2 Determine the location of the overflow protection device (OPD).Is the OPD located in the end cap of the fuel tank?

Yes — Go to Step 3.No — Go to Step 6.

3 Check the fuel gauge in the instrument cluster.Is the gauge indicating less than 1/4 full?

Yes — Go to Step 4.


4 Check to see if the OPD is being activated.

Fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.

a. Loosen the fuel fill line at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line and release the OPD valve. Retighten the fill line.

b. Install a fuel fill pressure tester on the fill valve and close the ball valve.

c. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.

d. Did the tank fill?


5 Remove the fuel fill pressure tester and attempt to fill the vehicle fuel tank to full 80% capacity.Does the vehicle fuel tank fill to capacity?

Yes — Diagnostic is complete.No — Go to Step 6.

6 Check the fuel gauge in the instrument cluster.Is the gauge indicating more than 1/2 full?


7 Reverse direction of vehicle at the pump and try to fill the vehicle.Does the vehicle fuel tank fill?

Yes — Vehicle not on level ground. Diagnostic is complete.No — Drive vehicle until fuel gauge indicates less than 1/2 full and go to Step 8.

TROUBLESHOOTING

Page 23

8 Attempt to fill the vehicle fuel tank.Does the fuel tank fill?



9 Open bleeder valve.Does liquid fuel vent?


10 Check fuel gauge.Does fuel gauge read full?

Yes — Diagnostic complete.

No — Refer to Fuel Level Indication Check.

11 Check for sufficient fill station pressure.

a. Connect pressure gauge service tool to the fuel tank bleeder valve and record pressure.

b. Using a fuel fill pressure tester installed on the fill valve, attempt to fill the vehicle.

c. With the dispensing pump on and dispensing nozzle open, measure and record fill station pump pressure.

d. Is fill station pump pressure at least 20 psi (138 kPa) greater than tank pressure?

Yes — Go to Step 12.No — Fill station may not be providing enough pressure to fill. Go to Step 19.

12 Check body side fuel fill valve; it may be stuck closed.

a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line.

b. Attempt to push open the piston in the fill valve to determine if it is stuck closed.

c. Is the fill valve piston stuck closed?

Yes — Replace body-side fill valve and go to Step 13.

No — Replace filter in the fuel fill line and go to Step 15.



14 Replace the filter in the fuel fill line and then attempt to fill the vehicle fuel tank.Does the vehicle fuel tank fill?

Yes — Diagnostic is complete.





16 Replace the OPD valve in the vehicle fuel tank.Is the OPD valve located in the end cap of the fuel tank?


17 Attempt to fill the vehicle fuel tank as follows:

When filling a new tank that has the OPD valve mounted in the end cap of the fuel tank, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.

a. Install a fuel fill pressure tester on the fill valve and close the ball valve.

b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.

c. Remove the fuel fill pressure tester.

d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle.

e. Did the tank fill?


No — Call ROUSH CleanTech Customer Service at 800-597-6874.


Yes — Diagnostic is complete.No — Call ROUSH CleanTech Customer Service at 800-597-6874.


TROUBLESHOOTING

Slow Fill

19 Fill station is not providing enough pressure to fill.

a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature.

b. Is the vehicle fuel tank pressure greater than 20 psi (138 kPa) over the nominal expected pressure?


No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 12.

20 Vehicle fuel tank is at a higher pressure.

a. Higher pressure is likely caused by heavy vehicle usage heating the fuel.

b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank.

When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 21.

21 Measure and compare vehicle fuel tank and fill station pressures.

a. Connect a pressure gauge service tool to the fuel tank bleeder valve and record fuel tank pressure.



d. Is fill station pump pressure at least 20 psi (138 kPa) greater than fuel tank pressure?

Yes — Go to Step 22.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 22.

Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility).





1 Inspect vehicle to check for kinked fill lines.Are fill lines kinked?

Yes — Replaced kinked fill lines.No — Go to Step 2.

2 Determine flow rate at which the vehicle fuel system fills.

a. Time the fill station pump for 10 seconds and record the number of gallons dispensed.

b. Multiply the gallons dispensed by six to determine the flow rate in gallons per minute.

c. Is the fill station pump flow rate at least 6 gal (23 L) per minute?

Yes — System fill rate is OK; diagnostic is complete.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 3.







No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 11.

4 Check fuel fill valve; it may not be opening completely.

a. Loosen the fuel fill line connection at the fill valve or at the inlet to the fuel filter to relieve any pressure in the fill line.

b. Attempt to push open the piston in the fill valve to determine if it is opening completely. Piston should travel 1/4 inch.

c. Is the fill valve piston opening completely?

Yes — Replace the filter in the fuel fill line and then go to Step 7.No — Replace the fuel fill valve and then go to Step 5.

5 Attempt to fill the vehicle fuel tank.Does the fuel tank fill at greater than six gal (23 L) per minute?



TROUBLESHOOTING

Page 25

6 Replace the filter in the fuel fill line.Does the vehicle fuel tank fill at greater than six gal (23 L) per minute?





8 Replace the overfill protection device (OPD) valve in the vehicle fuel tank.Is the OPD valve located in the end cap of the fuel tank?



9 Attempt to fill the vehicle fuel tank as follows:

When filling a new tank that has the OPD valve mounted in the end cap, fuel splashing off the sides of the empty tank could be activating the OPD float and shutting off the fuel fill line.

a. Install a fuel fill pressure tester on the fill valve and close the ball valve.

b. Connect the fuel dispensing nozzle to the pressure tester and turn on the pump. Slightly open the ball valve to slowly add approximately 10 gal (38 L) of fuel.

c. Remove the fuel fill pressure tester.

d. Attempt to fill the remaining tank volume (to 80% full capacity) at full flow from the dispensing nozzle.

a. Did the tank fill?


No — Call ROUSH CleanTech Customer Service at 800-597-6874.



11 Fill station is not providing enough pressure to fill.

a. Using the tables provided at the front of this section, determine expected propane tank pressure based on ambient temperature.

b. Is the vehicle fuel tank pressure greater than 20 psi (38 kPa) over the nominal expected pressure?


No — Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility). Then, go to Step 2.

12 Vehicle fuel tank is at a higher pressure.

a. Higher pressure is likely caused by heavy vehicle usage heating the fuel.

b. Allow the vehicle (fuel tank) to cool and then recheck pressure in the fuel tank.

When tank pressure is within 10 psi (69 kPa) of expected tank pressure, go to Step 13.



b. Using a fuel fill pressure tester installed on the fuel fill valve, attempt to fill the vehicle.



Yes — Go to Step 14.No — Fill station is not providing enough pressure to fill vehicle tank. Go to Step 14.

Locate a dispensing facility with pump output capacity in excess of 100 psi (689 kPa) (preferably an Auto Gas-type facility).




TROUBLESHOOTING

Over Fill


1 Suspect overfill because fuel fill volumes achieved during refueling exceed the rated fuel capacity or excessive vehicle range between refueling.

a. Check the fuel gauge.b. Is the gauge reading below 1/2 tank?

Yes — Go to Step 2.No — Drive vehicle until gauge reads below 1/4 tank.

2 Open bleeder valve located on the tank or remotely mounted on the vehicle.

a. Listen at valve to verify propane vapor is venting.b. Is propane vapor venting?


No — Bleeder valve is not functioning properly. Replace the valve.

3 Park the vehicle at the refueling station.

a. Check to determine if the vehicle is level using the vehicle frame as reference.

b. Does the vehicle sit level?


No — Using a jack, raise the vehicle to obtain a level condition. Then, go to Step 4.

4 Locate the American Society of Mechanical Engineers (ASME) inspection plate on the fuel tank.

a. Note the tank water capacity listed on the plate.b. Multiply the listed capacity by 0.05 (5%) and record the value.

With the value recorded, go to Step 5.

5 Refuel the vehicle as follows:

If the key is on during refueling, it will take the fuel level gauge in the instrument cluster longer to register full.

a. Verify that the ignition is in the OFF position.b. Install the fuel fill pressure tester on the fill valve and close the ball

valve.

c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is open.

d. With the bleeder valve open, turn on the pump. Open the ball valve slightly to very slowly refuel the vehicle.

e. While refueling, observe the bleeder valve for fuel discharge.

f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically.

g. Did a solid stream of liquid flow from the bleeder valve?

Yes — Record the volume of fuel dispensed and then go to Step 6.No — Go to Step 7.

6 Resume filling until the dispensing pump stops automatically.

a. Record the total volume of fuel dispensed and subtract the amount from the volume recorded in Step 5.

b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4?

Yes — Tank does not overfill. Diagnostic is complete.No — Tank is overfilling. Replace the OPD fill valve in the fuel tank; then, go to Step 8.

7 The dispensing pump stopped automatically and a liquid fuel stream was not observed flowing from bleeder valve.

Tank does not overfill. Diagnostic is complete.

TROUBLESHOOTING

Page 27

Engine Does Not Crank

8 Refuel the vehicle as follows:

If the key is ON during refueling, it will take the fuel level gauge in the instrument cluster longer to register full.

a. Verify that the ignition is in the OFF position.

b. Install the fuel fill pressure tester on the fill valve and close the ball valve.

c. Connect the fuel dispensing nozzle to the pressure tester. Verify that the bleeder valve is OPEN.

d. With the bleeder valve open, turn ON the pump. Open the ball valve slightly to very slowly to refuel the vehicle.

e. While refueling, observe the bleeder valve for fuel discharge.

f. Stop filling when a solid stream of liquid fuel flows from the bleeder valve or the dispensing pump stops automatically.

g. Did a solid stream of liquid flow from the bleeder valve?

