Ford F150 Pickup. Instruction — part 1530

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Faulty PCM

Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Disconnect CV
solenoid connector. Connect a test light between CV and VPWR circuits at CV solenoid harness
connector. See Fig. 270. Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST
MODE. See OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS. Using scan tool
commands, attempt to open and close CV solenoid driver. Select ALL OFF mode. Observe test light
while cycling START button ON and OFF. If test light illuminates and then go off, go to next step. If test
light is always off, go to step 67). If test light is always illuminated, go to step 70).

66) Check CV Solenoid Resistance

Turn ignition switch to OFF position. Using a DVOM, measure resistance between CV solenoid
terminals. If resistance is 48-65 ohms, fault is unable to be duplicated at this time. Go to TEST Z, step 1).
If resistance is not 48-65 ohms, replace CV solenoid. Perform EVAPORATIVE EMISSIONS
SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) at EVAP test port to
verify leak did not occur during component replacement. Perform OBD-II DRIVE CYCLES under
DRIVE CYCLES. Ensure EVAP MONITOR PROCEDURE is performed.

67) Check For Open VPWR Circuit Between CV Solenoid & Power Relay

Using a DVOM, measure voltage between negative battery cable and VPWR circuit at CV solenoid
harness connector. See Fig. 270. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5
ohms or less, repair open in VPWR circuit.

68) Check VPWR Circuit For Open In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). Using a DVOM, measure resistance
of VPWR circuit between CV solenoid harness connector and VPWR fuse to power relay (vehicles with
150-pin PCM), or PCM harness connector (all others). If resistance is less than 5 ohms, go to next step. If
resistance is 5 ohms or more, repair open in VPWR circuit.

69) Check CV Circuit For Open In Harness

Using a DVOM, measure resistance of CV circuit between PCM harness connector and CV solenoid
harness connector. If resistance is less than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair
open in CV circuit.

70) Check CV Circuit For Short To PWR GND In Harness

Turn ignition switch to OFF position. Disconnect PCM connector(s). Disconnect scan tool from DLC.
Using a DVOM, measure resistance between negative battery terminal and CV circuit at CV solenoid
harness connector. See Fig. 270. If resistance is more than 10 k/ohms, reconnect scan tool to DLC and go
to next step. If resistance is 10 k/ohms or less, repair short to PWR GND in CV circuit.

71) Check CV Circuit For Short To PWR Or Chassis Ground In Harness

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and CV
circuit at PCM harness connector. If voltage is less than one volt, turn ignition switch to OFF position and
replace PCM. If voltage is one volt or more, turn ignition switch to OFF position and repair short to
VREF, VPWR or chassis ground in CV circuit.

76) For KOEO, KOER & Continuous Memory DTC P0460, P0462 & P0463: Check Fuel Tank
Level
DTC is set when PCM detects Fuel Level Input (FLI) circuit signal falls below minimum or exceeds
maximum allowable calibrated parameters for a specified fuel fill percentage in fuel tank. Possible causes
are:

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Empty Fuel Tank

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Fuel Pump Module (FPM) Stuck Open

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Incorrectly Installed Fuel Gauge

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Faulty Fuel Gauge Or Instrument Cluster

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CASE GND Circuit Open Or Shorted To VPWR

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FLI Circuit Open, Or Shorted To CASE GND, PWR GND Or VPWR

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Faulty PCM

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Overfilled Fuel Tank

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Fuel Pump Module (FPM) Stuck Closed

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Faulty Fuel Pump

Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Start engine and
allow to idle. Access fuel level input voltage (FLI) PID. If the fuel level input voltage (FLI) PID reading
is between .25 and 4.5 volts, go to next step. If the fuel level input voltage (FLI) PID reading is not
between .25 and 4.5 volts, go to step 80).

77) Check For Fuel Tank Float Level Response

Turn ignition switch to ON position. Observe both fuel gauge and FLI PIDs. If fuel level is less than 1/4
(25 percent on FLI PID), add 2-3 gallons of fuel to fuel tank. If fuel level is more than 3/4 (75 percent on
FLI PID), drain 2-3 gallons of fuel from fuel tank. If fuel gauge or FLI PID value does not increase or

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 71) to step 76). No test procedures have been omitted.

NOTE:

For additional testing information, see DIAGNOSTIC AIDS.

NOTE:

On Econoline 4.6L and 5.4L, Escape, Excursion, Expedition, Explorer,
Focus, LS, Mountaineer, Mustang, Navigator, Pickup 4.6L and 5.4L
(including Lightning 5.4L SC), Thunderbird, Town Car and Windstar, for
fuel level indicator or Rear Electronic Module (REM) diagnosis, see
appropriate INSTRUMENT PANELS article in ACCESSORIES &
EQUIPMENT.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

decrease as fuel is added or drained, see appropriate INSTRUMENT PANELS article in ACCESSORIES
& EQUIPMENT for inoperative fuel level sender. If either fuel gauge or FLI PID value increases or
decreases as fuel is added or drained, no concern found at this time. Go to TEST Z, step 1).

80) Check FLI Circuit Voltage At Fuel Pump Module

Reconnect all connectors. Disconnect appropriate instrument cluster connector to fuel gauge. For
instrument cluster connector location and removal and installation, see appropriate INSTRUMENT
PANELS article in ACCESSORIES & EQUIPMENT. Turn ignition switch to ON position. Using a
DVOM, measure voltage by backprobing between FLI circuit at fuel pump module harness connector and
negative battery terminal. See Fig. 271-Fig. 274 . If voltage is more than 5 volts, go to next step. If
voltage is 5 volts or less, go to step 82).

Fig. 271: Identifying Fuel Pump Module Circuits & Connector Terminals (Crown Victoria,
Explorer Sport, Explorer Sport Trac, Grand Marquis, Ranger - Except 3.0L Flex Fuel, Sable &
Taurus)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

Fig. 272: Identifying Fuel Pump Module Circuits & Connector Terminals (Econoline)
Courtesy of FORD MOTOR CO.

Fig. 273: Identifying Fuel Pump Module Circuits & Connector Terminals (Ranger 3.0L Flex Fuel)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline