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TSG-416 Service Manual - Coulson Compression & Measurement

1. After engine start up the temperature should rise steadily to about 85 C 185 F It then stabilizes when the thermostat opens If the engine has not been run for several hours overnight the engine coolant temperature and intake air temperature displays should be close to each other A fault in the engine coolant sensor circuit will seta DTC 221 or DTC 222 08 6 Rt NOM TEMP TEMP F OHMS VOLTS 40 40 925 021 4 54 35 31 673 787 4 50 30 22 496 051 4 46 25 13 368 896 4 41 20 4 276 959 4 34 15 5 209 816 4 25 10 14 160 313 4 15 5 23 123 485 4 02 0 32 95 851 3 88 5 41 74 914 371 10 50 58 987 3 52 15 59 46 774 3 32 20 68 37 340 3 09 25 77 30 000 2 86 30 86 24 253 2 62 35 95 19 716 2 39 40 104 16 113 2 15 45 113 13 236 1 93 50 122 10 926 1 72 55 131 9 061 1 52 60 140 7 548 1 34 65 149 6 332 1 18 70 158 5 335 1 04 75 167 4515 91 80 176 3 837 79 85 185 3 274 70 90 194 2 804 61 95 203 2 411 53 100 212 2 080 47 105 221 1 801 41 110 230 1 564 36 115 239 1 363 32 120 248 1 191 28 125 257 1 044 25 130 266 918 29 135 275 809 19 140 284 715 17 145 293 633 15 150 302 563 14 Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations TSG 416 ENGINE CONTROLS PRELIMINARY Intake Air Temperature IAT Senso
2. EIER EH LR tte 08 11 Use of Circuit Testing su S 08 11 Electrostatic Discharge 1 E eee h e ees resa dese si asb u 08 11 Diagraims and Schemlatics u umu u dee ER E 08 12 08 12 EPM Fuse and Relay Information sise 08 13 ICM Fuse and Relay Information sise 08 14 Wire 08 15 Power Distribution EPM tien l uu eoe eot Eee HM q ee et 08 16 Engine Ignition EPM fon Pan nals 08 17 Starting System EPM cer REPRE ede eet teuer kalte ee estet A Pr eut sn iua ge 08 18 Charging itat b aUe 08 19 Engine Controls Sensors EPM siennes 08 20 Engine Controls Injectors 08 21 Engine Controls Actuator Data Link Connector DLC EPM 08 22 Engine Controls Connectors ICM Jumper Patch 08 23 Engine Controls Sensors amp Data Link Connector DLC ICM Jumper Patch Harness 08 24 ECM To EPM Conversion Harness Adapter 1 of 2 08 25 To EPM Conversion Harness Adapter 2 of 2 08 26 to EPM Engine Wiring Diagram 1 5 08 27 ECM to EPM Engine Wiring Diagram 2 o
3. TSG 416 ENGINE CONTROLS PRELIMINARY Power Distribution EPM JOJIUON punolo L weds MSA EA ee al Lc eS ea FR aa ead L _98 L _ 98 _ j L _ _ 98 GONE NOG gr sez 1109 ww ama r MAE 91 025 L 5 dung ENT uldzy 4 49 91 4 8b 9L MAG 91 029 Wald 91 8 EE MAG 91 046 8 40201 lt Be 9 F la MAG 91 0 6 K r 97 4 8 91 19M d MMS L 1019 Jeued esn4 piu SS has en VS Woe ag 4 zd ia lg pesny Ee a s 4 jou SI 5141 seuin JOH 08 16 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Ignition EPM 109 21102 waa 1 t tt 4 109 M8 A 81 098 81 198 VLIE e e f VLIE Eo 3 Set Jaueg 95 4
4. Josuag 193 1981002 97 856 u A9 0692 EIS 065 792 Josuag 9 41 uonisod Emory 105005 91404993 94155914 einjsqy PIOJIUEN 08 30 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Wiring Diagram 5 of 5 J0j259uuo 5 1 1 SsouJeH t rubis wnay 1 ewa _ _ _ 0595 _ _ _ _ c3 eg ex 10128uu02 026 605 Y TE9E 905 M H9 tz 20S 52 Josueg peyeey une 92155923 punog sosueg IEUbIS O e oe CE way 19 H er K K gt puno TT A i l aese 1 1 De gt Se Ss u eH UIEW 9c ere ASD OSE 90S fosse 715 A i aes 1 1 els I I vese HAD V6SE EN T C 20809 10SU8S dWO einssaid yeusweg yeysxuzg HO 08 31 Heated Oxygen Sensor HO2S pH k mm N AG X I doe na gt TSG 416 ENGINE CONTROLS PRELIMINARY Throttle Position TP Sensor Electronic Actuator Engine Component Locator View Oil Pressure Camshaft Position CMP Se
5. 9 29 087 926 TT 48 I yomg i S _ _ _1 2 L 10joefuj ng lang any 899 1196 4 484 98 Los 58 AJE 08 28 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Wiring Diagram 3 of 5 Jopeuuon d 201 SsouJeH prO Jeduinf punog MM oe te d ex M H8 029 605 9 889 045 125 859 LON 101280002 yun 9 SHOA G Req 1321 ejeg jeuaS es JOJOBUUND SSAUIPH Wy TTT NY 8t LL 91 516 Hd M 602 O L1 16 31201 9 d 859 08 29 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Wiring Diagram 4 of 5 JOJ99uuOO ssouleH 1 be Jeduunf RES paies 12066 m I SSOUIEH I poads peadg lonuoo 108095 i josus re es l Im m 4 Tin 28 _ D at 3L moe dv 2704 AVN AS IM PES 194 er Td bn ra d u o1 vse ree UIEN 205 92 106 gt 55 90S osueg Av 1 Sc ve Jv
6. DTC 111 Closed Loop Multiplier High LPG DTC 353 MegaJector Delivery Pressure Higher than Expected DTC 112 HO2S Open Inactive Bank 1 DTC 354 MegaJector Delivery Pressure Lower than Expected DTC 113 HO2S Open Inactive Bank 2 DTC 355 MegaJector Communication Lost DTC 121 Closed Loop Multiplier High Bank 1 Gasoline DTC 361 MegaJector Voltage Supply High DTC 122 Closed Loop Multiplier Low Gank 1 Gasoline DTC 362 MegaJector Voltage Supply Low DTC 124 Closed Loop Multiplier Low LPG DTC 363 MegaJector Internal Actuator Fault Detection DTC 125 Closed Loop Multiplier High Natural Gas DTC 364 MegaJector Internal Circuitry Fault Detection DTC 126 Closed Loop Multiplier Low Natural Gas DTC 365 MegaJector Internal Communication Fault Detection DTC 131 Closed Loop Multiplier High Bank 2 Gasoline DTC 411 Coil Driver 1 Open DTC 132 Closed Loop Multiplier Low Bank 2 Gasoline DTC 412 Coil Driver 1 Shorted DTC 141 Adaptive Lean Fault High Limit Gasoline DTC 413 Coil Driver 2 Open DTC 142 Adaptive Rich Fault Low Limit Gasoline DTC 414 Coil Driver 2 Shorted DTC 143 Adaptive Learn High LPG DTC 511 FPP1 High Voltage DTC 144 Adaptive Learn Low LPG DTC 512 FPP1 Low Voltage DTC 145 Adaptive Learn High Natural Gas DTC 513 FPP1 Higher Than IVS Limit DTC 146 Adaptive Learn Low Natural Gas DTC 514 FPP1 Lower Than IVS Limit DTC 161 System Voltage Low DTC 521 FPP2 High Voltage DTC 162 System Voltage High DTC 522 FPP2 Low Voltage DTC 211
7. Normal will change to the Injector you have selected The injector driver can be re enabled by selecting again If the engine is running below 1000 RPM the injector driver will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the injector driver will stay disabled for 5 seconds and then re set Record the change in rpm or closed loop multiplier while each driver is disabled Throttle Test To select this test mode the engine must be off but the key must be in the ON position The DBW Test mode allows the technician to control the throttle directly without the engine running with the foot pedal or entering a number into the TPS Command box It is used during the diagnostic routines specified for FPP and TPS related faults FPP position displays the current position of the foot pedal as a percentage FPP volts display the voltage that the EPM is reading from the FPP sensor TPS Command displays the commanded throttle position expressed as a percentage which is being sent to the throttle TPS Position is the actual percent of throttle opening being sent to the EPM from the throttle TPS volts display the actual TPS signal voltage the EPM is receiving from the throttle 08 61 TSG 416 ENGINE CONTROLS PRELIMINARY RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits Use the keys at the upper left corner or the page comman
8. 15 151 LB BK Foot Pedal Position FPP 0 5 volt input 1 16 Not used 17 Not used 18 150 DG WH Aux analog pull up circuit 19 Not used 20 358 LG BK Manifold Absolute Pressure MAP sensor input 21 Not used 22 Not used 23 Not used 24 74 GY LB HEGO 1 0 1 volt input 25 Not used 26 Not used 27 743 GY Intake Air Temperature IAT sensor input 28 354 LG RD Engine Coolant Temperature ECT sensor input 29 Not used 30 Not used 31 Not used 32 349 DB Crankshaft Position CKP sensor 33 350 GY Crankshaft Position CKP sensor 34 282 DB OR Camshaft Position CMP sensor 35 452 GY RD Camshaft Position CMP sensor 08 47 ECM to EPM Jumper Harness Conversion Black TSG 416 ENGINE CONTROLS PRELIMINARY Fuse em Data Link DLC Connector Grounding Connector 581 01 60 Ciruit Description Black Grey 001 C3 C2 CINCH INJ 1 7 S3 INJ 3 8 51 INJ 4 9 T1 INJ 2 10 S2 INJ 5 11 Y3 INJ 6 12 w2 MAP 20 B1 FPP1 15 Al IAT 27 D1 ECT 28 D2 AUX ANA PU1 18 L1 POWER GROUND 1 X2 X3 T3 ANA RTN 13 B2 5 VOLT REF 14 A2 VSW 3 K1 HEGO 1 24 E2 CRANK 32 G1 CRANK 33 H2 CAM 34 CAM 35 VBAT 4 5 F2 COIL 1 1 x1 A Jumper Harness Adapter is available to convert an ECM system to an EPM module Crankshaft Position CKP Sensor Data Link DLC Connector AR Electronic Actua
9. DTC 351 Fuel Pump Loop Open or High Side Short to Ground DTC 352 Fuel Pump High Side Shorted to Power 08 83 TSG 416 ENGINE CONTROLS PRELIMINARY REMOVAL AND INSTALLATION Camshaft Position Sensor CMP Removal Camshaft Position CMP Sensor FPP00297 1 Disconnect the negative battery cable 2 Disconnect electrical connector 3 Remove screws 4 Remove the sensor Installation 1 Install the sensor 2 Install screws Tighten to 5 7 Nm 45 61 Ib in 3 Connect electrical connector 4 Connect the negative battery cable Engine Coolant Temperature ECT Sensor Removal 1 Disconnect the negative battery cable 2 Partially drain the cooling system 3 Disconnect the electrical connector 4 Remove the sensor Engine Coolant Temperature ECT TEMPERATUR SENSOR NI FPP00299 FPP00299 Installation Install the sensor Tighten to 16 24 Nm 12 17 lb ft Connect the electrical connector Connect the negative battery cable Fill the cooling system with the proper coolant Intake Air Temperature IAT Sensor Removal Intake Air Ho ed TEMPERATURE IAT Sensor SENSOR FPP00298 1 Disconnect the negative battery cable 2 Disconnect the electrical connector 3 Remove the sensor Installation 1 Install the sensor Tighten to 13 16 Nm 7 12 Ib ft 2 Connect electrical connector 3 Connect the negative battery c
10. JOJ99uuoo MIC os iu CO ipu pp paynu ee LN eoueuuojeed 26064 26205 41 SdL _ _ he gh EL DS LE ee ce GE ceo e Le 0 811699 38 0 81867 e LSE yg o 81867 84699 8L 668 E ER a _ 2 _ fo 410 D9UUOD uly eje A 8165 O AD 81152 8 19 SLESSe L r s 9 Jojenjoy 08 22 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Controls Connectors ICM Jumper Patch Harness Connector 1 Connector 2 851 18 YE RD 850 18 YE BK SA 57 16 gt e 16 16 RD LG 1 o 674 18 DB YE l 72 18 354 18 LG RD Plug 1 l 359 18 GN RD 1 m JjJ Plug il 11 18 TN YE y lt 253 18 DG WH 113 18 YE LB 71 18 OG LG 693 18 OG 08 23 Ignition Control Module ICM 3 Coil 2 Coil 1 Ground VBAT Fuel Select 1 Fuel Select 2 ECT ANA Return Tachometer Starter Lock Oil Pressure Aux Out Overspeed CL UEM TSG 416 ENGINE CONTROLS PREL
11. Diagnostic Trouble Codes CAUTION When checking codes with the diagnos tic software the DTC terminal can NOT be ground ed CAUTION Removing battery power before access ing diagnostic program will errase all codes record ed This section contains circuit description information and troubleshooting charts on all the DTC s obtained by diagnostic software or a Malfunction Indicator Lamp MIL When diagnostic trouble codes are obtained by a Malfunction Indicator Lamp MIL the following secquence will be flashed 123 will flash 3 times to indicate the beginning of the flash code display sequence Any active DTC s will flash 3 times each 123 will flash 3 times indicating the end of the code display sequence If code 123 is the only code present the system does not have any active codes all systems are working fine If an active DTC is present refer to the corresponding DTC chart Begin with the lowest number code first NOTE If you have a symptom of the pedal not working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage is 75 1 25 volts and idle validation switch says you re at idle replace the pedal 08 82 TSG 416 ENGINE CONTROLS PRELIMINARY Diagnostic Trouble Code DTC Diagnostic Trouble Code DTC
12. EPM Software nennen nnns 08 55 Using EPM Software Menu ens 08 56 Using IGM Ese 08 62 Visual and Physical 08 67 Intermittent 08 67 Symptom Charts ld idee dave lived 08 68 Malfunction Indicator Lamp MIL ON Steady 08 68 No Malfunction Indicator Lamp 08 69 Engine Cranks But Doesn t 08 71 EESTI 08 72 Engine SHIQeSL uu uu tti p i ted ee lee ene CE ep s pee 08 73 Lack of Power or Sluggish iai ec eere bade do 08 74 Detonation spank IKnock ae era S e xe te deese ERR Rae ae s d 08 75 Rough Unstable or Incorrect Idle 08 76 Excessive Fuel Consumption 28888 08 77 Dieseling RUMPON edet lad added de 08 78 gt qi 08 79 Hesitation Sag Stumbl 1 ea eden ee de a 08 80 Cuts Out MISSCS eret ne T rest 08 81 Multiple Sensor DTC S Set endian 08 84 Engine Performance Module EPM Diagnostic Trouble
13. TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Harness Connector C1F K J H G F E DC B A Pin Circuit Circuit Function A1 151 LB BK FPP1 A2 351 BN WH 5 Volt eference VREF A3 Not used B1 358 LG BK Manifold Absolute Pressure MAP sensor signal B2 359F GY RD Signal return B3 Not used C1 Not used C2 Not used C3 Not used D1 743 GY Intake Air Temperature IAT sensor signal D2 354 LG RD Engine Coolant Temperature ECT sensor signal D3 148 YE RD Aux PU2 E1 Not used E2 74 GY LB Heated Oxygen Sensor HO2S signal E3 Not used F1 Not used F2 37B YE Keep alive Memory KAM Battery voltage F3 238A DG YE Fuel pump monitor G1 349 DB Crankshaft Position CKP sensor signal G2 Not used G3 Not used H1 Not used H2 350 GY Crankshaft Position CKP sensor return H3 209 WH PK Self Test Input STI J1 Not used J2 306 TN LB Governor speed select 1 J3 253B DG WH Oil pressure switch K1 361L RD Vehicle power VPWR K2 307 BK YE Governor speed select 2 K3 72 YE BK Fuel Select 08 44 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Harness Connector C1M AB C D E F GH J K Pin Circuit Circuit Function 1 151 LB BK FPP1 A2 351 BN WH 5 Volt eference VREF A3 Not us
14. 1 967616 1 CONNECTOR 458 0 18 px O BK 18 458A 965906 5 TERMINAL AMP 961067 1SEAL FPP COMM COMM 08 26 TSG 416 ENGINE CONTROLS PRELIMINARY 0 SSauJeH I o1 1 ssouJeH t 02 no 4 Inoxoo1 p824 uapu SpunoJ Aeyxny Aeng L LA Ly cM x 1 1o 9 uuoo 6 045 861 JOJOBUUOD s EL St 8 10 98UU09 eogpnoju o uon yg 391 5 D 391 ZE 5 ui amp 59i 216 Wy 08 27 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Wiring Diagram 2 of 5 lt lt lt lt ee ER ee 5 sseuleH Jj dunr dung dung nuog j03u02 pees Ka 1019911 _ _ _ 022 222 ere egy 777 C Ss 55 EX 55 M oss gua 855 11995
15. 22 352 BR LG EGR Pulse Width Modulation PWM output 23 360 BR PK Exhaust Gas Recirculation EGR output 24 74 GY LB HO2S 1 0 1 volt input 25 392 RD LG HO2S 2 Catalyst Monitor 26 Not used 27 743 GY Intake Air Temperature IAT sensor input 28 354 LG RD Engine Coolant Temperature ECT sensor input 29 Not used 30 Not used 31 Not used 32 349 DB Crankshaft Position CKP sensor 33 350 GY Crankshaft Position CKP sensor 34 282 DB OR Camshaft Position CMP sensor 35 452 GY RD Camshaft Position CMP sensor 08 34 TSG 416 ENGINE CONTROLS PRELIMINARY ICM Connector C2 Gray O Pin Circuit Circuit Function 1 11 TN YL Tachometer output 2 Not used 3 851 YE RD Coil 2 ground output 4 71 OG LG Aux out 1 5 342 LG VT Starter lockout 6 850 YE BK Coil 1 ground output 7 674 DB YE Fuel Select 1 8 6 YE BK Fuel select 2 9 359 GY RD Signal return 10 570 BK Ground 11 16 RD LG VBAT Power 12 Not used 13 Not used 14 198 DG OG Auxiliary IN 15 253 DG WH Oil pressure input 16 351 BN WH 5 Volt reference 17 358 LG BL Manifold Absolute Pressure MAP Input 18 354 LG RD Engine Coolant Temperature ECT Input 19 349A DB Overspeed 20 669 DG WH RS 232 positive Transmit 21 458 OR BK RS 232 negative Receive 22 350 GY Crank negative 23 349
16. 54 S s 4 08 17 TSG 416 ENGINE CONTROLS PRELIMINARY Starting System EPM f Nda empon L _ 98 rs fc 97 4 91 Pe VS pued 2 EL 4 08 18 TSG 416 ENGINE CONTROLS PRELIMINARY Charging System EPM 08 19 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Controls Sensors EPM 410 D9UUOD waa einpow eoueuuojeg Ec vse 695 e Josueg 193 1 65 81 656 65 Josues dvi 55 2 E 7 8 esc 65 e A9 72 YAS 88 CSV 300 Jed suan OL ISIML 658 8015 105 96 8 15 105 6 12 uonisod uonisod 2 855 9 yeyswe9 08 20 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Controls Injectors EPM JO 99uuoo yeg waa einpow eoueuuojgedg L 911955 919855 eu 103oefu 1o 5 ul 8 1 9L 299 191 SSS LH 1032efu 08 21 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Controls Actuator Data Link Connector DLC EPM
17. 926A LB OG Fuel pump relay control R1 Not used R2 77 DB YE Gaseous Trim R3 658 PK LG Malfunction Indicator Lamp MIL 51 557 BN YE Fuel injector 3 2 556 WH Fuel injector 2 3 555 TN Fuel injector 1 T1 558 BN LB Fuel injector 4 T2 Not used T3 57 BK Ground W1 570B BK WH Power ground W2 570H BK WH Power ground W3 Not used X1 95 TN WH Ignition Coil 1 X2 570 BK WH Power ground X3 570A BK WH Power ground Y1 96 TN OG Ignition coil 2 Y2 Not used Y3 Not used 08 42 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Harness Connector C2M L MN PR S T W X Y Pin Circuit Circuit Function L1 198 DG OG Auxillary input L2 Not used L3 342 LG PK Starter lockout M1 107 PK Data link M2 914 TN OG RS 485 M3 Not used N1 Not used N2 915 PK LB RS 485 N3 Not used P1 Not used P2 242 DG Fuel Lockoff P3 926A LB OG Fuel pump relay control R1 Not used R2 77 DB YE Gaseous Trim R3 658 PK LG Malfunction Indicator Lamp MIL 51 557 BN YE Fuel injector 3 2 556 WH Fuel injector 2 3 555 TN Fuel injector 1 T1 558 BN LB Fuel injector 4 T2 Not used T3 57 BK Ground W1 570B BK WH Power ground W2 570H BK WH Power ground W3 Not used X1 95 TN WH Ignition Coil 1 X2 570 BK WH Power ground X3 570A BK WH Power ground Y1 96 TN OG Ignition coil 2 Y2 Not used Y3 Not used 08 43
18. Codes 08 82 Removal and Installation siesena ane aenn pier 08 5 Camshaft Position Sensor CMP eee 08 84 Engine Coolant Temperature ECT Sensor 08 84 Intake Air Temperature IAT Sensor 08 84 Heated Oxygen HO2S 1 2 4 1 2 4441 08 85 Glossary of Terms E 08 86 08 2 TSG 416 ENGINE CONTROLS PRELIMINARY GENERAL INFORMATION EPM ICM and Sensors Ignition Control Module ICM The Ignition Control Module ICM has the following features Programmable emergency warning shut down feature for high water temperature low oil pressure etc Starter lockout Programmable overspeed protection Automatic altitude compensation Diagnostic software allows viewing of active faults with on demand diagnostics to assist technicians and reduce equipment downtime Shut down output that will send a ground signal when the ICM shuts down due to low oil high ECT or rev limit Engine Performance Module EPM The Engine Performance Module EPM has the following features 08 3 Programmable four speed electronic governing throttle by wire or variable speed control governing Programmable emergency warning shut down feature for high water temperature low oil pressure etc Starter lockout Auto crank
19. DB Crank positive 08 35 TSG 416 ENGINE CONTROLS PRELIMINARY EPM Connector C1F 000960660 1000 OOO Q OOO OOO 29990999 Pin Circuit Circuit Function 1 16 RD LG Ignition voltage 2 11 TN YL Tachometer output 3 461 OG RS 485 4 511 LG RD Brake switch input 5 787A PK BK To fuel pump 12 volt output 6 658 PK LG Malfunction Indicator Light MIL output 7 72 YL BK Fuel select input 8 Not used 9 37 YL Battery voltage input 10 148 YL RD Auxiliary analog pull up circuit 2 11 DG OG RS 485 12 114 LB YL Secondary throttle control 0 5 volt variable input FPP2 13 32 RD LB Starter Solenoid Output 14 151 LB BK Primary throttle control 0 5 volt variable input FPP1 15 32A RD LB 12 volts in start non auto crank system 16 39 RD WH Water temperature output 17 Not used 18 458 OG BK RS 232 Self Test Input 19 Not Used 20 669 DG WH RS 232 21 71 OG LG Aux Out 1 22 Not used 23 307 BK YL Governor select 2 24 306 TN LB Governor select 1 25 307 BK YL Idle validation switch ivs input 26 253 DG WH Oil pressure warning light output Only use with 5 volt supplied light 27 Not used 28 662 DG PK Can bus communications 29 459 OR LG Can bus communications 30 349A DB Overspeed 31 351 BN WH 5 volt vref output 32 198 DG OR Au
20. IAT High Voltage DTC 531 TPS1 Signal Voltage High DTC 212 IAT Low Voltage DTC 532 TPS1 Signal Voltage Low DTC 213 IAT Higher Than Expected 1 DTC 533 TPS2 Signal Voltage High DTC 214 IAT Higher Than Expected 2 DTC 534 TPS2 Signal Voltage Low DTC 215 Oil Pressure Low DTC 535 TPS1 Higher Than TPS2 DTC 221 CHT ECT High Voltage DTC 536 TPS1 Lower Than TPS2 DTC 222 CHT ECT Low Voltage DTC 537 Throttle Unable to Open DTC 223 CHT Higher Than Expected 1 DTC 538 Throttle Unable to Close DTC 224 CHT Higher Than Expected 2 DTC 545 Governor Interlock Failure DTC 231 MAP High Pressure DTC 551 Max Govern Speed Override DTC 232 MAP Low Voltage DTC 552 Fuel Rev Limit DTC 234 BP High Pressure DTC 553 Spark Rev Limit DTC 235 BP Low Pressure DTC 611 COP Failure DTC 242 Crank Sync Noise DTC 612 Invalid Interrupt DTC 243 Never Crank Synced At Start DTC 613 A D Loss DTC 244 Camshaft Sensor Loss DTC 614 RTI 1 Loss DTC 245 Camshaft Sensor Noise DTC 615 Flash Checksum Invalid DTC 253 Knock Sensor Open DTC 616 RAM Failure DTC 254 Excessive Knock Signal DTC 631 External 5V Ref Lower Than Expected DTC 311 Injector Driver 1 Open DTC 632 External 5V Ref Higher Than Expected DTC 312 Injector Driver 1 Shorted DTC 655 RTI 2 Loss DTC 313 Injector Driver 2 Open DTC 656 3 Loss DTC 314 Injector Driver 2 Shorted DTC 315 Injector Driver 3 Open DTC 316 Injector Driver 3 Shorted DTC 321 Injector Driver 4 Open DTC 322 Injector Driver 4 Shorted