Yes — Record the volume of fuel dispensed and then go to Step 9.No — Go to Step 7.

9 Resume filling until the dispensing pump stops automatically.

a. Record the volume of fuel dispensed and subtract the amount from the volume recorded in Step 8.

b. Is the additional amount of fuel dispensed less than 5% of the tank water capacity determined in Step 4?

Yes — Tank does not overfill. Diagnostic is complete.No — Tank is overfilling. Replace the fuel tank assembly.



1 Is battery voltage above 10 volts? Yes — Go to Step 2.

No — Determine cause of low battery voltage.

2 Verify that the smart relay module (SRM) has communication.

Can fuel rail pressure and temperature be read with a scan tool?


No — Go to the Smart Relay Module Electrical Test procedure.

3 Refer to the Ford Powertrain Control/Emission Diagnosis Service Manual.Is the problem corrected?


TROUBLESHOOTING

Engine Cranks, No Start

For harness and connector layout diagrams and system electrical schematics, refer to Wiring Diagrams and Electrical Schematics.


1 Verify the following:

a. Is there fuel in the tank of at least 1/8 tank or more? (add fuel if necessary).

b. Is the tank supply manual shutoff valve fully open?

c. Is battery voltage above 10 volts?


No — Correct fault and retry.

2 Check for diagnostic trouble codes (DTC).Are any codes present?


3 Is the DTC identified on the ROUSH LPA DTC list? Yes— Refer to Diagnostic Trouble Code List.No — Refer to Ford service manual DTC chart.

4 Check fuel pressure.

a. Measure and record fuel rail and fuel tank pressure, Key ON Engine OFF (KOEO).

b. While monitoring fuel pressure, attempt to start engine.

c. Record the highest pressure observed.

d. Does fuel pressure rise 25 psi (172 kPa) before engine crank?



5 Check fuel pump operation.

a. Using a current clamp, check current draw on both fuel pump power wires at the fuel tank. Refer to In-Tank Harness for correct circuits.

b. Turn ignition switch to START position and release. Vehicle will start the flush cycle and pumps should be running. Check current draw. A minimum of 2 amps should be recorded on both fuel pump circuits.

c. Do fuel pumps draw current?

Yes — Go to Step 6.No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 10.

6 Check excess flow valve (XFV).

a. Turn ignition key to the OFF position.

b. Close the manual shutoff valve on tank.

c. Wait 1 minute and then slowly open manual shutoff valve.

d. Measure and record fuel pressure, using a scan tool, at integrated pressure temperature sensor (IPTS).

e. Is problem resolved?


7 Check ROUSH fuel pump (FP) fuse.Is fuse intact and OK?


No — Determine the cause of the short and repair; replace the fuse. Diagnostic is complete.

8 Check the tank solenoid (TS) and supply solenoid (SS) fuses.

a. Locate the TS fuse (E3-E4) and check its condition.b. Locate the SS fuse (F1-F2) and check its condition.

c. Are the fuses blown?

Yes — Determine the cause of the short and repair; replace the fuse.No — Go to Step 9.

TROUBLESHOOTING

Page 29

9 Verify that there is power and proper grounding at the tank solenoid (TS) and supply solenoid (SS) wiring circuits.

a. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure.

b. Is +12 volts present at the TS connector?

c. Is +12 volts present at the SS connector?

Yes — Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly.No — Check for an open(s) in the wiring circuits and repair. Diagnostic is complete.

10 Verify that there is power and proper grounding in the wiring circuit to the tank.

a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Pump Electrical Check procedure.

b. Is +12 volts present at the FP1 connector?

c. Is +12 volts present at the FP2 connector?


No — Check for an open(s) in the wiring circuits and repair.

11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification procedure?

Yes — Refer to the Integrated Pressure Temperature Sensor Electrical Check.

No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor.

12 Check wiring.

a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information.

b. Remove tank service cover.

c. Check for open or short circuits on tank pass-through harness.

d. Is a wiring problem present?

Yes — Replace harness.


13 Check fuel hoses and quick-connect fittings.

� Are in-tank fuel hoses and quick-connect fittings connected and in good condition?

Yes — Replace fuel pump assembly.No — Replace hose assemblies as needed.


TROUBLESHOOTING

Engine Stumble, Stall, Rough Idle




a. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.)

b. Is the tank supply manual shutoff valve fully open?

c. Is battery voltage above 11 volts with engine running?


No — Correct the fault and retry.

2 Check for diagnostic trouble codes (DTCs).Are any codes present?


3 Identify the DTC.

a. Is the DTC covered in the ROUSH CleanTech DTC listing for LPA-fueled vehicles?

b. Correct all DTCs before continuing.

Yes — Refer to ROUSH CleanTech Diagnostic Trouble Code List.No — Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.

4 Does the problem occur only after cold start? Yes — Go to Step 6.No — Go to Step 5.

5 Determine fuel pressure.

a. Measure tank pressure with Key ON Engine OFF (KOEO).b. Measure fuel rail pressure with Key ON Engine Running (KOER).

c. Subtract the KOEO pressure from the KOER pressure to obtain the difference. Compare to the chart in Expected Fuel Rail Pressure.

d. Is the resulting fuel pressure reading within the expected range?



6 Determine if the excess flow valve (XFV) is tripped.

a. Turn OFF the engine.

b. Wait one minute and then restart the engine.

c. Is the fault condition resolved?

Yes — Refer to the Excess Flow Valve Check procedure.







8 Verify that there is power and proper grounding in the wiring circuit to the tank.

a. Check for +12 volts at the fuel pump 1 (FP1) and fuel pump 2 (FP2) connectors. Refer to the Fuel Rail Pressure Control Module Electrical Check procedure.



Yes — Go to Step 9.No — Check for an open/short in the wiring circuit and repair.

TROUBLESHOOTING

Page 31

Excess Flow Valve Check

The excess flow valve (XFV) is designed to restrict fuel exiting the tank if the pump is energized while the fuel lines are not connected to the fuel tank. Under normal circumstances, the XFV should not trip. The XFV will reset itself after the fuel pumps have been off for about one minute.

It is common to trip the XFV after the fuel lines have been serviced and contain no pressure. If the XFV trips, turn the vehicle off, wait one minute, and restart. This may take more than one attempt.

If the fuel lines have not been serviced recently and the problem persists, there may be a leak in the supply side fuel line. If the problem is only present after the vehicle has been sitting for a length of time, but not present during a short soak, or there is a propane odor when the vehicle is running, refer to the Fuel Line Leak Detection procedure.

9 Check wiring.

a. Drain the propane from the fuel tank. Refer to the Fuel Tank Draining Procedure in the appropriate ROUSH CleanTech Service Manual for more information.

b. Remove tank service cover.

c. Check for open or short circuits on tank pass-through harness.

d. Is a wiring problem present?

Yes — Replace harness.


10 Check fuel hoses and quick-connect fittings.

� Are in-tank fuel hoses and quick-connect fittings connected and in good condition?

Yes — Replace fuel pump assembly.No — Replace hose assemblies as needed.

11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification? Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure.


No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor.

12 Refer to the appropriate Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.

—



1 Verify fuel supply line pressure prior to cranking engine.

a. Read fuel rail pressure and tank pressure.b. Energize bleed solenoid until rail pressure is at least 50 psi

(345 kPa) below tank pressure. If rail is bled, skip to Step D.

c. Let pressure stabilize for 1 minute.

d. Open the supply solenoid.

e. Read fuel rail pressure and tank pressure.

f. Does fuel rail pressure jump to tank pressure?

Yes — Check is OK.No — Repair the leak in the fuel supply line.

TROUBLESHOOTING

Maximum Pressure Check

The LPA system operates over a wide range of pressures depending on ambient temperature, driving mode, etc. When the vehicle is subjected to a severe drive cycle in high ambient temperatures, the fuel rail pressure can rise to the limit of the injectors capabilities. This limit is a function of injector voltage and fuel rail pressure. The PCM protects for this condition by reducing the fuel pump speed when the condition is sensed, however, there still may be drive concerns. When the PCM starts controlling the fuel pump a P116E code is set. While this

condition can occur in a normally functioning vehicle, it can also be exacerbated by several factors. If the fuel tank was not properly bled during the first fill, trapped air in the vapor space can increase tank pressure. In this condition there is often only a faint smell of propane when the bleeder valve is opened. The tank should be vented until there is a strong propane odor coming from the bleeder valve. The tank pressure should be confirmed against the expected pressure.

Allow the fuel tank to cool to ambient temperature before performing the following procedure.

Supply Solenoid Check



1 Measure tank pressure and tank surface temperature.Is tank pressure more than 15 psi (103 kPa) over expected tank pressure?

Yes — Vent the tank until pressure is within the expected range.

No — Vehicle is working properly; inform and explain operating characteristics to customer.



a. Is there fuel in the tank of at least 1/8 tank or more? (Add fuel if necessary.)

b. Is the tank supply manual shutoff valve fully OPEN?


Yes — Go to Step 2.No — Correct fault and retry.

2 Check for diagnostic trouble codes (DTC).Are any codes present?


3 Is the DTC identified on the ROUSH liquid propane autogas DTC list?

Yes — Refer to Diagnostic Trouble Code List.No — Refer to the Ford service manual DTC chart.

