Ford training section3 symptom charts
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SECTION 3
Symptom Charts
Contents
QT:
Powertrain Control Module (PCM) Quick Test ......................3-1
No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart Index ..................................................................................3-2
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts ..........................................................................................3-5
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-1
Table of Contents
Powertrain Control Module (PCM)
Quick Test
QT1
Test Step
CARRY OUT THE PCM QUICK TEST
Note: For vehicles indicating not ready for inspection
maintenance (I/M) testing, refer to the Owner Literature,
Readiness For Inspection/Maintenance (I/M) Testing to
complete the system readiness. If an I/M testing system
readiness concern is still present, GO to Pinpoint Test QC.
Note: If the vehicle was brought in with an emission
compliance concern, GO to Pinpoint Test EM.
Note: For applications that use a stand-alone transmission
control module (TCM), the PCM does not output TCM
related diagnostic trouble codes (DTCs). Refer to the
Workshop Manual Section 307-01, Automatic
Transaxle/Transmission, diagnostic strategy to continue
diagnosis.
Note: If unable to access the PCM DTCs, or a scan tool
communication concern exists, GO to Pinpoint Test QA in
Section 5. For additional information on retrieving malfunction
indicator lamp (MIL) and non-MIL DTCs, refer to Section 2,
Quick Test Description for the Continuous Memory Self-Test.
• Complete the preliminary checks looking for obvious
concerns that may relate to the symptom. Check for the
following items:
— fuses
— electrical circuits and connectors
— vacuum lines (leaks, routing)
— air intake system (leaks, restrictions)
— fuel quality (octane, contamination, winter/summer
blend)
— cooling system (engine operating at correct
temperature)
• Access any related On-line Automotive Service
Information System (OASIS) or Technical Service Bulletin
(TSB) information (if available).
• Carry out the PCM self-test to access any DTCs. Record
any key on engine off (KOEO), key on engine running
(KOER) (if the engine runs) and continuous memory (MIL
and non-MIL) DTCs.
• Are any DTCs present?
QT
Results / Action to Take
Yes
GO to Section 4, Diagnostic
Trouble Code (DTC) Charts and
Descriptions for direction to repair
DTCs after noting the following:
DIAGNOSE the DTCs in the
following order (begin diagnosis
with the first DTC output in that
mode and diagnose any circuit
related DTCs first). For multiple
circuit DTCs that are set as a result
of a concern with more than one
component, REFER to the Wiring
Diagrams Manual Electronic Engine
Controls Cell and identify the
common cause such as SIGRTN,
VREF, or VPWR. CONTINUE DTC
diagnosis by referring to the
appropriately identified pinpoint
test.
(1) Any KOEO self-test
DTCs
(2) Any KOER self-test
DTCs
(3) Any continuous memory
self-test DTCs. Retrieve
any available freeze
frame data and disregard
any identical/related
continuous DTCs already
repaired.
No
GO to No Diagnostic Trouble
Codes (DTCs) Present Symptom
Chart Index for direction to the
correct symptom chart in No
Diagnostic Trouble Codes (DTCs)
Present Symptom Charts.