21. The EPM ICM is designed to withstand normal current draws associated with engine operation When servicing the EPM observe the following guidelines Do not overload any circuit e When testing for opens and shorts do not ground or apply voltage to any of the EPM ICM s circuits unless instructed to do so When measuring voltages use only a digital voltmeter with an input impedance of at least 10 megohms Do not employ any non standard practices such as charging the battery with an arc welder Take proper precautions to avoid static damage to the EPM ICM Refer to electrostatic Discharge Damage for more information Use of Circuit Testing Tools Do not use a test light to diagnose the engine electrical systems unless specifically instructed by the diagnostic procedures A test light can put an excessive load on an EPM ICM circuit and result in component damage For voltage measurements use only a digital voltmeter with an input impedance of at least 10 megohms Electrostatic Discharge Damage Electronic components used in the EPM ICM are often designed to carry very low voltage Electronic components are susceptible to damage caused by electrostatic discharge Less than 100 volts of static electricity can cause damage to some electronic components By comparison it takes as much as 4000 volts for a person to feel the spark of a static discharge There are several ways for a person to become statically charged T
22. desired speed for testing Crank Engine Toggle Toggle to ON to crank and start engine Test Mode Toggle Toggle to ON to test system for any diagnostic trouble codes DTC which will cause MIL to blink if any codes 5 Malfunction Indicator Light MIL will blink when test mode toggle switch is in the ON position and there are any DTC s gt 08 51 TSG 416 ENGINE CONTROLS PRELIMINARY Breakout Box Conversion In order to use the breakout box with the Engine Performance Module EPM System the following changes must be made to the wires coming out of the 42 pin connector The breakout box will then work with both Engine Performance Module EPM and ECM sysems The wire pin 3 must be spliced to the wire 18 Solder the splice and cover with sealable heatshrink tubing The wire from pin 11 must be moved to pin 23 To move the pin first remove the red plastic retaining clips in the 42 pin connector Lightly pry back the black plastic retainer that presses against the terminal of pin 11 and slide the wire out the back of the connector Insert this wire into pin 23 or the 42 pin connector Insert the red plastic retaining clips back into the 42 pin connector The new wire in pin 23 must be spliced to the wire in pin 25 Solder the splice and cover with sealable heatshrink tubing The conversion is now complete The Breakout box will now work for an EPM system as well as an ECM system I
23. or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on Data Stream Reading Sensor amp Actuator Values Most applicable sensor and actuator values are displayed on the Gauges Screen The display shows the voltage the FORD system EPM is reading and for sensors the sensor value in engineering units This is one of three main screens GAUGES FAULTS AND RAW VOLTS The GAUGES screen shows the following Manifold Absolute Pressure MAP Engine Coolant Temperature ECT Intake Air Temperature IAT Throttle Position TP Foot Pedal Position FPP Battery Voltage Engine speed RPM Exhaust Gas Oxygen HO2S Hour meter Number of continuous starts Run mode power mode and fuel type Use the keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on NOTE If a DTC for a sensor is current the engineering value for that sensor may be a default limp home value and the voltage value will be the actual sensor voltage Use the voltage value when performing diagnostics unless directed to do otherwise by the diagnostic trouble tree 08 58 TSG 416 ENGINE CONTROLS PRELIMINARY Plotting and Data Logging Recording the values and voltages can be a very useful tool while diagnos
24. rich mixture which will result in a lean command to compensate 2 P Specifications Accuracy of measurement 1 5 Operating Temp Range 350 C to 850 C sensor tip e Sensor Response Time 300 1500 msec Heater Current Draw 1 A steady state Voltage Output 0 450 mV lean exhaust gas 450 1000 mV rich exhaust gas Manifold Absolute Pressure MAP Sensor The Manifold Absolute Pressure MAP Sensor responds to changes in intake manifold pressure vacuum The MAP sensor signal voltage to the EPM varies from below 2 volts at idle high vacuum to above 4 volts with the ignition ON engine not running or at wide open throttle low vacuum The MAP sensor consists of a pressure sensing element capacitor and signal conditioning electronics The capacitor has a vacuum pressure reference which results in one surface diaphragm of the capacitor being partially deflected Further changes in pressure produce corresponding changes in the deflection of the diaphragm and therefore a change in capacitance This capacitance change is converted to a frequency by the conditioning electronics The MAP sensor is used to determine the following Engine vacuum level for engine control purposes e Barometric pressure BARO Specifications e Range of Measurement 1 7 15 2 psi Measurement Accuracy 0 2 psi Sensor Response Time 3 15 msec Resolution 0 02 psi Present design Si
25. select 1 25 307 BK YL Idle validation switch ivs input 26 253 DG WH Oil pressure warning light output Only use with 5 volt supplied light 27 Not used 28 662 DG PK Can bus communications 29 459 OR LG Can bus communications 30 349A DB Overspeed 31 351 BN WH 5 volt vref output 32 198 DG OR Aux analog pull down circuit 33 359 GY RD Auxilary signal return 34 570 BK WH Power ground 35 169 LG BK Vehicle Speed Sensor 36 172 LB RD Vehicle Speed Sensor 37 150 DG WH Aux analog pull up circuit 38 18 OR YL Exhaust Gas Recirculation EGR input 39 32 RD LB 12 Volts in start Auto crank only 40 352 BN LG Pulse Width Modulation PWM output 41 360 BN PK Exhaust Gas Recirculation EGR output 42 Not used 08 37 TSG 416 ENGINE CONTROLS PRELIMINARY Actuator Pigtail to Actuator Pin Circuit Circuit Function 1 317 GY OG Drive by Wire Negative 2 359 GY RD Signal Return 3 351 BN WH VREF 5 volts Input 4 151 LB BK Drive by Wire Positive 5 357 YE WH Throttle Position Sensor TPS 2 6 355 GY WH Throttle Position Sensor TPS 1 08 38 TSG 416 ENGINE CONTROLS PRELIMINARY Drive By Wire Harness Connector 2U1L 12B476 AA 10 Circuit Circuit Function 1 Not Used 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 307 BK YE IVS Si
26. the edis_saplot software located in the Windows Start Programs FPP_Dis folder or the data can be viewed in Notepad or Excel Here is a sample of a plot Logging Logging variables means the variables are stored to the PC During logging there is no plot shown on the screen To log variables you must first TAG the variables by right clicking them same as plotting Next click on Plot Log and then Log Tags An Edis Log window will pop up You can type in a custom log File name or select a custom folder to save the log file to The default filename is edis log and the default folder is FPP_Dis The sample interval and time interval can also be changed from the default To start logging click on the START button You will see the progress bar moving from 0 to 100 When the logging is complete you can close the Edis Log box or start another log file If you start another log file you must change the Log File name or the first log file will be overwritten To view the contents of a saved log file you can use Notepad or Excel The following are examples showing the Edis Log box before starting a log file and during a log file 08 59 TSG 416 ENGINE CONTROLS PRELIMINARY Ignition System Test The Spark Kill diagnostic mode allows the technician to disable the ignition on individual cylinders If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM the minimum throt
27. to a maximum opening of 20 If Power Derate 2 is active it will remain active until the active DTC goes away and the ignition input to the EPM usually the ignition switch is cycled DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit e DTC 524 FPP2 lower than IVS limit DTC 515 FPP1 higher than FPP2 DTC 516 FPP1 lower than FPP2 DTC 353 MegaJector delivery pressure higher than expected 354 MegaJector delivery pressure lower than expected DTC 355 MegaJector communication lost e DTC 363 MegaJector internal actuator fault detection e 364 MegaJector internal circuitry fault detection e DTC 365 MegaJector internal communication fault detection e DTC 611 COP failure Internal EPM failure 08 49 TSG 416 ENGINE CONTROLS PRELIMINARY DTC 614 1 loss internal EPM failure DTC 655 2 loss internal EPM failure DTC 656 RTI 3 loss internal EPM failure DTC 613 A D loss internal EPM failure DTC 612 Invalid interrupt internal EPM failure DTC 615 Flash checksum invalid internal EPM failure DTC 616 RAM failure internal EPM failure Fault Low Rev Limit The engine RPM will be limited to a maximum of 1600 RPM If the Fault Low Rev Limit is active it will remain active until the active DTC goes away and the ignition input to the E
28. uuoo jueuoduo9 peyoeye 10 M919S jueuodu09 JO ped poeiip eseo jueuoduuoo e Jo 4 ple 4 JOJOBUUOD Jojoeuuoo 4 punolg uonoeuuoo eds uonoeuuoo pesso19 o 08 12 TSG 416 ENGINE CONTROLS PRELIMINARY EPM Fuse and Relay Information Fuse Amps Circuits protected 1 30 Ground 2 5 VSW Relays EPM 3 20 VBAT EPM 4 15 Fuel pump 5 15 EPM trim valve coil lockoff solenoid 6 Not used 08 13 TSG 416 ENGINE CONTROLS PRELIMINARY ICM Fuse and Relay Information Relay 2 Starter Relay Fuse Amps Circuits protected 1 10 Ignition Voltage to ICM Starter Relay and Ignition Coil 2 Not used 3 Not used 4 Not used 5 Not used 6 Not used 08 14 TSG 416 ENGINE CONTROLS PRELIMINARY Wire Colors Symbol Color BK BLACK BN BROWN BU BLUE DB DARK BLUE DG DARK GREEN GN GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN NA NATURAL OG ORANGE PK PINK RD RED SR SILVER TN TAN VT VIOLET WH WHITE YE YELLOW 08 15 Nda
29. 1 Not used 12 Not used 13 Not used 14 72 YL BK Fuel select 15 148 YL RD Aux analog pull up circuit 2 16 306 TN LB Gov select 1 17 307 BK YL Gov select 2 18 Not used 19 Not used 20 642 DG OR RS 485 positive 21 461 OR RS 485 negative 22 342 LG PK Starter lockout 23 242 DG Fuel lockoff 24 Not used 25 Not used 26 77 DB YL Gaseous trim vacuum control 27 658 PK LG MIL light ground 28 151 LB BK Drive by wire positive 29 317 GY OR Drive by wire ground 30 355 GY WH Throttle Position Sensor TPS 1 31 357 YL WH Throttle Position Sensor TPS 2 32 Not used 33 Not used 34 669 DG WH RS 232 positive TX 35 458 OR BK RS 232 negative RX 08 46 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Jumper Harness Connector C3F Black OOOOODOOOOO0 t Circuit Circuit Function 1 570 BK WH Power ground 2 570 BK WH Power ground 3 16 RD LG Fused ignition voltage 4 361 RD Fused VBAT 12 volts 5 Not used 6 Not used 7 555 TN Fuel injector 1 ground 8 557 BR YL Fuel injector 3 ground 9 558 BR LB Fuel injector 4 ground 10 556 WH Fuel injector 2 ground 11 Not used 12 Not used 13 359 GY RD Signal return TMAP ECT foot pedal HEGO throttle communication 14 351 BR WH VREF 5 volt output