4 Check fuel pressure.

a. Measure and record fuel rail pressure and fuel tank pressure at Key ON Engine OFF (KOEO).

b. While monitoring fuel pressure, attempt to start engine.

c. Record the highest pressure observed.

d. Does fuel pressure rise 20 psi (138 kPa) before engine crank?


TROUBLESHOOTING

Page 33




a. Do fuel pumps draw current?


No — If both circuits are showing no current, check the OEM fuel pump (FP) fuse. If only one fuel pump circuit shows current, check the ROUSH CleanTech fuel pump fuse. (See ROUSH CleanTech fuse box for location.)

If both fuel pump fuses (OEM and ROUSH CleanTech) are good, go to Step 10.

6 Check XFV.

a. Turn OFF engine.b. Wait 1 minute and then restart engine.

c. Measure and record fuel rail pressure and fuel tank pressure.

d. Is problem resolved?


7 Check ROUSH FP fuse.Is fuse intact and OK?

Yes — Go to Step 8.No — Determine the cause of the short and repair; replace the fuse.

8 Check the TS and SS fuses.

a. Locate the TS fuse (E3-E4) and check its condition.b. Locate the SS fuse (F1-F2) and check its condition.

c. Are the fuses blown?

Yes — Determine the cause of the short and repair; replace the fuse.No — Go to Step 9.

9 Verify that there is power and grounding in the TS and SS wiring circuits.

a. Check for +12 volts at the TS and SS connectors. Refer to the Tank Solenoid Electrical Check procedure.

b. Is +12 volts present at the TS connector?

c. Is +12 volts present at the SS connector?

Yes — Voltage present at SS, replace FRPCM. Voltage present at TS, replace fuel supply valve assembly.No — Check for an open/short in the wiring circuit and repair.

10 Verify that there is power and grounding in the wiring circuit to the tank.




Yes — Refer to Engine Stumble, Stall, Rough Idle Step 12.

No — Check for an open/short in the wiring circuit and repair.

11 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification?

Yes — Go to Step 12.No — Verify that wiring in circuit is OK. Refer to the Integrated Pressure Temperature Sensor Electrical Check procedure. If not, repair wiring. If OK, replace sensor.


—


TROUBLESHOOTING

Fuel System Fails to Bleed


1 Check for diagnostic trouble codes (DTC).

a. Are both DTC 26B3 and P009E present?


2 Check for oil contamination at vapor port/EVAP line.

a. Disconnect EVAP line from vapor port.

b. Is oil present in EVAP line or vapor port?

Yes — Replace vapor port and perform Step 3.No — Go to Step 3.

3 Determine if fault condition repeats.

a. START the engine and allow it to run for a few minutes.b. Turn OFF the engine and wait one minute.

c. Measure and record the fuel rail pressure, fuel rail temperature and fuel tank pressure with the Key ON Engine OFF (KOEO).

d. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.

e. With the engine OFF, monitor fuel rail pressure for 15 minutes.

f. Does fuel rail pressure drop more than 20 psi (138 kPa)?

Yes — Potential intermittent fault. Return vehicle to customer and see if problem persists.


4 Verify vapor port function.

a. Disconnect the EVAP line from the FRPCM port.

b. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.

c. Is there propane flowing from the port?


5 Verify bleed solenoid function.

a. Disconnect the EVAP line from the FRPCM port.

b. Remove the vapor port.

c. Energize the bleed solenoid. Refer to the Manual Solenoid Activation Procedure. Verify wiring integrity and voltage to solenoid.

d. Is there propane flowing from the port?

Yes — Replace vapor port and repeat Step 3.No — Go to Step 6.

6 Verify that wiring is in good condition and functioning.

a. Perform wiring checks of the FRPCM harness.

b. Is the wiring OK?

Yes — Bleed solenoid stuck closed. Replace the FRPCM.

No — Repair wiring and repeat Step 3.

7 Check for a kinked EVAP line.

a. Inspect the EVAP line between the FRPCM and EVAP canister.

b. Are there kinks in the line?

Yes — Replace the kinked EVAP line and then repeat Step 3.


8 Check for leaks to the FRPCM.

a. START the engine and allow it to run for a few minutes.b. Turn OFF the engine.

c. Measure and record fuel rail pressure.

d. Activate bleed solenoid to bleed pressure from fuel rail until fuel pressure drops more than 50 psi (345 kPa). Refer to the Manual Solenoid Activation Procedure.

e. De-energize bleed solenoid.

f. Disconnect the FRPCM and wait 120 minutes.

g. Measure fuel rail pressure and fuel tank pressure.

h. Does fuel rail pressure rise more than 10 psi (69 kPa)?

Yes — FRPCM leaks at either supply solenoid or return check valve. Replace FRPCM.

No — Potential intermittent fault. Return vehicle to customer and see if problem persists.

TROUBLESHOOTING

Page 35

Fuel Pressure Drop




a. Is there fuel in the tank of at least 1/8 tank?b. Is the tank supply manual shutoff valve fully open?



No — Correct the fault condition and retry.

2 Determine fuel pressure.

a. Measure and record fuel tank pressure.b. Measure and record fuel rail pressure with Key ON Engine

Running (KOER).

c. Subtract the tank measurement from the KOER measurement.

d. Is the resulting fuel pressure in the expected range?


3 Determine if the excess flow valve is tripped.

a. Turn OFF the engine.b. Wait one minute and then restart the engine.

c. Is the problem resolved?

Yes — Refer to the Excess Flow Valve Check procedure.No — Go to Step 4.






5 Check tank solenoid (TS) and supply solenoid (SS) fuses.

a. Locate the TS (E3-E4) and SS (F1-F2) fuses.b. Are the fuses blown?

Yes — Find and repair the short; replace the fuse.No — Go to Step 8.

6 Verify that there is power and ground in the wiring circuit to the tank.




Yes — Refer to Engine Stumble, Stall, Rough Idle Step 9.

No — Check for an open/short in the wiring circuit and repair.

7 Integrated Pressure Temperature Sensor RationalityDoes temperature and pressure make sense to verification? See the Integrated Pressure Temperature Sensor Electrical Check procedure.

Yes — Go to Step 8.No — Verify that wiring in circuit is OK. If not, repair wiring. If OK, replace sensor.


—

TROUBLESHOOTING

Fuel Level Indication Check

The ROUSH CleanTech fuel level indication system differs from the gasoline system as the fuel level sender is not wired directly to the instrument cluster. Instead, the fuel level sender is wired to the SRM, which reads the fuel level and transmits the signal to the PCM via the CAN bus, and to the FLIM, which in turn simulates the resistance the instrument cluster expects to see for a given fuel level.

The gauge on the sending unit must not be used for any diagnostics. The gauge is not accurate. Only resistance or voltage outputs should be used for diagnostic purposes.

Symptom Cause/Action to be taken

Fuel gauge does not move on a partial fill This behavior is not uncommon. The fuel level sender may not move far enough to trigger movement on the gauge if only a small amount of fuel is added to the tank. Once driven, the gauge may move to reflect the fill.

Malfunction Indicator Lamp (MIL) There is a circuit fault that has been identified by the PCM. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is called for, refer to the Fuel Level Interface Module Electrical Test procedure.

Gauge points below E This is an indication of an error state. Initially follow the Ford Powertrain Control/Emissions Diagnosis Service Manual, whenever a circuit check is called for, refer to the Fuel Level Interface Module Electrical Test procedure.

Doesn’t read full after a fill This could be the result of either a fuel level sender fault or an OPD valve triggering prematurely. Refer to fill issues and the Fuel Level Sender Electrical Check procedure for more information.

TROUBLESHOOTING

Page 37

Tank Solenoid Electrical Check


CONNECTORS

1

Figure 1 — Underhood Harness Connectors2

Figure 2 — Rear Frame Harness Connectors3

Figure 3 — Solenoid Harness Connectors

100070a

FUSE BOX

F E D C B A

4 5 3

5 53 332

14

2

A B

1

42

2

11E

F

55

36

44

21

1 15

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

44

100071aA

A B C D E F

B C D

21 30

100072aD C B A A B

1 9

TROUBLESHOOTING

PROCEDURE


1 Unplug the solenoid harness connector 9 from the tank solenoid. Go to Step 2.

2 Using a multimeter, measure resistance of the solenoid.Is the measured resistance within 6–35 ohms?

Yes — Go to Step 3.No — Replace the tank solenoid.

3 Using a multimeter, measure voltage at the tank solenoid as follows:

a. With the ignition key ON, check for voltage present at pin-A, connector 9 (solenoid harness). Use the body as the reference ground.

b. Is battery (B+) voltage present?

Yes — Supply circuit OK.No — Go to Step 4.

4 Check fuse (E3-E4, 20A) in auxiliary fuse box.Is fuse blown?

Yes — Replace fuse.

No — Fuse OK; go to Step 5.

5 Check relay.Is relay functioning properly?

Yes — Go to Step 6.No — Replace relay.

6 Check supply circuit continuity from solenoid harness to fuse box.

a. Check continuity between:� Pin-A, connector 9 and pin-A, connector 1 (solenoid harness)

� Pin-A, connector 21 and pin-A, connector 30 (rear wiring harness)

� Pin-A, connector 15 and cavity A5, fuse box (underhood harness)

b. Is there good continuity in the circuit?


No — Repair supply circuit wiring.