If the symptom is not listed,
REFER to the applicable Workshop
Manual Section to continue
diagnosis.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-2
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart Index
OASIS
Number
Chart
Number
Page
Number
Hard Start/Long Crank/Erratic
Start/Erratic Crank
602300
Chart Number:
2
8
No crank
601300
Chart Number:
22
21
No start (engine cranks)
603300
Chart Number:
3
8
Slow return to idle
617400
Chart Number:
4
9
Rolling idle
618400
Chart Number:
1
5
Fast idle
619400
Chart Number:
5
9
Low/Slow idle
607400
Chart Number:
6
10
Idle/Acceleration/Cruise
607x00
Chart Number:
1
5
Deceleration
607700
Chart Number:
6
10
Stall after start
607000
Chart Number:
1
5
Runs Rough
608x00
Chart Number:
1
5
Misses
609x00
Chart Number:
1
5
Buck/Jerk
610x00
Chart Number:
1
5
Hesitation/Stumble
611x00
Chart Number:
1
5
Surge
612x00
Chart Number:
1
5
Backfires
613x00
Chart Number:
7
11
Lack/Loss of Power
614x00
Chart Number:
8
11
Spark Knock
615x00
Chart Number:
9
13
System / Symptom
Driveability
Starting Concerns
Unique Idle Concerns
Driveability - Performance While Driving Concerns
Stalls/Quits
Note: OASIS identifiers (the x means any number (1-9) can be used) xxx4xx equals during idle, xxx5xx
equals during acceleration, xxx6xx equals during cruise, xxx7xx equals during deceleration.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-3
No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart Index
OASIS
Number
Chart
Number
Page
Number
Diesels/Runs On
621000
Chart Number:
5
9
Poor Fuel Economy
622000
Chart Number:
10
14
Emissions Compliance
623000
Chart Number:
11
16
Malfunction indicator lamp (MIL)
698298
Chart Number:
12
16
Transmission control indicator
lamp (TCIL)
698298
Chart Number:
12
16
Power take off (PTO)
507000
Chart Number:
12
16
Temperature warning indicator
or gauge (for vehicles equipped
with a cylinder head
temperature (CHT) sensor only)
206000
Chart Number:
12
16
Check fuel cap indicator
206000
Chart Number:
12
16
Powertrain malfunction indicator
(wrench)
698298
Chart Number:
12
16
Tachometer inoperative
204000
Chart Number:
14
17
Speedometer/odometer
inoperative
204000
Chart Number:
14
17
Boost gauge indicates higher
than normal boost
204000
Chart Number:
14
17
Fuel gauge inoperative
204000
Chart Number:
14
17
High oil consumption
401000
Chart Number:
15
18
Leaks
401000
Chart Number:
15
18
Electric cooling fan(s) does not
operate (low, high or variable
speed)
402000
Chart Number:
16
18
Cooling fan clutch does not
operate
402000
Chart Number:
16
18
Electric cooling fan(s) always
runs
402000
Chart Number:
17
18
System / Symptom
Additional Driveability Concerns
Electrical
Warning Indicators
Instrumentation
Engine
Oil System Concerns
Cooling System Concerns
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-4
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart Index
OASIS
Number
Chart
Number
Page
Number
Visible smoke
403000
Chart Number:
18
19
Odor (sulfur or rotten egg smell)
403000
Chart Number:
21
21
Odor, engine compartment
404000
Chart Number:
19
20
497000
Chart Number:
20
20
Upshift
501000
Chart Number:
13
17
Downshift
502000
Chart Number:
13
17
Engagement
503000
Chart Number:
13
17
Not working correctly
507000
Chart Number:
12
16
System / Symptom
Engine (Continued)
Exhaust System Concerns
Fuel System Concerns
Engine Noise (under hood)
Driveline
Automatic Transmission
(A/T) Shift Concerns
Power Take Off (PTO)
PTO Concerns
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-5
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
Chart 1
— Stalls/Quits: Idle, Acceleration, Cruise, Stall After Start
— Runs Rough
— Misses
— Buck/Jerk
— Hesitation/Stumble
— Surge
— Unique Idle Concerns: Rolling Idle
Note: For some vehicle applications, the engine may stall if left running while refueling. Advise
the customer to turn the engine off while refueling to avoid contamination or damage to the
evaporative emission (EVAP) system.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Check the following
parameter identifiers (PIDs):
— DPFEGR (if equipped)
(hot idle value within
0.15 volt of the ignition
ON, engine OFF value)
— LONGFT1/LONGFT2
(value between -20 and
+20%)
— VPWR (value between
10.5 and 17.0 volts, and
within 0.5 volt of battery
voltage)
DPFEGR PID value not within 0.15 volt of ignition ON, engine OFF value:
For vehicles equipped with an exhaust gas recirculation system module (ESM),
GO to Pinpoint Test HH.
For all others, GO to Pinpoint Test HE.
LONGFT1/LONGFT2 value low (-):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
rich.