30. 5 to EPM Jumper Harness Connector C2F Gray 08 46 to EPM Jumper Harness Connector C3F Black 08 47 ECM to EPM Jumper Harness Conversion 08 48 DI8gHOSIS E M 08 49 EPM Diagnostic OV6rvVieW aysa uapa eee eee 08 49 On Board Diagnostics 08 49 Engine Performance Module EPM Limp Home Mode Strategy 08 49 Power Derate T en cite 08 49 Power Derate 2 tni t el nee aeree es epe aeu eeu E 08 49 Fault Low Rev Limit MEC 08 50 Force to dieser ee Sum hoa 08 50 Breakout BOX desa 08 51 Breakout Box Conversion see 08 5210 Intermittent suede 08 52 Using the to EPM Jumper Harness to Diagnose the FORD 08 52 Malfunction Indicator Lamp MIL DTC Retrieval 08 52 AIITEM 08 53 Diagnosis Using a Personal Computer sise 08 53 Equipment 660000 eee 08 53 dade Ert e dua e oae d du dune noL annee dua dee 08 54
31. DB YL Gaseous trim vacuum control 27 658 PK LG MIL light ground 28 151 LB BK Drive by wire positive 29 317 GY OR Drive by wire ground 30 355 GY WH Throttle Position Sensor TPS 1 31 357 YL WH Throttle Position Sensor TPS 2 32 15 RD YL Coil and heated oxygen sensor power relay ground output 33 349A DB Overspeed 34 669 DG WH RS 232 positive TX 35 458 OR BK RS 232 negative RX 08 33 TSG 416 ENGINE CONTROLS PRELIMINARY EPM Connector C3 Black Pin Circuit Circuit Function 1 570 BK WH Power ground 2 570 BK WH Power ground 3 16 RD LG Fused ignition voltage 4 361 RD Fused VBAT 12 volts 5 361 RD Fused VBAT 12 volts 6 361 RD Fuel injector power 7 555 TN Fuel injector 1 ground 8 557 BR YL Fuel injector 3 ground 9 558 BR LB Fuel injector 4 ground 10 556 WH Fuel injector 2 ground 11 Not used 12 Not used 13 359 GY RD Signal return TMAP ECT foot pedal HEGO throttle communication 14 351 BR WH VREF 5 volt output 15 151 LB BK Foot Pedal Position FPP 0 5 volt input 1 16 114 LB YL Foot Pedal Position FPP 0 5 volt input 2 17 307 BK YL Idle Validation Switch IVS input 18 150 DG WH Aux analog pull up circuit 19 198 DG OR Aux analog pull down circuit 20 358 LG BK Manifold Absolute Pressure MAP sensor input 21 18 OR YL Exhaust Gas Recirculation EGR input
32. F to 125 C 57 F Measurement Accuracy 3 C Resolution 0 6 C max Output Range 4 8 min to 91 max of VREF Current Draw 5mA from VREF Load Impedance gt 100 kohms 08 7 TSG 416 ENGINE CONTROLS PRELIMINARY Heated Oxygen Sensor HO2S The Heated Oxygen Sensor HO2S is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output This voltage should constantly fluctuate from approximately 100mV to 900 mV when the engine is running in closed loop fuel control The Heated Oxygen Sensor HO2S voltage can be monitored on an IBM PC compatible computer with diagnostic software By monitoring the voltage output of the oxygen sensor the EPM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture The 4 wire HO2S indicates whether the air fuel ratio is rich or lean with respect to stoichiometry The signal from this sensor contains valid air fuel ratio information only when the sensor element has reached its normal operating temperature The 4 wire HO2S also has an isolated case ground which goes to Signal Return SIGRTN either in the processor as a dedicated HO2S ground or as a jumper to SIGRTN in the wiring harness Low HO2S voltage indicates a lean mixture which will result in a rich command to compensate High HO2S voltage indicates a
33. GASEOUS gt OVERSPEED lt 18 CAN 1 62 06 018 RS 485 21 461 0 18 5 86 lt 3 ____669 068 RS 232 TX 35 458 0 BK 18 RS 232RX lt 08 25 TSG 416 ENGINE CONTROLS PRELIMINARY ECM To EPM Conversion Harness Adapter 2 of 2 FORD SERVICE ADAPTER PCB NOT USED BS 555 116 B7 558 BR LB 16 B8 556 W 16 B9 559 T BK 16 B10 557 BR Y 16 560 LG O 16 B12 358 LG BK 18 820 151 LB BK 18 15 703 GY 18 B27 354 LG R 18 B28 150 DG W 18 B18 510 16 B1 570 BK W 16 B2 359 GY R 18 B13 351 BR W 18 Bis 36 R LG 18 83 74 GY LB 18 B24 349 0818 832 350 GY 18 833 37 Bh 850 Y BK 18 Gi 851 Y R 18 G2 857 Y w 18 63 342 LG P 18 622 242 DG 18 G23 926A 1B 0 18 69 253 DG W 18 GT 658 PK LG 18 G27 238 DG Y 18 60 12 Y BK 18 5 148 Y R 18 615 306 T LB 18 616 307 BK Y 18 GT 71 DB Y 18 626 642 06 018 G20 461 018 621 351 BR W 18 2 359 GY R 18 Wi 458A O BK 18 3 BOSCH THROTTLE PED 12015798 CONNECTOR PED 17010975 CONN PED SEAT NAL MALE 12089188 TERM FEMALE 18 20 355 GY W 18 us a 35 Y W18 359 GY R 18 D 151 LB BK 18 2 377 GY O 18 1 1 351 BR W 18 Cody tb 351 BR W 18 359 GY R 18 3 669 DG W 18 x
34. IMINARY Engine Controls Sensors amp Data Link Connector DLC ICM Jumper Patch Harness 8 55 s co DE 35 S m Ga Od 2 349 18 DB Crank 350 18 Crank l rank 38 1 Ba E 1 1 11 458 18 5 RS 232 RX 669 18 DG WH ol RS 232 TX eS E i 1 1 _ il 5 222 0226 9 142 359 18 GR RD Return 358 18 LG BU 2 k MAP 351 18 BR WH 5 Volt Ref 08 24 TSG 416 ENGINE CONTROLS PRELIMINARY ECM To EPM Conversion Harness Adapter 1 of 2 FPPECM3 CONNECTOR AMP 776164 1 TERMINAL AMP 770520 3 J1 BLACK iis 6 55 TI 8 558 BR LB 16 Wee 556 W 16 2 lt 10 559 T BK 16 MEE 557 BR Y 16 lt 2 560 16 0 16 AUX OUT 2 2 2 AUX ANA RIT 358 LG BK 18 15 151 LB BK 18 FEL OST 763 GY 18 lt m 354 LG R 16 AUX ANA lt z 50 DG W 18 lt 5 gt i EGR RECRE 570 BK W 16 POWER GROUND lt 212 6 POWER GROUND lt E 359 GY R 18 ANA RTN lt I 1 351 BR W 18 SVOLTREF gt
35. Inspect EPM sensors and actuators for physical damage Inspect EPM grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamination winter summer blend Inspect intake air system and air filter for restrictions Inspect battery condition and starter current draw If no evidence of a problem is found after visual inspection has been performed proceed to Diagnostic System Check Intermittent Problems NOTE An intermittent problem may or may not turn on the MIL or store a DTC Do not use the DTC charts for intermittent problems The fault must be present to locate the problem NOTE Most intermittent problems are caused by faulty electrical connections or wiring Perform a careful visual inspection for the following conditions Poor mating of the connector halves or a terminal not fully seated in the connector backed out Improperly formed or damaged terminals Improper contact tension All connector terminals in the problem circuit should be carefully checked Poor terminal to wire connections This requires removing the terminal from the connector body to check Improperly installed aftermarket equipment accessories Operate the engine with accessories OFF and a suitable multimeter connected to the suspected circuit An abnormal voltage when the malfunction occurs is a good indic
36. PM usually the ignition switch is cycled 511 FPP1 high voltage DTC 512 FPP1 low voltage DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit DTC 524 FPP2 lower than IVS limit DTC 515 FPP1 higher than FPP2 DTC 516 FPP1 lower than FPP2 DTC 545 IVS Brake interlock failure Force to Idle The engine RPM will be limited to a maximum of 800 RPM If the Force to Idle is active it will remain active until the active DTC goes away DTC 511 FPP1 high voltage DTC 512 FPP1 low voltage DTC 521 FPP2 high voltage e DTC 522 FPP2 low voltage DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit DTC 524 FPP2 lower than IVS limit e DTC 515 FPP1 higher than FPP2 DTC 516 FPP1 lower than FPP2 08 50 TSG 416 ENGINE CONTROLS PRELIMINARY Breakout Box The breakout box XU1L 12T650 AA can be used to diagnose the EPM system However modification must be made to the wires coming out of the 42 pin connector Battery Battery Negative Positive black red 42 pin N Connector Fuel sae aum Ground Connector black 10 Amp Fuse 10 Amp Fuse Fuel Pump Positive 30 Amp Fuse Connector red Clip to Starter Solenoid S Terminal Power Switch Flip to ON to energize system Speed Select Switch Turn to
37. Programmable overspeed protection Automatic altitude compensation Sequential port fuel injection gasoline with pressure regulator to precisely control fuel delivery Dry fuel lockout controlled by the EPM produces a reliable transition when switching fuels Certified closed loop dry fuel control Configurable inputs available based on customer requirements Configurable outputs available based on ECT RPM or MAP signals and customer requirements Diagnostic software allows viewing of historical and active faults with on demand diagnostics to assist technicians and reduce equipment downtime TSG 416 ENGINE CONTROLS PRELIMINARY The Engine Performance Module EPM engine control system is a complete engine control system for Ford industrial engines running on gasoline propane or natural gas Each module can be set up to run an engine on any two of the three fuels in certified closed loop control with virtually transparent on the fly fuel switching Each module can also be set up to run on a variety of electronic governing It can be programmed to provide up to four specific speeds with use of a matching toggle switch tcan be programmed to provide an infinite variety of speeds with customer specified minimum and maximum based on a variable signal input It can be an electronic replacement for a throttle cable with maximum speed governing throttle by wire Orit can switch between throttle by wi
38. S 3 0 software 64 08 53 TSG 416 ENGINE CONTROLS PRELIMINARY Interface Hook up For connection to a laptop use kit PN 2U1L 6K947 AA Connect serial cable to RS232 port on the back of the laptop computer Connect interface cable to serial cable Connect interface cable to the 4 pin diagnostic connector on the engine harness Laptop Computer Serial Communication Cable Interface Cable To Diagnostic Connector For connection to a PDA use kit PN 2U1E 6K947 AA Connect as shown below PDA To Diagnostic Connector HotSync Cable Interface Cable 08 54 TSG 416 ENGINE CONTROLS PRELIMINARY EPM Software Installation Insert CD into CD ROM drive Double click My Computer Icon Double Click CD ROM drive letter This will display the contents of the CD as shown technicians EPM software FPP Display msi Windows Installer Package setup x FPPDisplay Double click FPP Display icon You will now see a welcome screen 7 FPP Display Setup Click next Welcome to the FPP Display Installation Wizard It is strongly recommended that you exit all Windows programs before running this setup program Click Cancel to quit the setup program then close any programs you running Click Next to continue the installation WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or
39. TSG 416 ENGINE CONTROLS PRELIMINARY Subject Page General Information u 08 3 oe toti esi Lb ie f At lues 08 3 Ignition Control Module ICM usines 08 3 Engine Performance Module 12 2124 111 1 1 41 i S 08 3 EPM Inputs operating conditions 08 4 EPM Outputs systems controlled 08 4 Crankshaft Position 08 5 Camshaft Position CMP sise 08 5 Engine Coolant Temperature ECT Sensor 08 6 Intake Air Temperature Sensor ss 08 7 Heated Oxygen Sensor 25 2 2 222 2 24 1411 2 2 44 4 404114214 yu E h trt en 08 8 Manifold Absolute Pressure MAP Sensor 08 8 Throttle Position TP Sensor Electronic 08 9 Fuel System Components 08 9 ns memes 08 9 FURR TERRE 08 10 Fuel Pressure Regulalpr uyu i Peg onte stehe bl Men bed qux eta Med 08 10 Fuel Pump Electrical 08 10 Electronic xiu dria en ee e dte dedu 08 10 Open Loop and Closed Loop Operation 08 11 EPM IGM Service PreCautlons teet