7 Check ground circuit continuity from solenoid harness to smart relay module (SRM) connector.

a. Check continuity between:

� Pin-B, connector 9 and pin-B, connector 1 (solenoid harness)� Pin-B, connector 21 and pin-E, connector 30 (rear wiring

harness)� Pin-E, connector 15 and pin-44, connector 1 (underhood

harness)


Yes — Refer to the Smart Relay Module Electrical Test procedure.No — Repair ground circuit wiring.

TROUBLESHOOTING

Page 39

Fuel Rail Pressure Control Module Electrical Check


CONNECTORS

4

Figure 4 — Underhood Harness Connectors

PROCEDURE

100073a

FUSE BOX

4 5 3

5 53 332

14

2

A B

1

42

2

11E

F

55

36

44

21

1 11

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

46

F1-F2

33

17 F E D C B A


1 Unplug the fuel rail pressure control module (FRPCM) connector from connector 11 of underhood harness.

Go to Step 2.

2 Using a multimeter, check the resistance of each solenoid.

a. Check resistance across the terminals of the FRPCM connector in sequence as follows:

� Supply Solenoid — Pin-A and pin-F� Flow Control Solenoid — Pin-B and pin-E� Bleed Solenoid — Pin-C and pin-D

b. Is the measured resistance for each solenoid within 6–35 ohms?

Yes — Go to Step 3.No — Replace the FRPCM if resistance for any one of the solenoids is not within the specified range.

3 Check supply voltage to FRPCM solenoids.Using a multimeter, measure voltage between the terminal for each solenoid at the harness side connector 11 and ground as follows:

Go to Steps 4–6.

TROUBLESHOOTING

4 Supply Solenoid — Pin-A and body ground B+ Voltage — Go to Step 5.

No Voltage — Go to Step 5.

5 Flow Control Solenoid — Pin-B and body ground B+ Voltage — Go to Step 6.No Voltage — Go to Step 6 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7.

6 Bleed Solenoid — Pin-C and body ground B+ Voltage — Continue with Step 9.No Voltage — Go to Step 8 if Step 4 has voltage; if Step 4 has no voltage, go to Step 7.

7 Check fuses (F1-F2, 10A) in auxiliary fuse box.Is a fuse blown?

Yes — Replace fuse.No — Go to Step 8.

8 Check solenoid supply circuit continuity.

a. Check continuity between:� Supply Solenoid — Pin-A, connector 11 (underhood harness)

and cavity F2 (auxiliary fuse box)

� Flow Control Solenoid — Pin-B, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box)

� Bleed Solenoid — Pin-C, connector 11 (underhood harness) and cavity F2 (auxiliary fuse box)

b. Is there good continuity in all three circuits?

Yes — Go to Step 9.No — Repair wiring circuit.

9 Check solenoid ground circuit continuity.

a. Check continuity in the underhood harness between:� Supply Solenoid — Pin-F, connector 11 and pin-46, connector

1 at SRM� Flow Control Solenoid — Pin-E, connector 11 and pin-33,

connector 1 at SRM� Bleed Solenoid — Pin-D, connector 11 and pin-17, connector 1

at SRMb. Is there good continuity in all three circuits?

Yes — Refer to the Smart Relay Module Electrical Test procedure.No — Repair wiring circuit.

TROUBLESHOOTING

Page 41

Integrated Pressure Temperature Sensor Electrical Check


CONNECTORS


PROCEDURE


1 Unplug the connector 8 (underhood harness) to the IPTS. Go to Step 2.

2 Check resistance of the integrated pressure temperature sensor (IPTS).

a. With vehicle at ambient room temperature (20–30°C, 68–86°F) and using a multimeter, measure resistance across the IPTS terminals (between pin-1 and pin-3).

b. Is the resistance value between 8K–12K ohms?

Yes — Go to Step 3.No — Replace the IPTS.

3 Check circuit continuity between the IPTS and the smart relay module (SRM).

a. Using a multimeter, check continuity in the underhood harness between:� Pin-1, connector 8 and pin-40, connector 1

� Pin-2, connector 8 and pin-7, connector 1� Pin-3, connector 8 and pin-5, connector 1� Pin-4, connector 8 and pin-25, connector 1

b. Is there good continuity in the circuits?

Yes — Refer to the Smart Relay Module Electrical Test procedure.

No — Repair circuit wiring.

TROUBLESHOOTING

Fuel Pump Electrical Test


CONNECTORS5


Figure 7 — In-Tank Harness Connectors

PROCEDURE

100075a

4 1B A

B A8 5

12 13 24 27

100076a

A B

B

A

1 2 4A 4B


1 Check fuel pump circuit continuity.

a. Unplug the FPCM connector 12 for fuel pump 1. Check fuel pump circuit continuity.

b. Using a multimeter, measure resistance between pin-5 and pin-8.

c. Is resistance between 0.4–1.0 ohm?


2 Check fuel pump circuit continuity.

a. Unplug the FPCM connector 13 for fuel pump 2.b. Using a multimeter, measure resistance between pin-5 and pin-8.


Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure.


3 Check resistance of each fuel pump.

a. Unplug the fuel pump connectors (in-tank harness) at the fuel pump assembly.

b. Using a multimeter, measure resistance for fuel pump 1 across the terminals of the fuel pump.


Yes — Go to Step 4.No — Replace fuel pump assembly.

TROUBLESHOOTING

Page 43

4 Check resistance continued.

a. Using a multimeter, measure resistance for fuel pump 2 across the terminals of the fuel pump.

b. Is resistance between 0.4–1.0 ohm?


No — Replace fuel pump assembly.

5 Check harness circuit continuity from fuel pumps to FPCM.

a. Check continuity for pump 1, wire FPPWR, V+ across:� Pin-A, connector 4A (in-tank harness) to pin-A, connector 1

(in-tank harness)� Pin-A, connector 24 (rear frame harness) and pin-5, connector

12 (rear frame harness)

b. Check continuity for pump 1, wire FPRTN, V– across:

� Pin-B, connector 4A (in-tank harness) to pin-B, connector 1 (in-tank harness)

� Pin-B, connector 24 (rear frame harness) and pin-8, connector 12 (rear frame harness)

c. Check continuity for pump 2, wire FPPWR, V+ across:

� Pin-A, connector 4B (in-tank harness) to pin-A, connector 2 (in-tank harness)

� Pin-A, connector 27 (rear harness) and pin-5, connector 13 (rear harness)

d. Check continuity for pump 2, wire FPRTN, V– across:

� Pin-B, connector 4B (in-tank harness) to pin-B, connector 2 (in-tank harness)

� Pin-B, connector 27 (rear frame harness) and pin-8, connector 13 (rear frame harness)

e. Is there good continuity in all circuits?

Yes — Refer to the Fuel Pump Control Module Electrical Continuity Test procedure.No — Repair circuit wiring.


TROUBLESHOOTING

Fuel Pump Control Module Electrical Continuity Test


CONNECTORS7


Figure 9 — Rear Frame Harness Connectors

100077a

4 5 3

5 53 332

14

2

AD

B

1

42

2

11E

F

55

36

44

21

A5 A3

FUSE BOX E4

15

F E D C B AC

100078a

1 4

5 8

A B C D E F B

4 1

8 5

B A

A

1

30 41

1312 27

TROUBLESHOOTING

Page 45

PROCEDURE


For fuel pump control module (FPCM) functional testing and diagnostic trouble codes, refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual at www.motorcraft.com.

1 Check Ford FPCM circuit continuity to Ford harness.

a. Disconnect rear frame harness connectors 1 and 12.

b. Check for continuity in the rear frame harness across:

� Pin-1, connector 1 and pin-1, connector 12

� Pin-3, connector 1 and pin-3, connector 12� Pin-4, connector 1 and pin-4, connector 12� Pin-5, connector 1 and pin-5, connector 12

� Pin-6, connector 1 and pin-6, connector 12� Pin-7, connector 1 and pin-7, connector 12

c. Is there good continuity in each circuit?

Yes — Go to Step 2.No — Repair circuit wiring.

2 Check FPCM circuit continuity to Ford harness.

a. Disconnect rear frame harness connector 13.b. Check wire VPWR (V+) for continuity across:

� Pin-1, connector 13 (rear frame harness) and pin-A, connector 30 (rear frame harness)

� Pin-A, connector 15 (underhood harness) and cavity-A5, fuse box (underhood harness)

� Cavity-A3, fuse box (underhood harness) and cavity-E4, fuse box (underhood harness)

c. Is there good continuity in each circuit?



3 Check fuse condition (E3-E4).Is the fuse blown?

Yes — Replace the fuse.No — Go to Step 4.

4 Check Roush CleanTech FPCM circuit continuity to Ford harness.

a. Check for continuity in the rear frame harness across:� Pin-A, connector 30 and pin-1, connector 13

� Pin-4, connector 1 and pin-4, connector 13� Pin-A, connector 27 and pin-5, connector 13� Pin-6, connector 1 and pin-6, connector 13

� Pin-B, connector 27 and pin-8, connector 13� Pin-A, connector 41 and pin-7, connector 13

b. Is there good continuity in each circuit?

Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the FPCM.


TROUBLESHOOTING

Smart Relay Module Electrical Test


CONNECTORS9


Figure 11 — CAN Harness Connectors

PROCEDURE

100079a

FUSE BOX

4 5 3

5 53 332

14

2

A B

1

42

2

11E

F

55

36

44

21

1

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

31

2

E1-E2

100080a

7

14 8

1 C

D F

5 9A


1 Disconnect the smart relay module (SRM) connector 1 (underhood harness).

Go to Step 2.