LONGFT1/LONGFT2 value high (+):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
lean.
VPWR not between 10.5 and 17.0 volts:
REFER to the Workshop Manual Section 414-00, Charging System and carry out the
Inspection and Verification to continue diagnosis.
VPWR between 10.5 and 17.0 volts, but not within 0.5 volt of battery voltage:
CHECK the B+ voltage to the powertrain control module (PCM) power relay. CHECK
the VPWR circuit between the PCM and the PCM power relay. CHECK the PWR
GND circuits.
For vehicles that run rough
at idle:
Check the INJx F PIDs
(the ‘‘x’’ indicates the
injector number) with the
ignition ON, engine running.
There is 1 INJx F PID for
each engine cylinder. All
INJx F PIDs must indicate
no fault (or NO).
The INJx F PID(s) indicate a fault (an injector circuit concern is indicated). For Flex
GTDI 3.5L, MKS 3.5L, MKT 3.5L and Taurus GTDI 3.5L vehicles, GO to Pinpoint Test
DI. For all others, GO to Pinpoint Test KG.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-6
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Mass Air Flow (MAF)
Sensor
GO to Pinpoint Test DC.
Manifold Absolute Pressure
(MAP) Sensor (Flex GTDI
3.5L, MKS 3.5L, MKT 3.5L
and Taurus GTDI 3.5L)
GO to Pinpoint Test DN.
Secondary Ignition System
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Fuel Delivery System
GO to Pinpoint Test HC.
Exhaust System
GO to Pinpoint Test HF.
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
EVAP System
For Fiesta, GO to Pinpoint Test HZ. For all others, GO to Pinpoint Test HX.
Charging System
Visual. REFER to the Workshop Manual Section 414-00, Charging System and carry
out the Inspection and Verification to continue diagnosis.
Universal Heated Oxygen
Sensor (HO2S) (Edge,
Escape, E-Series 4.6L,
E-Series 5.4L, Expedition,
Fusion 2.5L, Fusion 3.0L,
F-150, Flex, F-Series Super
Duty, Mariner, Milan, MKS,
MKT, MKX, Mustang,
Navigator, and Taurus)
GO to Pinpoint Test DZ.
Automatic Transmission
REFER to the Workshop Manual Section 307-01, Automatic Transaxle/Transmission,
Diagnosis By Symptom to continue diagnosis.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Intake Air System
GO to Pinpoint Test HU.
Additional Testing
GO to Pinpoint Test Z.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-7
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
Additional Checks:
— Some vehicles have a
TQ_CNTRL PID
available. Check this PID
to determine if the PCM
is reducing torque, and if
so, why the torque is
being reduced. As a PID
display example; 0
equals no torque
reduction requested, 1
equals torque truncation,
which cuts fuel to protect
when line pressure falls
to minimum limit and 2
equals traction control
event, which cuts
fuel/spark for traction
control.
— Correct PCM vehicle
identification (VID) block
information. Refer to
Section 2, Flash
Electrically Erasable
Programmable Read
Only Memory (EEPROM)
to carry out the Making
Changes to the VID
Block procedure.
— Be aware of engine
RPM/speed limiting
functions of the PCM
(look for incorrect high
vehicle speed signal
from ABS, VSS, or
OSS).
— Verify the fuel filler cap
is correctly tightened or
the capless fuel tank
filler pipe is correctly
sealed and not physically
damaged.
— Drivelines
— Manual
transmission/clutch
— Charging system
— Traction control system
(if equipped)
— A/C system (for surge
with A/C on)
— Speed control system
(for surge with speed
control on)
REFERENCE (Section 5 Pinpoint Test unless noted)
REFER to the applicable Workshop Manual section.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-8
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
Chart 2
— Starting Concerns: Hard Start/Long Crank/Erratic Start/Erratic Crank
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Battery Condition and
Current Draw
REFER to the Workshop Manual Section 414-00, Charging System and carry out the
Inspection and Verification to continue diagnosis.
Secondary Ignition System
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Fuel Delivery System
GO to Pinpoint Test HC.
Exhaust System
GO to Pinpoint Test HF.