40. able 08 84 TSG 416 ENGINE CONTROLS PRELIMINARY Heated Oxygen HO2S Sensor Removal Heated Oxygen HO2S Sensor 1 Disconnect the negative battery cable 2 Disconnect electrical connector 3 Remove the sensor using an oxygen sensor wrench NOTE If necessary lubricate sensor using penetrating lubricant such as E8AZ 19A501 B or equivalent Installation 1 Apply a light coat of Anti seize compound such as F6AZ 9L494 AA or equivalent meeting Ford specification ESE M12AAA to the threads of the Sensor 2 Install the sensor using an oxygen sensor wrench Tighten to 36 46 Nm 27 33 Ib ft 3 Connect electrical connector 4 Connect the negative battery cable 08 85
41. after the engine is shut down causing long crank times Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines Fuel Pressure Regulator The fuel pressure regulator is a relief valve mounted in the fuel filter It provides a constant fuel pressure of 441 kPa 64 psi If the pressure is too low poor performance and a DTC 121 or 141 will set If the pressure is too high excessive odor and or a DTC 122 or 142 will result When replacing the fuel filter be sure to use an identical filter regulator assembly A standard fuel filter does not regulate pressure and could cause engine problems or component damage Fuel Pump Electrical Circuit When the key is first turned the EPM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly If the engine is not started within two seconds the EPM shuts the fuel pump off and waits until the engine is cranked When the engine is cranked and crankshaft position signal has been detected by the EPM the EPM supplies 12 volts to the fuel pump relay to energize the electric fuel pump An inoperative fuel pump will cause no start condition A fuel pump which does not provide enough pressure will result in poor performance Electronic Ignition The electronic ignition system controls fuel
42. ant pressure A return line delivers unused fuel back to the tank The main control sensor is the heated oxygen sensor 25 located in the exhaust system The HO2S tells the EPM how much oxygen is in the exhaust gas The EPM changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system The EPM monitors signals from several sensors in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes All modes are controlled by the EPM Refer to Open Loop and Closed Loop Operation for more information Fuel Injector The Electronic Fuel Injection EFI fuel injector is solenoid operated device controlled by the EPM The EPM energizes the solenoid which opens a valve to allow fuel delivery The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve Excess fuel 08 9 TSG 416 ENGINE CONTROLS PRELIMINARY not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank A fuel injector which is stuck partly open will cause a loss of fuel pressure
43. any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law screen will pop up telling you the name of the destination folder i FPP Display Setup Destination Folder Select a folder where the application will be installed Click next You will now see a screen telling you it is ready to install the software FPP Display Setup Ready to Install the Application Click Next to begin installation Click next 08 55 TSG 416 ENGINE CONTROLS PRELIMINARY You will see an Installation Success screen when the software is finished installing 7 FPP Display Setup FPP Display has been successfully installed Click the Finish button to exit this installation Click Finish A screen will pop up asking if it is ok to reboot your system ir Installer Information Click yes Your system will shut down and reboot The software is now installed on your system in a folder called FPP Display Refer now to Using Technicians EPM Software in this Section Using EPM Software Menu Functions You can begin using the technicians EPM software after installation by clicking Start Programs FPP Display FPP Display as shown FPP Display m CT 00 gt the Password which be found on the label of the CD ROM Enter Password Cle
44. ar Password Paste Password Single Serial Number Access w Save password and S N Place the ignition key the ON position The FORD system Gauge screen should now appear and a green banner in the upper left hand corner will read Connected 08 56 TSG 416 ENGINE CONTROLS PRELIMINARY Diagnostic Trouble Codes The System Fault screen is used to view and clear DTC s which have been set ee Cee Sa Soe Co Pa RE CCS aa F Cee p gt ke he 1 a w 31 Ciam Checking Diagnostic Trouble Codes The System Fault screen contains a listing of all of the Historic and Active DTC s set within the FORD system DTC is stored in memory the screen will display that fault in the Historic Faults column If the fault condition currently exists the DTC will also show up in the Active Faults column Opening Diagnostic Trouble Codes To open a DTC click on the DTC in the Historic Faults column A DTC Dialog Box will pop up on the screen The DTC Dialog Box contains the following useful information If the fault occurred during the current key cycle Ifthe fault caused current engine shutdown How many key cycles since the fault was active Snapshot Data explained later Flight Data Recorder explained later The DTC Dialogue Box also allows you to clear a single fault by clicking on the Clear This Fau
45. ation that there is a fault in the circuit being monitored To check EPM for loss of diagnostic code memory disconnect the MAP sensor connector and idle the engine until the MIL illuminates Perform MIL DTC retrieval procedure DTC should be stored and kept in memory when the ignition is turned OFF If not the EPM is faulty When this test is completed make sure that you clear the DTC from memory An intermittent MIL with no stored DTC may be caused by the following DIS ignition coil shorted to ground and arcing at ignition wires or plugs MIL circuit to EPM shorted to ground Poor EPM grounds 08 66 TSG 416 ENGINE CONTROLS PRELIMINARY Symptom Charts validation switch says you re at idle replace the pedal NOTE If you have a symptom of the pedal not working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage is 75 1 25 volts and idle Symptom Go to Page Malfunction Indicator Lamp MIL ON Steady No Malfunction Indicator Lamp MIL Engine Cranks but Does Not Start Hard Start Engine Surges Lack of Power or Sluggish Detonation Spark Knock Rough Unstable or Incorrect Idle Stalling Excessive Fuel Consumption Dieseling Run on Backfire Hesitation Sag Stumble Cuts Out Misses 08 67 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Performance Module EPM
46. combustion by providing a spark to ignite the compressed air fuel mixture at the correct time To provide optimum engine performance fuel economy and control of exhaust emissions the EPM controls the spark advance of the ignition system Electronic ignition has the following advantages over a mechanical distributor system No moving parts Less maintenance Remote mounting capability No mechanical load on the engine More coil cooldown time between firing events Elimination of mechanical timing adjustments Increased available ignition coil saturation time The electronic ignition system uses a coil pack with one ignition coil for each two cylinders in the engine Each cylinder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark The primary coils in the coil pack are triggered by the ignition coil feed 1 and ignition coil feed 2 signals from the EPM 08 10 TSG 416 ENGINE CONTROLS PRELIMINARY Open Loop and Closed Loop Operation NOTE No DTC will be set unless engine has operated in closed loop status for more than 6 seconds The EPM will operate in the following two modes Open loop Closed loop When the engine is first started the system is in open loop operation In open loop the EPM
47. d to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on Using ICM Software You can begin using the technicians ICM software after installation by clicking Start Programs FPP 6 Cylinder ICM EDis FPP 6 Cylinder ICM EDis Main Screen The first screen shown is the MAIN screen This is one of six screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL2 SPARK FAULT CONFIGURATION The MAIN screen shows the following Engine Speed RPM Manifold Pressure PSIA Coolant Temperature F Spark Timing CADBTDC Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on 08 62 TSG 416 ENGINE CONTROLS PRELIMINARY Plots Screen If you toggled to the right the next screen will be the PLOTS screen The PLOTS screen shows the following values over time Engine Speed RPM Manifold Pressure PSIA e Coolant Temperature F Spark Timing CADBTDC Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on Base Spark Screen If you toggled to the right the nex
48. e TP sensor 5 volt reference or signal circuits for greater than 2 consecutive seconds will set a DTC 531 DTC 533 A hard failure with the TP sensor ground circuit for more than two consecutive seconds may set DTC 532 If any TP DTC is set the EPM will shut down the engine immediately Specifications e Range of Measurement 0 85 angular e Measurement Accuracy 2 of VREF Resolution 0 5 max Fuel System Components Gasoline The fuel metering system is made up of the following parts The fuel injectors The fuel rail The fuel pressure regulator filter assembly EPM Crankshaft Position CKP Sensor The Camshaft Position CMP Sensor The fuel pump The fuel pump relay Heated Oxygen HO2S Sensor Manifold Absolute Pressure MAP Sensor The basic function of the air fuel metering system is to control the air fuel delivery to the engine Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve The fuel metering system starts with the fuel in the fuel tank The fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail through an in line fuel filter The pump is designed to provide fuel at a pressure above the pressure needed by the injectors A fuel pressure regulator in the fuel filter assembly keeps fuel available to the fuel injectors at a const