2 Check for battery voltage (B+) to the SRM.

a. Using a multimeter, check for B+ voltage at cavity 2, connector 1. Use a body ground for reference.

b. Is there voltage (B+)?




a. Check circuit continuity between cavity 2, connector 1 and cavity E2, auxiliary fuse box.




TROUBLESHOOTING

Page 47


a. Check condition of SRM power fuse (E1-E2, 25A) in the auxiliary fuse box.

b. Is fuse blown?

Yes — Replace fuse.


5 Check the SRM ground circuit for continuity.

a. Using a multimeter, check ground at cavity 31, connector 1 (underhood harness). Use a body ground for reference.

b. Is there good continuity?



6 Check for active signal to SRM.

a. Using a multimeter, check the underhood harness for continuity in the E-Series system between pin-26, connector 1 and pin-A, connector 23 and in F-Series system between pin-26, connector 1 and pin-1, connector 51/55.


Yes — E-Series: Go to Step 8, F-Series: Go to Step 9.


7 Check fuse.

a. Check condition of fuse (F5-F6, 5A) in auxiliary fuse box.

b. Is fuse blown?

Yes — Replace fuse.No — Repair circuit wiring

8 E-Series Only: Check CAN harness for SRM circuit continuity.

a. Check continuity between pin-A, connector 9 and pin-12, connector 5.



9 Check CAN and underhood harness continuity.

a. Check CAN-H(+) continuity across:� Pin-28, SRM connector 1 (underhood harness) and pin-C,

connector 23 (underhood harness)

� Pin-C, connector 9 (CAN harness) and pin-2, connector 5 (CAN harness)



10 Check CAN and underhood harness continuity.

a. Check CAN-H(−) continuity across:� Pin-43, SRM connector 1 (underhood harness) and pin-B,

connector 23 (underhood harness)

� Pin-B, connector 9 (CAN harness) and pin-3, connector 5 (CAN harness)


Yes — Refer to the Ford Powertrain Control/Emissions Diagnosis Service Manual for functional testing of the CAN bus.No — Repair circuit wiring.


TROUBLESHOOTING

Fuel Level Sender Electrical Check


CONNECTORS11



Figure 14 — Solenoid Harness Connectors

100081a

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

151

F E D C B A3

100082aA B C D

A B C D E F21 30

100083aD C BB

A

A

1 6

TROUBLESHOOTING

Page 49

PROCEDURE


For fuel level sender (FLS) functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes.

1 Check resistance in FLS circuit wiring.

a. Disconnect the SRM connector 1 (underhood harness).

b. Using a multimeter, measure the resistance between pin-3 and pin-40 of the harness connector.

c. Is resistance between 24–260 ohms?

Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure.No — Go to Step 2.

2 Check resistance of the FLS.

a. Disconnect the FLS connector 6 (solenoid harness).b. Using a multimeter, measure the resistance across the FLS

connector pins.

c. Is resistance between 24–260 ohms?

Yes — Go to Step 3.No — Replace the FLS.

3 Check circuit wiring continuity between FLS connector and SRM connector.

a. Disconnect connector 1 of the solenoid harness.

b. Check continuity between pin-B, connector 6 (solenoid harness) and pin-C, connector 1 (solenoid harness).

c. Is there good continuity in the circuit?



a. Disconnect connector 30 of the rear frame harness.

b. Check continuity between pin-C, connector 21 (rear frame harness) and pin-D, connector 30 (rear frame harness).




a. With SRM connector 1 and connector 15 of the underhood harness disconnected, check continuity between pin-C, connector 15 and pin-3, SRM connector 1.




a. Check continuity between pin-A, connector 6 (solenoid harness) and pin-D, connector 1 (solenoid harness).


Yes — Go to 7.



a. Check continuity between pin-D, connector 21 (rear frame harness) and pin-C, connector 30 (rear frame harness).





a. Check continuity between pin-D, connector 15 (rear frame harness) and pin-40, SRM connector (underhood harness).


Yes — Refer to the Smart Relay Module Electrical Test procedure or the Fuel Level Interface Module Electrical Test procedure.


TROUBLESHOOTING

Fuel Level Interface Module Electrical Test


CONNECTORS14


15

Figure 16 — Rear Frame Harness Connectors

PROCEDURE

100084a

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

1 3537

B A

C D

2

A

100085a

B C D E F9 30


For FLIM functional testing and diagnostic trouble codes, use Diagnostic Tests and Procedures and Diagnostic Trouble Codes.

1 Check FLIM circuit wiring for continuity to SRM.

a. Disconnect underhood harness connector 1 to SRM.b. Check underhood harness continuity between pin-A, connector 35 and pin-26,

connector 1.





a. Check underhood harness continuity between pin-B, connector 35 and pin-37, connector 1.





a. Check underhood harness continuity between pin-C, connector 35 and body ground.




a. Disconnect underhood harness connector 15 to rear frame harness.

b. Check underhood harness continuity between pin-D, connector 35 and pin-F, connector 15.




a. Disconnect rear frame harness connector 9 to Ford harness.b. Check rear frame harness continuity between pin-F, connector 30 and pin-2,

connector 9.


Yes — Refer to the Smart Relay Module Electrical Test procedure.


TROUBLESHOOTING

Page 51

Manual Solenoid Activation Procedure


CONNECTOR16

Figure 17 — Connector End View

17

Figure 18 — FRPCM Solenoid Locations

PROCEDURE

100351a

30 31

PBT/ASA-GF20

32

1 23 15

44 45 46

1716

A12918

4633

17

FLOW CONTROLSOLENOID

FUELSUPPLY

SOLENOIDBLEED

SOLENOID

BLEED/VAPORPORT

100108c


1 Disconnect the smart relay module (SRM) wire harness connector at the SRM. —

2 Energize the individual solenoids on the FRPCM by providing a ground to the following pins in the SRM connector:

• Pin 17 – Bleed Solenoid

• Pin 33 – Flow Control Solenoid• Pin 46 – Supply Solenoid

—

WIRING DIAGRAMS AND SCHEMATICS

Page 52

WIRING DIAGRAMS AND ELECTRICAL SCHEMATICS


E-150/250/350 Wiring Harnesses and Connector Layout

UNDERHOOD HARNESSCAN HARNESS

REAR FRAME HARNESS

IN-TANK HARNESSSOLENOID HARNESS

2124271

6

UNDER BODY LPAFUEL TANK

9

144B4A

9 1341

30

47

1527

8

11

23 9

5

1

135

12 1GNDGNDR2 PASS

THRUGNDR1

7

100129a

APPROXIMATE LOCATION OF LPA SYSTEM HARNESSES AND CONNECTORS


E-150/250/350 Extended Range Wiring Harnesses and Connector Layout


REAR FRAME HARNESS


IN-BED FUEL TANK JUMPER

212427

16

IN-V

EH

ICL

E L

PAF

UE

L T

AN

K

9 14

4B4A941

30

47

1527

8

11

23 9

5

1

135

GNDGNDR2 PASS

THRUGNDR1

13 12 1

7

916

13

41A1B GND

100152a



E-450 Custom Body Wiring Harnesses and Connector Layout

100153a


REAR FRAME HARNESS



IN-BED FUEL TANK JUMPER

2124271

6

AFT-AXLE LPAFUEL TANK

9

144B4A

1 1241

30

47

1527

8

11

23 9

5

1

135

13 GNDGNDR2 PASS

THRUGNDR1

7


F-250/350 Pickup, In-Bed Tank Wiring Harnesses and Connector Layout

IN-B

ED

LPA

IN-B

ED

LPA

FU

EL

TA

NK

FU

EL

TA

NK


REAR FRAME HARNESS


IN-BED FUEL TANK JUMPERFTPT JUMPER HARNESS

212427

16

IN-B

ED

LPA

FU

EL

TA

NK

9 41

4B4A

9

41

30

47

15

27

8

11

23 9

5

1

1

35

5155

GND

GNDR2

PASSTHRU

GNDR1

BATTERY

+–

1 13 12

7

913

16

41A1BGND

1

4

*FTPT Harness depends upon the Ford Fuel Tanks

6

*

100187a



F-650 Chassis Cab Wiring Harness and Connector Layout

BATTERY

T3T2T1+ –

FB C4

C3C3

C1

G1

C2

14

7

14

7

C7

C9C8

C10 C16 C15 C14C15 C14

C13C19 C13 C11C12

C13C13C19

C18

C18

C11C12

C6

C5

T4

UNDERHOOD HARNESS

CAN HARNESS

IN-TANK HARNESSTANK SOLENOID HARNESSFUEL TANK JUMPER HARNESS

IN-TANK HARNESS (LH AND RH)1 FUEL PUMP #1 INLINE 2-PIN4 FUEL PUMP #2 INLINE 2-PIN7 GROMMET

UNDERHOOD HARNESSC3 UNDERHOOD/CAN INLINE

CONNECTOR 2-PINC4 SRM 46-PIN

UNDERHOOD HARNESS (CONT.)C5 IPTS 4-PINC6 FRPCM 6-PINC7 FLIM 4-PINC8 FORD EFPR 8-PINC9 RCT EFPR 8-PINC10 TO FORD INLINE CONNECTOR 8-PINC11 UNDERHOOD/IN-TANK FP#1 INLINE