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
EVAP System
For Fiesta, GO to Pinpoint Test HZ. For all others, GO to Pinpoint Test HX.
Intake Air System
GO to Pinpoint Test HU.
Starting System
REFER to the Workshop Manual Section 303-06, Starting System and diagnose the
engine cranks slowly symptom.
Mass Air Flow (MAF)
Sensor
GO to Pinpoint Test DC.
Additional Testing
GO to Pinpoint Test Z.
Additional Checks:
— For vehicles equipped
with two camshaft
position (CMP) sensors,
verify the CMP1 and
CMP2 circuits are not
shorted together.
Visual.
Chart 3
— Starting Concerns: No Start (Engine Cranks)
Note: An extended crank because of a no start may load the exhaust system with raw fuel,
damaging the catalytic converter after the engine starts.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Add-on Anti-Theft Devices
Visual. CHECK with the customer.
Fuel/Ignition
GO to Pinpoint Test A.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-9
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Intake Air System (Ranger).
If the engine will not start at
closed throttle, but will start
and run normally at part
throttle, check the IAC
valve.
GO to Pinpoint Test KE.
Exhaust System Restrictions
GO to Pinpoint Test HF.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Additional Testing
GO to Pinpoint Test Z.
Chart 4
— Unique Idle Concerns: Slow Return To Idle
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Vacuum Leaks, Throttle
Body
Visual.
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
Intake Air System Leaks
GO to Pinpoint Test HU.
Chart 5
— Unique Idle Concerns: Fast Idle
— Diesels/Runs On
Note: If the vehicle runs normally with the ignition in the OFF position, check for a damaged
ignition switch, an IGN START/RUN or ISP-R circuit short to voltage, or a VPWR circuit
short to voltage.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-10
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Base Engine
Check for air leaks,
including correct sealing of
intake manifold and
components/vacuum lines
attached to intake air (such
as the PCV, EGR or IAC
valve/vacuum lines).
Visual. REFER to the Workshop Manual Section 303-00, Engine System and carry
out the Inspection and Verification to continue diagnosis.
Verify the engine operates
at normal temperature.
Visual. REFER to the Workshop Manual Section 303-03, Engine Cooling or No
Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index, to diagnose any
cooling system concerns that are present.
Fast idle concerns (Ranger)
With the ignition ON, engine
OFF monitor the TP MODE
PID while wiggling the TP
sensor circuits. The TP
MODE PID can also be
monitored during vehicle
drive. With the throttle
closed, the TP MODE PID
must be C/T (closed
throttle).
TP MODE PID is not C/T with the throttle closed:
At vehicle start, the TPREL begins at about 1.25 volts and counts down to the lowest
TP voltage value seen since engine start. If the TP voltage value goes below the
normal range, then increases again, TPREL sets to the lower voltage. If the TP
voltage is about 0.04 volt greater than the TPREL value at closed throttle, the PCM
goes into part throttle mode.
MONITOR the TP voltage and TPREL PIDs for sudden changes while checking for
intermittent TP circuit/connector concerns. CHECK for loose or worn throttle plates. If
no concern is found, GO to Pinpoint Test Z.
Intake Air System Leaks
GO to Pinpoint Test HU.
Additional Testing
GO to Pinpoint Test Z.
Chart 6
— Unique Idle Concerns: Low/Slow Idle
— Stalls/Quits: Deceleration
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Verify the fuel filler cap is
correctly tightened or the
capless fuel tank filler pipe
is correctly sealed.
Visual.
Automatic Transmission
(stalls/quits on deceleration)
REFER to the Workshop Manual Section 307-01, Automatic Transaxle/Transmission
to diagnose the torque convertor operation concerns.
Fuel Delivery System
GO to Pinpoint Test HC.
Intake Air System
GO to Pinpoint Test HU.