49. e position of the 1 piston during its power stroke The CMP uses a Hall Effect sensor to measure piston position This allows the EPM to calculate true sequential fuel injection SFI mode of operation If the EPM detects an incorrect CMP signal while the engine is running DTC 245 will set If the CMP signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse and the engine will continue to run As long as the fault DTC 244 is present the engine can be restarted It will run in the previously established injection sequence Op 08 5 TSG 416 ENGINE CONTROLS PRELIMINARY Engine Coolant Temperature ECT Sensor The Engine Coolant Temperature ECT Sensor is a thermistor a resistor which changes value based on temperature mounted in the engine coolant stream Low coolant temperature produces a high resistance of 100 000 ohms at 40 C 40 F High temperature causes a low resistance of 70 ohms at 130 C 266 F The EPM supplies a 5 volt signal to the ECT sensor through resistors in the EPM and measures the voltage The signal voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the EPM calculates the engine coolant temperature Engine coolant temperature affects most of the systems that the EPM controls
50. ed 1 358 LG BK Manifold Absolute Pressure MAP sensor signal B2 359F GY RD Signal return B3 Not used C1 Not used C2 Not used C3 Not used D1 743 GY Intake Air Temperature IAT sensor signal D2 354 LG RD Engine Coolant Temperature ECT sensor signal D3 148 YE RD Aux PU2 E1 Not used E2 74 GY LB Heated Oxygen Sensor HO2S signal E3 Not used F1 Not used F2 37B YE Keep alive Memory KAM Battery voltage F3 238A DG YE Fuel pump monitor G1 349 DB Crankshaft Position CKP sensor signal G2 Not used G3 Not used H1 Not used H2 350 GY Crankshaft Position CKP sensor return H3 209 WH PK Self Test Input STI J1 Not used J2 306 TN LB Governor speed select 1 J3 253B DG WH Oil pressure switch K1 361L RD Vehicle power VPWR K2 307 BK YE Governor speed select 2 K3 72 YE BK Fuel Select 08 45 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Jumper Harness Connector C2F Gray Circuit Circuit Function 1 850 YE BK Coil 1 ground output 2 851 YE RD Coil 2 ground output 3 852 YE WH Coil 3 ground output 4 Not used 5 Not used 6 Not used 7 253 DG WH Oil pressure input 8 Not used 9 926A LB OR Enable fuel pump relay 10 238 DG YL Fused fuel pump 12V monitor 1
51. engine from hazards such as over speed over temperature over voltage low oil pressure unauthorized tampering over cranking starter motor The EPM controls the following Fuel metering system Ignition timing On board diagnostics for engine functions The EPM constantly observes the information from various sensors The EPM controls the systems that affect engine performance The EPM performs the diagnostic function of the system It can recognize operational problems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTC s DTC s identify the problem areas to aid the technician in making repairs The EPM supplies either 5 or 12 volts to power various sensors or switches The power is supplied through resistances in the EPM which are so high in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low Therefore a digital voltmeter with at least 10 meg ohms input impedance is required to ensure accurate voltage readings The EPM controls output circuits such as the fuel injectors electronic governor etc by controlling the ground or the power feed circuit through transistors or other solid state devices The EPM is designed to maintain exhaust emission levels to government mandated standards while providing excellent operati
52. f SJ 08 28 to EPM Engine Wiring Diagram 3 of 5 08 29 to EPM Engine Wiring Diagram 4 5 7 08 30 to EPM Engine Wiring Diagram 5 5 08 31 Engine Component Locator View 08 32 Connector End VIews xen er pe ea UN ea Pb uttter eri ULM 08 33 EPM Connector C2 eee dette e nr een e Re le 08 33 EPM G3 E MER 08 34 2 Gray iet risen be ta e pen pee Ht Cup ap 08 35 EPM Connector tet teet PUR 08 36 EPM Connector CIM itt edem em e eri e P dedere uds 08 37 Actuator Pigtall to Actuator ae eka aia S ec tad 08 38 Drive By Wire Harness Connector 2U1L 12B476 AA 08 39 EPM IPM Foot Pedal Connector 08 40 ICM Body Side Harness 14324 cuins 08 41 08 1 TSG 416 ENGINE CONTROLS PRELIMINARY Subject Page Connector End VISWS u Men ede dete ate aed eee are 08 33 to EPM Engine Harness Connector 08 42 to EPM Engine Harness Connector 2 7 08 43 ECM to EPM Engine Harness Connector 08 44 to EPM Engine Harness Connector 08 4
53. gine control module ECM by using either the MIL or an IBM compatible personal computer or hand held Palm Pilot using the optional serial interface available Refer to Equipment Setup for information about using a personal computer to assist with unit diagnosis DTC s can be retrieved by shorting the Self Test Input STI connector to ground The STI circuit is a white purple wire exiting pin 3 of the 42 pin connector The STI white purple wire branches off to terminal A of the 4 pin diagnostic connector If no DTC is stored with key on engine off KOEO a DTC 123 is flashed indicating that all systems are OK During key on engine running KOER operation with no DTCs stored the MIL is not illuminated If during KOER operation a DTC is stored the MIL will illuminate and remain on steady if the code is active 08 52 TSG 416 ENGINE CONTROLS PRELIMINARY MIL Bulb Test The MIL bulb test occurs KOEO with the STI connector not grounded The ML bulb will stay on and remain on if no DTCs are present If DTCs are present except DTC 123 the MIL bulb will blink If the MIL bulb does not illuminate when bulb test is performed access diagnostic software and view the fault indicator on screen If the screen fault indicator is lilluminated and the MIL light is not inspect the bulb and replace it if damaged If bulb is OK or does not illuminate after replacement refer to MIL circuit test procedure Once MIL bulb illumination has bee
54. gnal 7 361 BK IVS Ground 8 151 GY WH FPP1 9 359 GY RD Analog Return 10 351 BN WH 5V Reference 08 39 EPM IPM Foot Pedal Connector C5 TSG 416 ENGINE CONTROLS PRELIMINARY Pin Circuit Circuit Function 1 Not Used 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 307 BK YL Idle Validation Switch Input 7 361 RD 57 BK Ground 8 151 LB BK Drive By Wire Signal Input 9 359 GY RD Drive By Wire Signal Return 10 351 BR WH VREF 5 Volts 08 40 ICM Body Side Harness 14324 TSG 416 ENGINE CONTROLS PRELIMINARY Pin Circuit Circuit Function A YL BK Fuel Select 2 Input B PK LB Fault Shutdown Line LB RD Engine Run Indicator D OG LG Tachometer Output E RD LB Starter Lockout Relay Input F XXX RD LB Starter Lockout Relay Output G Not used H XXX OG Aux IN J XXX RD LG 12 Volt Switched Ignition Input K XXX BR WH Fuel Select 1 Input 08 41 TSG 416 ENGINE CONTROLS PRELIMINARY ECM to EPM Engine Harness Connector C2F Y X WT S R PN ML Pin Circuit Circuit Function L1 198 DG OG Auxillary input L2 Not used L3 342 LG PK Starter lockout M1 107 PK Data link M2 914 TN OG RS 485 M3 Not used N1 Not used N2 915 PK LB RS 485 N3 Not used P1 Not used P2 242 DG Fuel Lockoff P3
55. he Fault_Cfg screen The Fault configuration screen will show Fault Shutdown Configuration Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on 08 65 TSG 416 ENGINE CONTROLS PRELIMINARY Visual Inspection Perform a careful visual and physical engine inspection before performing any diagnostic procedure Perform all necessary repairs before proceeding with additional diagnosis this can often lead to repairing a problem without performing unnecessary steps Use the following guidelines when performing a visual physical inspection check Inspect engine for modifications or aftermarket equipment that can contribute to the symptom verify that all electrical and mechanical loads or accessory equipment is OFF or disconnected before performing diagnosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect PCV valve for proper installation and operation Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires and corrosion Verify that harness grounds are clean and tight
56. he Diagnostic Trouble Codes stored in the memory of the FORD system EPM using a diagnostic jumper and the Malfunction Indicator Lamp With the key off connect the diagnostic jumper to the FORD system diagnostic connector located near the EPM Turn the ignition on but do not start the vehicle Switch the self test input to ground pin 18 of the body side harness The Malfunction Indicator Lamp MIL will begin to flash Diagnostic Connector The MIL displays three digit codes by flashing the first digit pausing then flashing the second digit pausing and then flashing the third digit There will be a long pause between codes For example a code 143 would be one flash followed by four flashes followed by three flashes The MIL will first display a 123 three times Code 123 indicates that the EPM based diagnostic MIL routine is now active Then any Diagnostic Trouble Codes DTC s stored in memory will flash three times each The MIL will then start over with the code 123 If the vehicle is started while the diagnostic jumper is in place the MIL will flash rapidly Diagnostic Trouble Codes may be cleared from the FORD system EPM s memory by moving the ignition key to the OFF position and removing the FORD system battery fuse for at least 15 seconds NOTE This will erase all of the memory in the computer including the adaptive learn Malfunction Indicator Lamp MIL DTC Retrieval Procedure NOTE DTC s can be retrived from the en
57. he most common methods of charging are by friction and induction An example of charging by friction is a person sliding across a seat Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity Static charges can cause damage therefore it is important to use care when handling and testing electronic components CAUTION To prevent possible electrostatic dis charge damage follow these guidelines Do not touch the EPM ICM connector pins or soldered components on the EPM ICM board Do not open the replacement part package until the part is ready to be installed Before removing the part from the package ground the package to a known good ground on the equipment e Ifthe part has been handled while sliding across seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part 08 11 TSG 416 ENGINE CONTROLS PRELIMINARY Diagrams and Schematics Symbols doo BuneeH JexeoJq NI esnj 10 eunsseJd Burjeeu Jo 205189 BE jueuoduuoo o 1olo
58. ignores the signal from the Heated Oxygen Sensor HO2S It uses a pre programmed routine to calculate the air fuel ratio based on inputs from the TP ECT MAP amp CKP sensors The system remains in open loop until the following conditions are met The ECT has reached 95 F 35 C 15 seconds has elapsed since starting the engine After these conditions are met the engine is said to be operating in closed loop In closed loop the EPM continuously adjusts the air fuel ratio by responding to signals from the HO2S except at wide open throttle When the 25 reports a lean condition low sensor signal voltage the EPM responds by increasing the on time of the fuel injectors thus enriching the mixture When the HO2S reports a rich condition high sensor signal voltage the EPM responds by reducing the on time of the fuel injectors thus leaning out the mixture Adaptive Learn Adaptive Learn is a fuel correction coefficient that is derived from the closed loop correction and is stored in the EPM s memory The normal purpose of the Adaptive Learn is to compensate fuel flow for the following Fuel composition variance Engine wear Component variation Component degradation The EPM system will operate in closed loop plus adaptive learn when the ECT reaches 165 F NOTE The adaptive learn coefficient will get erased if battery power falls below 9 5 volts EPM ICM Service Precautions