(LEFT TANK) 2-PINC12 UNDERHOOD/IN-TANK FP#2 INLINE

(LEFT TANK) 2-PINC13 TANK SOLENOID INLINE CONNECTOR

(LEFT TANK) 4-PINC14 UNDERHOOD/FUEL TANK JUMPER

INLINE CONNECTOR 2, 4-PIN

UNDERHOOD HARNESS (CONT.)C15 UNDERHOOD/FUEL TANK JUMPER

INLINE CONNECTOR 1, 4-PINC16 UNDERHOOD/FUEL PUMP AND

SENDER INLINE CONNECTOR 4-PINFB AUX FUSE BOXT1 PWR #1 RING TERMINALT2 PWR #2 RING TERMINALT3 GROUND RING TERMINALT4 TERMINAL INSERTED IN SPLICE PACK

TANK SOLENOID HARNESS (LH AND RH)C13 UNDERHOOD/TANK SOLENOID INLINE

CONNECTOR 4-PINC18 SUPPLY VALVE SOLENOID 2-PINC19 FUEL SENDER 2-PIN

FUEL TANK JUMPER HARNESSC11 FUEL TANK JUMPER/IN-TANK INLINE 1

(RIGHT TANK) 2-PINC12 FUEL TANK JUMPER/IN-TANK INLINE 2

(RIGHT TANK) 2-PINC13 FUEL TANK JUMPER/TANK SOLENOID INLINE

(RIGHT TANK) 4-PINC14 FUEL TANK JUMPER/UNDERHOOD INLINE 2, 4-PINC15 FUEL TANK JUMPER/UNDERHOOD INLINE 1, 4-PIN

CAN HARNESSC1 BODY MODULE 12-PINC2 TO FORD HARNESS CONNECTOR 12-PINC3 CAN/UNDERHOOD IN-LINE CONNECTOR 2-PING1 GROMMET

100254a



F-450/550 Roush Wiring Harnesses (Note: This wiring harness print does not include the attachment locations for the ROUSH CleanTech tank jumper harness to the rear chassis harness.)

100257a

CAN HARNESS

FUEL TANK JUMPER HARNESS

FORDHARNESS

CONNECTOR

TRAILER BRAKEMODULE CONNECTOR(IF EQUIPPED)

TO ROUSHHARNESS

TO ROUSHHARNESS

TO ROUSHHARNESS

TO ROUSHHARNESS

TO ROUSHHARNESS

TO ROUSHHARNESS

TO CANHARNESS

SYSTEMGROUND

MODULEGROUND

TO FORD AUXENGINE INLINE

MODULE

TO FORDHARNESS

TO REARFRAME

HARNESS

TO REARFRAME

HARNESS

TO IPTSSRM

TO FLM

BATTERYPOSITIVE

FUSE BOX

TOSOLENOID

MODULE

UNDERHOODHARNESS

TO ROUSHUNDERHOOD

HARNESS

TO ROUSHUNDERHOOD

HARNESS

CONNECT TOFORD HARNESS

FPCM

TO FUEL TANKSENDER

SOLENOIDTO FUEL

TANK 2 PWR

TO FUELTANK 1 PWR

FRAMEGROUND

TO FORD FUEL PUMPHARNESS CONNECTOR

TO FORD FPCM MODULEFUEL PUMP CONTROLMODULE 1

TO ROUSH FPCM MODULEFUEL PUMP CONTROL

MODULE 2

REAR CHASSISHARNESS


F-650 Chassis Cab, Roush Wiring Harnesses

SRMC4

FRPCMC6

IPTSC5

FLIMC7

UH/CANInline

C3

GND-BATT

TO SPLICEPACK(PIN D)

TERMINAL

FUSE_BOX

C4-FA

R_PWR_1 R_PWR_2

C4-MA

ROUSH EFPRC9

FORD EFPRC8

UH/FORDINLINE

C16

UH/FORDInlineC10

UH/IN-TANKINLINE 1

(FUEL PUMP)C11

(LH TANK)

UH/IN-TANKINLINE 2

(FUEL PUMP)C12

(LH TANK)

UH/TANKSOLENOID

INLINEC13

(LH TANK)

UH/TANKJUMPERInline 1

C15

UH/TANKJUMPERInline 2

C14

100255a

FORD HARNESSCONNECTOR

(12-PIN)C2

BODY MODULE(12-PIN)

C1

GROMMET

CAN HARNESS

TANK JUMPERHARNESS

UNDERHOODHARNESS

TANK SOLENOID HARNESS(LONG AND SHORT TANKS)

CAN/UNDERHOODINLINE CONNECTOR

(2-PIN)C3-F

BA

AB

TANK SOLENOID/UNDERHOOD INLINE

(4-PIN)C13-M

FUEL SENDER(4-PIN)

C19

SUPPLYVALVE

SOLENOID(2-PIN)

C18

UNDERHOOD/FUEL TANK JUMPERINLINE CONNECTORC14

FUEL TANK JUMPER/IN-TANK INLINE 2(RH TANK)C12-M

UNDERHOOD/FUEL TANK JUMPERINLINE CONNECTOR

C15

IN-TANK INLINE 1(RH TANK)

C11-M

FUEL TANK JUMPER/TANK SOLENOIDINLINE (RH TANK)

C13-F


F-53/59 Roush Wiring Harnesses


E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Underhood Harness

To BatteryPositive

2

AB

FDD EE

SUPP

LY_S

OL

BLEE

D_S

OL_

RTN

BLEE

D_S

OL

FLO

W_C

NTL

_SO

L

SUPP

LY_S

OL_

RTN

S1

E2E1

F6F5

F2F1

E4E3F4F3E6E5

PWR_W

A2A4A1

A3

A5

Normally Open12V/20A Relay

F1 25A

Connector

8

Connector

1

3 5 7 15 17 20 43

28

25 26 29

33 34 35 36 3731

40

44 46

1 2 3 4

FLO

W_C

NTL

_SO

L_R

TN

SOLENOID_PWR

IPTS

_PW

R

IPTS

_TEM

P_O

UT

IPTS

_PR

ES_O

UT

IPTS

_GN

D

A

B

C

D

E

F

VPWR_RO

S2

VPWR_RI

FL_SND

FL_RTN_1S3

FG_RTN

FG_SND

TANK_SOL_RTN

GN

D1

GND2 GND3

SRM_PWR

A

B

C

D

E

F

KEY_PWR_1

KEY_PWR_2

PLUG

LAMP_RTN_1

CAN-H_1(-)

CAN-H_1(+)

TO REARFRAME

HARNESS

TO CANHARNESS

Connector

11

Connector

15

Connector

23

Connector

27

FL_RTN_2

TO IPTS

TO SOLENOIDMODULETO SRM

TO FUELLEVEL

BLACK BOX

A

B

C

D

FG_RTN_SRM

S5

Connector

35

PWR

S4

PWR_W_1

PWR_W_2

PWR_W_3

PWR

_W_6

PLUG

FRAME GROUND(GND_R2)

TO REARFRAME

HARNESS

Connector

47

A

BPLUG

FPM_2

C

SRM_PWR_1

SRM_PWR_2

F2 10A

F3 20A

F6 5A

RELAY A

R2

FRAME GROUND(GND_R1)

R1

100130c

ELECTRICAL CENTER(FUSE BOX)

4

32

1

4544

29

15

46

163

PBT/ASA-GF2018

32

21

3130

17

A1

D1

D4

D2D5D3

A1

A4

A2A5A3

B1

B4

B2B5B3

C1

C4

C2C5C3

RELAY C RELAY B

E6 E5 E4 E3 E2 E1

F6 F5 F4 F3 F2 F1

RELAY A

RELAY DFUSE 2FUSE 4FUSE 6

FUSE 1FUSE 3FUSE 5


E-Series, Extended Range and E-450 Electrical Schematic — CAN Bus Harness

Connector

1CONNECT TO TRAILER

BRAKE MODULE

A

B

C

D

E

F

S1

PLUG

Connector

5

CONNECT TO FORD HARNESSCONNECTOR C2142

12347 56

89101114 1213

1

2

3

4

7

5

6

8

9

10

11

14

12

13

CAN-H(+)_1

CAN-H(-)_1

FUSE_18

BRK_PED_POS

GND

FUSE_33_1

TOW_BRK

FUSE

_33_

2

CAN-H(-)_2

CAN-H(+)_2

KEY_PWR_1

Connector

9

PLUG

PLUG

CONNECT TO ROUSH UNDERHOODHARNESS

7

14 8

1

D C

F A

1 8

7 14

100131b


E-Series, Extended Range and E-450, E-450 Stripped Chassis Electrical Schematic — Rear Frame Harness

Connector

1

Connector

9

CONNECTTO FORDHARNESS

FPCM

TO FORD FPCMMODULE (FUEL

PUMP CONTROLMODULE)_1

TO ROUSH FPCMMODULE (FUELPUMP CONTROL

MODULE)_2

1 2 3 4 75 68 1 2 3 4 75 68

CONNECT TOFORD HARNESS

FUEL PUMPMODULE

Connector

21

Connector

12Connector

13

Connector

30

1

2

3

4

7

5

6

8

S1

PLUG

PLU

G

VPWR_1

FPC_1

GND_1

A_F

PPW

R_1

ENS_1

FPM_1

A_F

PRTN

_1

VPW

R_2

VPWR_RI

S4

VPW

R_P

2

B A B A

S2

FPC

_2

FPC

_3

ENS_

2

ENS_

3

PLUG

PLUG

A_F

PRTN

_2

S3

PLU

G

GN

D_2

GN

D_3

D C B A

A_S

OL_

1

A_S

OLR

TN_1

A_F

LS_1

A_F

LSR

TN_1

S6

SHIE

LD_5

SHIE

LD_2 SH

IELD

_1

SHIE

LD_3

SHIE

LD_4

FRAME GROUND(SHIELD)