59. ing engine problems The FORD diagnostic software includes real time plotting and real time logging capabilities These features enhance the ability to diagnose and repair possible problems with the FORD system Both plotting and logging allows the user to record in real time any variable that can be seen in the FPP_Dis software In order to record variables the FPP_Dis software must be Connected to the EPM Plotting To plot a variable you must first the variable To do this use the mouse to right click on the variable The variable will highlight in green to let you know it is TAGGED Next press the P key or click the Plot Log button and then click the Plot Tags button to invoke the plotting feature This begins the plot function and you can observe the plotted variables The plot sweeps from right to left To stop the plotting feature simply click the STOP button To restart the plotter click on the START button The maximum number of variables that can be plotted at one time is 10 The range of the selected variables will be shown on the Y axis and the time will be shown on the x axis You may change the desired time interval and sample interval for the plot by stopping the plot and typing in a new intervals The plot can be saved to the PC by stopping the plot and clicking the SAVE button When saving a plot you will have to type in a filename Plot files can later be viewed with
60. licon Capacitive Absolute Pressure SCAP sensor with a maximum operating temperature of 100 C The output is a 50 duty cycle wave form whose frequency is proportional to the pressure input 08 8 TSG 416 ENGINE CONTROLS PRELIMINARY Throttle Position TP Sensor Electronic Actuator The Throttle Position TP Sensor is a dual track rotary potentiometer that uses a variable resistive element which is packaged inside a plastic housing The resistive element varies linearly and is directly proportional to the throttle plate angle The EPM applies reference voltage and ground to the sensor and monitors the 5 ratio metric output voltage to determine precise throttle position The electronic actuator has two TP outputs that the EPM monitors The Electronic Actuator consists of a throttle body an electronically actuated throttle plate and a built in throttle position TP Sensor The Electronic Actuator also acts as an idle air control IAC valve Changes in engine load are detected by the EPM by comparing manifold absolute pressure MAP with throttle position When the EPM detects a change in engine load it can adjust idle speed by changing the PWM signal to the actuator As the throttle valve opens the output increases so that at wide open throttle WOT the output voltage should be above 4 volts The EPM calculates fuel delivery based on throttle valve angle operator demand A hard failure in th
61. lt r lt SYAB S lt 2 603 lt 2 30 39 CRANKS 33 350 GY 8 CRANK lt gt 3 282 DB O 18 lt 35 452 GY R 18 ore 68 OG 2 VBAT e veat lt TWIST 10 360 DEG TURNS FOOT MIN FULL LENGTH 282 08 018 452 GY R 18 1FIT 14A464 AA CONN 97BG 14474 AEA TERM XW43 14603 AA SEAL CAMSHAFT POSITION SENSOR 10A PED_12092677 HOLDER PED 12033731 COVER PED 12033997 TERMINAL CONNECTOR AMP 776164 4 TERMINAL AMP 770520 3 n GREY SPKPWRGROUND lt e 7 851 YR gt 3 852 Y W 18 cons gt cons 5 5 CLS gt 2 w ips STARTER LOCKOUT gt 22 2 FUEL LOCKOFF S EDEN FUEL gt 5 RELAY CONTROL Test 31 351 Y W 18 52 28 LB BK 18 DE sas 31T GY 0 18 eS BRAKE SWITCH OLPRESSURE lt 23 DG W 18 TAH gt a ese PK LG 18 ML CE 238 DG Y 18 FUEL PUMP MON lt 5 AUX OUT 14 72 Y BK 18 FUEL SELECT lt 15 148 Y R 18 AUX ANA PU lt 16 306 T LB 18 amu i us 307 BK Y 18 GOV 2 11 ROAD SPEED 5 ROAD SPEED gt
62. lt button and it allows you to clear all faults by clicking on the Click All Faults button NOTE Record faults before clearing them This will aid in diagnosis Hear is an example of a DTC Dialogue Box Historic Fault Information DTC 315 Injector 3 n firing order circuit loop open or low side shorted to ground Snap Shot Data The Snap Shot Data is a listing of specific engine system variables These variables are recorded by the EPM at the instant the DTC sets By clicking on the View Snap Shot Data button a new window will pop up and you will be able to view these variables Here is an example of a Snap Shot Data window Snap Shot Date Gasoline 14 1072 08 57 TSG 416 ENGINE CONTROLS PRELIMINARY Flight Data Recorder The Flight Data Recorder is also a listing of specific engine system variables These variables are recorded by the EPM for an interval of 10 seconds The 10 second interval includes 8 seconds before the DTC sets and 2 seconds after the DTC sets By clicking on the View Flight Data Recorder Data button a new window will pop up and you will be able to view these variables Here is an example of a flight Data Recorder Data window The FAULTS screen shows the following Fault Access System States DBW Variables Closed Loop Control Digital Input Voltages Diagnostic Modes Historic Faults Active Faults Use the keys at the upper left corner
63. n its control algorithms All of the FORD system diagnostic self tests run continuously during normal engine operation The Diagnostic Trouble Codes can be read by using either the Malfunction Indicator Lamp MIL or a Laptop computer Refer to Using a Laptop Computer to Diagnose the FORD System and Using a Diagnostic Jumper to Diagnose the FORD System located in this section Diagnostic Trouble Codes can be cleared from memory with a laptop computer or by turning the ignition key to the OFF position and removing the FORD system main power fuse F3 for 15 seconds If more than one DTC is detected begin with the lowest number DTC and diagnose each problem to correction unless directed to do otherwise by the fault tree The DTC s are numbered in order of importance Having DTC 112 and DTC 122 both concerning the oxygen sensor is possible By repairing DTC 112 first the problem causing the DTC 122 may also be corrected On Board Diagnostics EPM The diagnostic tests and circuit charts are designed to assist the technician to locate a faulty circuit or component through a process of logical decisions The tests and charts are prepared with the requirement that the engine functioned correctly at the time of assembly and that there were not multiple faults present There is a continuous self diagnosis on certain control functions This diagnostic capability is complimented by the diagnostic procedures contained in this section The la
64. n verified or established DTCs can be extracted from the MIL as follows KOEO short the STI circuit to a known good ground There will be a 5 second delay before DTCs begin flashing When extracting DTCs via the MIL the following apply The flashing MIL is for 0 4 second and off for 0 4 second e The MIL is off for 1 2 seconds between digits of three digit DTCs The MIL is off for 2 4 seconds between DTCs Each DTC repeats 3 times before the next stored DTC begins flashing Upto 6 DTCs can be stored Once all stored DTCs are flashed the process repeats with the first stored DTC DTCs are flashed in the order in which they were set Once the DTC s is retrieved refer to the appropriate DTC chart for explanation of what caused the DTC to set Perform component and circuit test as required to conduct repair Diagnosis Using a Personal Computer Equipment Requirements You will need a laptop computer with a serial port or personal digital assistant PDA and a communications cable interface cable kit Kit for laptop part PN 2U1L 6K947 AA Kit for PDA or laptop part PN 2U1E 6K947 AA The required software is available from your local Ford Power Products distributor or you can download it from web fpp ford com Laptop Requirements Serial port 800 x 600 dpi screen Windows 95 or newer operating system e No speed minimum 32MB of RAM PDA Requirements Palm O
65. nguage for communicating the source of the malfunction is a system of diagnostic trouble codes When a malfunction is detected by the Engine Performance Module EPM a Diagnostic Trouble Code DTC is set and the Malfunction Indicator MIL lamp will be illuminated refer to MIL DTC Retrieval Procedure for process description Refer to Diagnosis Using a Personal Computer on page 53 or Palm Pilot Diagnosis for information regarding performing EPM and engine control system diagnosis Engine Performance Module EPM Limp Home Mode Strategy The EPM has four settings for limp home mode Depending on what Diagnostic Trouble Code DTC is set one or more of the limp home modes will be in effect The four limp home modes are as follows Power Derate 1 The actuator is limited to a maximum opening of 50 If Power Derate 1 is active it will remain active until the active DTC goes away The following DTC s will cause Power Derate 1 to take affect DTC 223 CHT ECT higher than expected 1 CHT ECT is greater than 240 F e DTC 213 IAT higher than expected 1 IAT is greater than 200 DTC 253 Knock sensor open 1 6L and 4 2L only DTC 254 Excessive knock signal 1 6L and 4 2L only DTC 511 FPP1 high voltage e DTC 512 FPP1 low voltage DTC 521 FPP2 high voltage DTC 522 FPP2 low voltage e DTC 545 IVS Brake interlock failure Power Derate 2 The actuator is limited
66. nsor Sensor Sender Pressure MAP Temperature Manifold Absolute Fuel Injectors Intake Air Temperature IAT Sensor 08 32 Coil Pack Ignition Power Distribution Engine Performance Module EPM Sensor Regulator Fuel Pressure Temperature ECT Sensor Crankshaft Position CKP Data Link Connector DLC Engine Coolant TSG 416 ENGINE CONTROLS PRELIMINARY Connector End Views EPM Connector C2 Gray Pin Circuit Circuit Function 1 850 YE BK Coil 1 ground output 2 851 YE RD Coil 2 ground output 3 Not used 4 570 BK WH Power ground 5 71 OG LG Aux out 1 6 511 LG RD Brake switch input 7 253 DG WH Oil pressure input 8 11 TN YL Tachometer output 9 926A LB OR Enable fuel pump relay 10 238 DG YL Fused fuel pump 12V monitor 11 169 LG BK Vehicle Speed Sensor VSS 12 172 LB RD Vehicle Speed Sensor VSS 13 Not used 14 72 YL BK Fuel select 15 148 YL RD Aux analog pull up circuit 2 16 306 TN LB Gov select 1 17 307 BK YL Gov select 2 18 662 DG PK Can bus positive 19 459 OR LG Can bus negative 20 642 DG OR RS 485 positive 21 461 OR RS 485 negative 22 342 LG VT Starter lockout 23 242 DG Fuel lockoff 24 Not used 25 Not used 26 77
67. ntermittent MIL Conditions that are only present from time to time are called intermittents To resolve intermittents perform the following steps 1 Evaluate the history of DTC s observed with this particular engine 2 Evaluate the symptoms and conditions described by the customer 3 Use strategy based diagnosis especially where it relates to the elimination of bad connectors and wiring 4 When using a personal computer with Ford Power Products software data capturing capabilities are available that can assist in detecting intermittents Contact the Ford Power Products Customer Service Center Technical Support Hotline 1 800 521 0370 for more information When a malfunction occurs for DTC s with the limp home mode feature a DTC will be set the MIL will illuminate and the corrective action limp home mode or default values will be initiated This will continue as long as the engine runs without being shut off If the malfunction occurs and then corrects itself while the engine is continuously running the DTC will be stored the MIL will remain illuminated and the engine will continue to run in the limp home mode until it is shut off and restarted Once restarted if the malfunction does not recur the MIL stays on and engine will resume running in a normal operating mode Using the ECM to EPM Jumper Harness to Diagnose the FORD System If you do not have access to a laptop computer it is still possible to access t
68. on and fuel efficiency The EPM monitors numerous engine functions via electronic sensors such as the throttle position TP sensor and the heated oxygen sensor 025 EPM Inputs operating conditions read Engine Coolant Temperature e Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery Voltage Throttle Position Electronic Actuator Fuel Pump Voltage Intake Air Temperature Camshaft Position EPM Outputs systems controlled Fuel control Electronic Throttle Control Electric Fuel Pump Diagnostics Malfunction Indicator Lamp check engine lamp Diagnostics Data Link Connector DLC 08 4 TSG 416 ENGINE CONTROLS PRELIMINARY Crankshaft Position CKP Sensor The Crankshaft Position CKP Sensor provides a signal used by the Engine Performance Module EPM to calculate the ignition sequence The sensor initiates the reference pulses which the EPM uses to calculate RPM and crankshaft position 9 Camshaft Position CMP Sensor The Camshaft Position CMP Sensor uses a variable reluctor sensor to detect camshaft position The CMP signal is created as piston 1 is a pre determined number of degrees after top dead center on the power stroke The Camshaft Position CMP Sensor sends a CMP signal to the EPM The EPM uses this signal as a sync pulse to trigger the injectors in the proper sequence The EPM uses the CMP signal to indicate th
69. r Mini inimum Maximum The Intake Air Temperature IAT Sensor is a thermistor Resistance Resistance which changes its resistance based on the temperature Temp Temp F ohms ohms of air entering the engine Low temperature produces a high resistance of 100 000 ohms at 40 C 40 F High 2 2 temperature causes low resistance of 70 ohms at 20 04 253 035 289 365 130 C 266 F The EPM supplies a 5 volt signal to the sensor through a resistor in the EPM and monitors the 0 132 98 001 1017193 signal voltage The signal voltage will be high when the 20 68 34 925 39 655 incoming air is cold and low when the incoming air is hot By measuring the voltage the EPM calculates the 40 104 15 148 17 150 incoming air temperature The IAT sensor signal is used to adjust spark timing according to the incoming m aes 5061 air density 100 212 1 948 2 190 120 248 1 107 1 245 The diagnostic software can be used to display the temperature of the air entering the engine The temperature should read close to the ambient air temperature when the engine is cold and rise as engine compartment temperature increases If the engine has not been run for several hours overnight the IAT sensor temperature and engine coolant temperature should read close to each other A failure in the IAT sensor circuit will set DTC 211 or DTC 212 Specifications Range of Measurement 40 C 40
70. re and a second fixed or variable input based on a neutral parking brake signal With the EPM system a laptop and a communications cable diagnosis becomes simpler The technician can either view engine data with a real time graphing program or store that data into a numeric data file Every time a fault is set the laptop will give you detailed information about the fault including when it happened ifthe fault still exists alist of essential engine data from the time of the fault It can also display a 10 second graph of critical engine data from 8 seconds before the fault occurred to two seconds after And if you only want to view engine parameters and fault codes all you need is a Personal Digital Assistant PDA and our easy to load software and a communications cable With many OEMs using control modules to control their machinery the new EPM has the ability to communicate engine data to and receive commands from other control modules through a Controller Area Network CAN link with messages written in the J1939 protocol This allows large amounts of data to move throughout the machine through only two wires and can be used to run some module based gauge packages The EPM also carries auxiliary features that can be programmed to control OEM devices allowing the OEM to eliminate components from their machinery The EPM is also equipped with multiple safety and protection devices that protect the user and
71. t screen will be the BASE SPARK screen The BASE SPARK screen will show Base Spark Advance CADBTDC at a given RPM and manifold pressure Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on FUEL1 Spark Screen If you toggled to the right the next screen will be the FUEL1 SPRK screen 08 63 TSG 416 ENGINE CONTROLS PRELIMINARY The FUEL1 SPRK screen will show Fuel Option 1 Spark Advance CADBTDC at a given RPM and manifold pressure Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on FUEL2 SPRK Screen If you toggled to the right the next screen will be the FUEL2 SPRK screen The Fuel2 Sprk screen will show Fuel Option 2 Spark Advance CADBTDC at a given RPM and manifold pressure Use the keys at the upper left corner or the page command to toggle the six main screens MAIN PLOTS BASE SPARK FUEL1 SPARK FUEL 2 SPARK amp FAULT CONFIGURATION NOTE F9 key will toggle to the last screen you were on FAULT CONFIGURATION Screen 08 64 TSG 416 ENGINE CONTROLS PRELIMINARY If you toggled to the right the next screen will be t
72. tle command will lock into the position it was in when the test mode was entered If the Spark System Test mode is selected with the engine running above 1000 RPM the throttle will continue to operate mormally Disabling Ignition Ouputs To disable the ignition system for an individual cylinder use the mouse to highlight the Spark Kill button and select the desired coil The spark output can be re enabled by using the mouse to highlight the Spark Kill button and selecting Normal If the engine is running below 1000 RPM the spark output will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the spark output will stay disabled for 5 seconds and then re set This test mode has a timeout of 10 minutes Record the rpm drop related to each spark output disabled The Spark outputs are arranged in the order which the engine fires not by cylinder number 08 60 TSG 416 ENGINE CONTROLS PRELIMINARY Injector Test The Injector Kill mode is used to disable individual fuel injectors If the Injector Kill mode is selected with the engine running below 1000 RPM the minimum throttle command will lock into the position it was in when the test mode was entered If the Injector Kill mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally Disabling Injectors To disable an injector use the mouse to select the desired injector The word
73. tor 5 2 Gray 581 01 60 Ciruit Description Black Grey 001 C3 C2 CINCH COIL 2 2 Y1 COIL 3 3 Y2 STARTER LOCKOUT 22 L3 FUEL LOCKOFF 23 P2 FUEL PUMP 9 P3 TPS1 30 TPS2 31 DBW 28 DBW 29 OIL PRESSURE 7 J3 MIL 27 R3 FUEL PUMP MON 10 F3 FUEL SELECT 14 K3 AUX ANA PU2 15 D3 GOV SELECT 1 16 J2 GOV SELECT 2 17 K2 GASEOUS TRIM 26 R2 RS 485 20 M2 RS 485 21 N2 RS 232 TX 34 RS 232 RX 35 SELF TEST H3 08 48 TSG 416 ENGINE CONTROLS PRELIMINARY DIAGNOSIS EPM Diagnostic Overview FORD Diagnostic Trouble Codes are set when the FORD system EPM runs a diagnostic self test and the test fails When a DTC is set the FORD system EPM will illuminate the Malfunction Indicator Lamp MIL on the instrument panel and save the code in memory The FORD system EPM will continue to run the self test unless the DTC is an oxygen sensor lean oxygen sensor rich or an EPM related DTC If the system continues to fail the test the lamp will stay illuminated and the DTC is current ACTIVE All DTC s are stored as historical faults until they are cleared All DTC s except the EPM related DTC s will automatically clear from memory if the DTC does not reset within 50 consecutive engine run cycles While a Diagnostic Trouble Code is current for a sensor the FORD system EPM may assign a default limp home value and use that value i
74. x analog pull down circuit 33 359 GY RD Auxilary signal return 34 570 BK WH Power ground 35 169 LG BK Vehicle Speed Sensor 36 172 LB RD Vehicle Speed Sensor 37 150 DG WH Aux analog pull up circuit 38 18 OR YL Exhaust Gas Recirculation EGR input 39 32 RD LB 12 Volts in start Auto crank only 40 352 BN LG Pulse Width Modulation PWM output 41 360 BN PK Exhaust Gas Recirculation EGR output 42 Not used 08 36 TSG 416 ENGINE CONTROLS PRELIMINARY EPM Connector C1M Pin Circuit Circuit Function 1 16 RD LG Ignition voltage 2 11 TN YL Tachometer output 3 461 OG RS 485 4 511 LG RD Brake switch input 5 787A PK BK To fuel pump 12 volt output 6 658 PK LG Malfunction Indicator Light MIL output 7 72 YL BK Fuel select input 8 Not used 9 37 YL Battery voltage input 10 148 YL RD Auxiliary analog pull up circuit 2 11 DG OG RS 485 12 114 LB YL Secondary throttle control 0 5 volt variable input FPP2 13 32 RD LB Starter Solenoid Output 14 151 LB BK Primary throttle control 0 5 volt variable input FPP1 15 32A RD LB 12 volts in start non auto crank system 16 39 RD WH Water temperature output 17 Not used 18 458 OG BK RS 232 Self Test Input 19 Not Used 20 669 DG WH RS 232 21 71 OG LG Aux Out 1 22 Not used 23 307 BK YL Governor select 2 24 306 TN LB Governor

TSG-416 Service Manual - Coulson Compression & Measurement

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TSG-416 Service Manual - Coulson Compression &amp; Measurement

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TSG-416 Service Manual - Coulson Compression & Measurement