4 3 2 1

PLUG

PLUG FG

_SN

D

A

B

C

D

E

F

TO ROUSH UNDERHOODHARNESS

S5

VPWR_RO

VPWR_RI

TO FUELTANK_SENDER_SOLENOID

Connector

24

TOFUEL_TANK_1_PWR

TOFUEL_TANK_2_PWR

Connector

27

A_F

PPW

R_2

Connector

41TO ROUSH UNDERHOOD

HARNESS

A

B PLUG

FPM_2

PLUG

100132b

4 1

8 5

4 1

8 5

14

58


E-Series, Extended Range and E-450, E-450 Stripped Chassis, F-53/59, F-250/350, F-450/550/650 Electrical Schematic — In-Tank Harness

IN-TANKHARNESS

PASS THRU

4

PU

PU

AB

A

B

4

INLINE FUEL PUMP-1 (V+)

INLINE FUEL PUMP-1 (V-)

INLINE FUEL PUMP-2 (V+)

INLINE FUEL PUMP-2 (V-)

FUEL PUMP-1 (V+)

FUEL PUMP-1 (V-)

FUEL PUMP-2 (V+)

FUEL PUMP-2 (V-)

A

B

B

A

2

A

B

MP-1

MP-2

1

100133b


E-Series, Extended Range and E-450 Electrical Schematic — Solenoid Harness

9

1

CONNECT TO FUELLEVEL SENDER

CONNECT TOTANK SOLENOID

CONNECT TO THEREAR HARNESS

SUPPLY SOLENOID V+

SUPPLY SOLENOID V-

FUEL LEVEL SENDER V-

FUEL LEVEL SENDER V+

100134b

D

A

B

C

A

B

A

B

6


E-450 Stripped Chassis CAN Harness

CAN-H (+)

CAN-H (-)

PLUG

PLUG

PLUG

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR PIN-23

SP3

C1-MPIN-21

SP2

C1-F

1

2

3

3 31 1

646 4

4

5

6

C2-F

A

A

B

C

C D

D

E

F

F

PIN-34

SP1

CBB80D

CBB80C

CBB80B

VDB05D

VDB04D

VDB04C VDB04A

VDB04B

VDB05B

VDB05C VDB05A

CBB80A

1

2

3

4

5

6

100262a


F-250/350 Pickup, F-450/550 Electrical Schematic — CAN Bus Jumper Harness

100189a

Connector

1

CONNECT TO TRAILERBRAKE MODULE

PLUG

Connector

5

CONNECT TO FORD HARNESSCONNECTOR C2142

147 56

9

1

2

3

4

7

5

6

8

9

10

11

14

12

13

CAN-H(+)_1

CAN-H(-)_1

FUSE_18

BRK_PED_POS

GND

FUSE_33

TOW_BRK

CAN-H(-)_2

CAN-H(+)_2

Connector

9

PLUG

CONNECT TO ROUSH UNDERHOODHARNESS

PLUG

PLUG

GROMMET

PASS-THROUGH

101114 1213 8

23

A

B

C

D

E

F


E-450 Stripped Chassis, F-53/59, F-250/350 Pickup, F-450/550 and F-650 Electrical Schematic — Tank Solenoid

SUPPLY SOLENOID V+

SUPPLY SOLENOID V-

FUEL LEVEL SENDER V-

FUEL LEVEL SENDER V+

100191a

1

A

B

CONNECT TO FUEL LEVEL SENDER

FUEL LEVEL SENDER CONNECTOR FROM TANK

CONNECT TO TANK (FUEL SUPPLY)SOLENOID

CONNECT TO REAR FRAME HARNESS

D

A

B

C

A

B

6

9


E-450 Extended Range, F-250/350 Pickup Electrical Schematic — In-Bed Fuel Tank Jumper Harness

D

C

B

A

D

C

B

ATANK (FUEL SUPPLY) SOLENOID_POWER

TANK (FUEL SUPPLY) SOLENOID _RETURN

FUEL_LEVEL _SENDER RETURN

FUEL_LEVEL _SENDER POWER

PUMP_1

B

A

B

A

B

A

B

A

FUEL_PUMP_1_PWR

FUEL_PUMP_2_PWR

FUEL_PUMP_1_RTN

FUEL_PUMP_2_RTN

S1

Connector

1A

Connector

4Connector

9

Connector

13

Connector

16

PUMP_2

SHIELD_1


SHIELD_2




CONNECT TO TANK SOLENOID HARNESS



SH

IEL

D_3Connector

1B

100192a


F-250/350 Pickup Electrical Schematic — FTPT Jumper Harness

r

Connector

1

CONNECT TO FTPT

CONNECT TO FTPT

Connector

4

C

VERSION DEPENDS ONTANK CONFIGURATION

ONNECT TO FORD HARNESS (14405)

1

2

3

1

2

3

FTP

SIGRTN

FTP_REF

FTP

SIGRTN

FTP_REF

Connector

1Connector

6

CONNECT TO FORD HARNESS (14405)

1

2

3

A

B

C

FTP

SIG_RTN

FTP_REF

FTP

SIG_RTN

FTP_REF

100193a


F-650 CAN Harness

SP1909

SP1908

C1_FORD_HARNESS_CONNC1

6

910

87

7 6

12 1

32

12

54

11

C3-F

AB

FORD_Gateway_Module

MSCAN(-)MSCAN(+)LAPISBICPBPSHIP-1HSCAN(-)HSCAN(+)HIP-2HIP-3SCSNOT USED

1908C

2181218021845033814

1909B1909A1908A

1909C

1908B1045A1045B

151ZA100

100261a

1

6

910

87

32

12

12 1

7 6

54

11

1


F-650 Fuel Tank Jumper Harness

C15- F C13_F

C14- M

A

A

B

D

C

B

C

D

C12- M

C11- M

A

B_SOLRTN

B_FLRTN

B_FLSND

B_FPPWR_1

B_FPRTN_1

B_FPPWR_2

B_FPRTN_2

B_SOLPWR

B

A

B

A

B

C

D

A

B

C

D

100264a


F-650 Underhood Harness Electrical Schematic

100269a

NOT USEDNOT USED

NOT USED

NOT USED

PLUG

NOT USED

NOT USED

PLUG

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

PLUG

NOT USED

PLUG

PLUG

PLUG

NOT USED

NOT USEDNOT USED

PLUG

PLUG

PLUG

PLUG

PLUG

PLUG

BATTERY +

BATTERY +

S7

PIN1

PIN2

PIN3

PIN4

PIN5

PIN6

PIN7

PIN8

PIN1

PIN2

S5

C8FORD EFPR

3

7

5

8

4

6

2

1

GND-BATT

S6

STERM_2

S4

STERM_4

C12PRI FUEL PUMP 2

A

B

C10FORD FUEL TANKHARNESS

1

2

3

4

5

6

7

8

C11PRI FUEL PUMP 1

A

B

A

B

S2

STERM_3

S1

R_PWR_2

S17

S12

S9

S8

STERM_1

S13

S14

R_PWR_1

S15

PIN1

PIN2

PIN3

PIN4

C16FORD FUEL TANK HARNESS

T4

T1

T2

T3

1

2

3

4

1

2

3

4

5

6

7

8

9

4516

312

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

A

B

C

D

C13PRIMARY TANK SOLENOID HARNESS

A

B

C

D

C3CAN

A

B

C6FRPCM

C

D

B

E

A

F

S3

C9ROUSH EFPR

3

7

5

8

4

2

6

1

A

B

C

D

S11

C15FUEL TANK JUMPER

A

B

C

D

AB

S16

C7FUEL LEVEL INTERFACE MODULE

A

B

C

D

S10

C14FUEL TANK JUMPER

A

B

C

D

A

B

C

D

TERMINAL C4-M1

FUSE BOX

F5

F6

E5

E6

F3

F4

E3E4

F1

F2

E1

E2

A3

A1

A2

A5

B3

B1

B2

B5

C3

C1

C2

C5

C4-F1

C5IPTS SENSOR

3

2

4

1

RELAY_B

SEC_TANK_PUMP_1

DEV432

PRI_FUEL_TANK

FUSE_5_20AA B

RELAY_C

SEC_TANK_PUMP_2

FUSE_3_20AA B

FUSE_6_5AA B

VPWR

NOT_USED_1

FUEL PUMP COMM.

GND

FUEL PUMP PWR

ENS

FUEL PUMP MONITOR

FUEL PUMP RETURN

FUSE_4_20AA B

FUSE_1_25AA B

FUSE_2_10AA B

DEV434

desc

KEY ON PWR

PWM DUTY CYCLE

GND

FUEL GAUGE SENDER SGN

SUPPLY_SOL

FLOW_CNTL_SOL

BLEED_SOL

BLEED_SOL_RTN

FLOW_CNTL_SOL_RTN

SUPPLY_SOL_RTN

VPWR

NOT_USED_1

FUEL PUMP COMM.

GND

FUEL PUMP PWR

ENS

FUEL PUMP MONITOR

FUEL PUMP RETURN

C4SRM MODULE

PIN1

BATT+

FUEL LEVEL SENDER # 1

PIN4

FUEL RAIL TEMPERATURE

PIN6

FUEL RAIL PRESSURE

PIN8

PIN9

FUEL LEVEL SENDER # 2

PIN11

PIN12

PIN13

SPARE INPUT_1

EFPR DIAGNOSTIC FEEDBACK

PIN16

BLEED SOLENOID

SPARE INPUT_2

PIN19

PIN20

PIN21

PIN22

PIN23

PIN24

XDRP +5V

WAKE

PIN27

FORD CAN+

SPARE INPUT_3

PIN30

GROUND

PIN32

FLOW CONTROL SOLENOID

FUEL PUMP RELAY

SPARE OUTPUT_1

SPARE OUTPUT_2

FUEL LEVEL OUTPUT (PWM)

PIN38

PIN39

XDRG

PIN41

PIN42

FORD CAN-

FUEL TANK SOLENOID

PIN45

SUPPLY SOLENOID

TEMP OUT

PRESSURE OUPUT

GND

PWR

FG_RTN

FG_RTN

PUMP_ACTIVE

B_FLRTN

GND_12

A_TANK_SOL

FL_SND

FPM_2

VPWR_P2

A_FLRTN

B_FLSND

CAN-H(+)

FLOW_CNTL_SOL

SUPPLY _SOL

BLEED_SOL

FG_SND

IP_TEMP

IP_GND

SRM_PWR_1

BLEED_SOL_RTN

FLOW_SOL_RTN

FL_RTN

CAN-H(-)

SUPP_SOL_RTN

SRM_PWR_2

IP_PRES

FG_RTN_SRM

IP_PWR

GN

D_1

B_SOL_1

B_FPPWR_2

GND

B_FPRTN_1

B_FPRTN_2

FORD_GND_1FORD_GND_3

FPC

_2

FPM_1

A_F

PP

WR

_1

A_F

PR

TN_1

VP

WR

_2

DRAIN_4

DR

AIN

_3

DR

AIN

_1

DRAIN_2

ENS_1ENS_3

A_F

PP

WR

_2

A_FPRTN_2

A_F

PR

TN_2

VPWR_1

FPC_1FPC_3

PUMP_PWR_6

PUMP_PWR_2

VP

WR

_RI

PWR_W

PWR_W_1

PWR_W_2

PUMP_PWR_3

PUMP_R2

PU_AC_2

B_FPPWR_1

PWR_W_6

B_SOLRTN

GND_4

GN

D_4

PUMP_PWR

PUMP_R1

B_F

PP

WR

_B

PUMP_PWR_4

PUMP_PWR_5

FOR

D_G

ND

_2

EN

S_2


D1

D4

D2D5D3

A1

A4

A2A5A3

B1

B4

B2B5B3

C1

C4

C2C5C3

RELAY C RELAY B

E6 E5 E4 E3 E2 E1

F6 F5 F4 F3 F2 F1

RELAY A


FUSE 1FUSE 3FUSE 5


F-53/59 CAN Harness

CAN-H (+)

CAN-H (-)

PLUG

PLUG

PLUG

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR

CAN-H (-)

CAN-H (+)

KEY_PWR PIN-13

SP3

C1-FPIN-4

SP2

C1-M

6

1 4 4 1

5 58 8

5

3

8

7

C2-F

A

A

B

C

C D

D

E

F

F

PIN-5

SP1

298D

298C

298B

1909D

1908D

1908C 1908A

1908B

1909B

1909C 1909A

298A

6

5

3

8

7

4

100263a

4


F-53/59/250/350/450 Rear Frame Harness Electrical Schematic

Connector

1

Connector

9

CONNECT TO FORD FPCMHARNESS CONNECTOR

TO FORD FPCM MODULE (FUELPUMP CONTROL MODULE)

TO ROUSH FPCM MODULE (FUELPUMP CONTROL MODULE)

1 2 3 4 75 68 1 2 3 4 75 68

CONNECT TO FORD FUEL PUMPHARNESS INLINE CONNECTOR

Connector

21

Connector

24

Connector

12Connector

13

Connector

30

1

2

3

4

7

5

6

8

S1

PLUG

PLU

G

VPWR_1

FPC_1

GND_1

A_F

PP

WR

_1

ENS_1

FPM_1

A_F

PR

TN_1

VP

WR

_2

VPWR_RI

S4

VP

WR

_P2

TO FUEL TANK JUMPERHARNESS INLINE CONNECTORS

B A B A

S2

FPC

_2

FPC

_3

EN

S_2

EN

S_3

PLUG

PLUG

A_F

PP

WR

_2

A_F

PR

TN_2

S3

PLU

G

GN

D_2

GN

D_3

D C B A

A_S

OL_

1

A_S

OLR

TN_1

A_F

LS_1

A_F

LSR

TN_1

S6

SH

ILE

D_1

SH

ILE

D_2

SH

ILE

D_3

SH

ILE

D_4

SH

IELD

_5


4

3

2

1

PLUG

PLUG

FG_SND

A

B

C

D

E

F

TO ROUSH UNDERHOOD HARNESSINLINE CONNECTOR

A

BConnector

41

TO ROUSH UNDERHOOD HARNESSINLINE CONNECTOR

S5

VPWR_RO

FL_SRTN

VPWR_RI

PLUG

FPM_2

Connector

27

GRAY BLACK

TO FUEL TANK JUMPERHARNESS INLINE CONNECTOR

RING TERMINAL

GND

14

58

4 1

8 5

4 1

8 5

100266a


F-53/59/250/350/450 Underhood Harness Electrical Schematic

100267a

To BatteryPositive

2

SUPP

LY_S

OL

BLEE

D_S

OL_

RTN

BLEE

D_S

OL

FLO

W_C

NTL

_SO

L

SUPP

LY_S

OL_

RTN

S1

PWR_W

A2A4A1

A3

A5

25A

10A

Connector

8

Connector

1

5A

3 5 7 1510 17 43

28

25 26 29

33 34 35 36 3731

40

44 46

1 2 3 4

FLO

W_C

NTL

_SO

L_R

TN

SOLENOID_PWR

IPTS

_PW

R

IPTS

_TEM

P_O

UT

IPTS

_PR

ES_O

UT

IPTS

_GN

D

A

B

C

D

E

F

VPWR_RO

20A

FRAME GROUND

S2

VPWR_RI

FL_SND

FL_RTN_1S3

FG_RTN

FG_SND

TANK_SOL_RTN

GN

D1

GND2 GND3

SRM_PWR

A

B

C

D

E

F

KEY_

PWR

_1

KEY_PWR_2

PLUG

CAN-H_1(-)

CAN-H_1(+)

TO REARFRAME

HARNESS

TO REARFRAME

HARNESS

TO CANHARNESS

Connector

11

Connector

15

Connector

47

Connector

23

Connector

27

FL_RTN_2

A1 = 85A2 = 86A3 = 30

A4 = 87AA5 = 87

TO IPTS TO SOLENOIDMODULE

TO SRM


TO FLIM

A

B

C

D

FG_RTN_SRM

S5

Connector

35

PWR

S4

PWR_W_1

PWR_W_2

PWR_W_3

PWR_W_6

PLUG

SRM_PWR_2

A

B

RELAYNO CONTACT20A@14VDC

16

15

14

13

12

11

9

10

8

7

6

5

4

3

1

2

TO FORD HARNESS12C508 (C1168)

TO FORD AUX ENGINEINLINE MODULE

Connector

51Connector

55

16

15

14

13

12

11

9

10

8

7

6

5

4

3

1

2

PLUG

S8J1 J1A

J2J9

J10J3

J11J4

J12J5

J6

J7

J8

J13

J14

J15

J16

PLUG

SRM_PWR_1

AB

FDD EE

C

FPM_2

F5

E1 E2

F1 F2

E4E3

GND_R2FRAME GROUND

Initial Print A.A20111403

Connector

GND

F6

4

32

1

4544

29

15

46

163

PBT/ASA-GF2018

32

21

3130

17

A1

D1

D4

D2D5D3

A1

A4

A2A5A3

B1

B4

B2B5B3

C1

C4

C2C5C3

RELAY C RELAY B

E6 E5 E4 E3 E2 E1

F6 F5 F4 F3 F2 F1

RELAY A


FUSE 1FUSE 3FUSE 5


F-53/59/450 Fuel Tank Jumper Harness Electrical Schematic

100268a

D

C

B

A

D

C

B

ASOLENOID_SPLY

SOLENOID _RTN

FUEL_LEVEL _RTN

FUEL_LEVEL _SPLY

B

A

B

A

B

A

B

A

FUEL_PUMP_PWR_1

FUEL_PUMP_PWR_2

FUEL_PUMP_RTN_1

FUEL_PUMP_RTN_2


S1

Connector

1B

Connector

4Connector

9

Connector

13

Connector

16

SHIELD_1SHIELD_2

CONNECT TO REAR FRAMEHARNESS INLINE CONNECTOR

CONNECT TO IN-TANK HARNESSINLINE CONNECTOR

CONNECT TO TANK HARNESSINLINE CONNECTOR

SHIE

LD_3

Connector

GND

BLACK

GRAY

Connector

1A



BLACK

GRAY

CONNECT TO IN-TANK HARNESSINLINE CONNECTOR

©2014 by ROUSH CleanTech. All rights reserved.

The information in this publication was accurate and effective at the time the publication was approved for publishing and is subject to change without notice or liability. ROUSH CleanTech reserves the right to revise the information herein and to make changes and discontinue pro-duction of described parts at any time.

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