Charging System
REFER to the Workshop Manual Section 414-00, Charging System and carry out the
Inspection and Verification to continue diagnosis.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-11
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Universal Heated Oxygen
Sensor (HO2S) (Edge,
Escape, E-Series 4.6L,
E-Series 5.4L, Expedition,
Fusion 2.5L, Fusion 3.0L,
F-150, Flex, F-Series Super
Duty, Mariner, Milan, MKS,
MKT, MKX, Mustang,
Navigator, and Taurus)
GO to Pinpoint Test DZ.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Additional Testing
GO to Pinpoint Test Z.
Chart 7
— Backfires
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Secondary Ignition
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Fuel Delivery System
GO to Pinpoint Test HC.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Exhaust System
GO to Pinpoint Test HF.
Additional Testing
GO to Pinpoint Test Z.
Chart 8
— Lack/Loss of Power
Note: Verify the symptom is reported under normal driving conditions without excessive engine or
vehicle load. Also, be aware of the engine RPM/speed limiting functions of the PCM.
Note: For vehicles equipped with a knock sensor (KS), a lack of power may result when the
vehicle is operated with a breakout box installed at the PCM. The KS circuits are not
shielded in a breakout box, and KS signal noise may be noticed by the PCM. If this
happens, spark timing is retarded and a lack of power may result.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-12
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
Note: For applications with a KS, a lack of power may result if the engine has developed an
abnormal noise. The KS may interpret some abnormal noise as detonation and retard
spark timing.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Automatic Transmission
Fluid
Visual.
Throttle Linkage
Visual.
Air Cleaner Element
Visual.
Check the following PIDS:
— LONGFT1/LONGFT2
(value between -20 and
+20%)
— IMTVF (if equipped): For
both ignition ON, engine
OFF and ignition ON,
engine running with the
transmission in
PARK/NEUTRAL and the
engine RPM greater than
3,000 RPM, the PID
should indicate no fault
(or NO) in both
situations.
LONGFT1/LONGFT2 value low (-):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
rich.
LONGFT1/LONGFT2 value high (+):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
lean.
IMTVF PID indicates a fault:
GO to Pinpoint Test HU.
Fuel Delivery System
GO to Pinpoint Test HC.
Secondary Ignition
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Mass Air Flow (MAF)
Sensor
GO to Pinpoint Test DC.
Exhaust System
GO to Pinpoint Test HF.
Variable Camshaft Timing
(VCT) System
GO to Pinpoint Test HK.
Accelerator Pedal Position
(APP) Sensor
GO to Pinpoint Test DK.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Automatic Transmission
REFER to the Workshop Manual Section 307-01, Automatic Transaxle/Transmission,
Shift Point Road Test to continue diagnosis.
Brake System Drag or
Binding
REFER to the Workshop Manual Section 206-00, Brake System.
Supercharger Bypass
System
GO to Pinpoint Test KJ.
Turbocharger System
GO to Pinpoint Test HN.
Additional Testing
GO to Pinpoint Test Z.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-13
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
Additional Checks:
— Some vehicles have a
TQ_CNTRL PID
available. Check this PID
to determine if the PCM
is reducing torque, and if
so, why the torque is
being reduced. As a PID
display example; 0
equals no torque
reduction requested, 1
equals torque truncation,
which cuts fuel to protect
when line pressure falls
to minimum limit, and 2
equals traction control
event, which cuts
fuel/spark for traction
control.
— Customer driving habits
— Correct PCM vehicle
identification (VID) block
information. Refer to
Section 2, Flash
Electrically Erasable
Programmable Read
Only Memory (EEPROM)
to carry out the Making
Changes to the VID
Block procedure.
— Intake manifold runner
control (IMRC) linkage (if
equipped)
— Clutch (M/T)
— Charging system
— Engine RPM/speed
limiting functions of the
PCM (look for incorrect
high vehicle speed signal
from ABS, VSS, or OSS)
REFERENCE (Section 5 Pinpoint Test unless noted)
Visual. REFER to the applicable Workshop Manual section.
Chart 9
— Spark Knock
Note: Carbon build up in the combustion chamber and on the back of valves can be a
contributing factor for engine spark knock concerns. Remove carbon deposits prior to any
component replacements.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-14
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Verify the engine operates
at normal temperature
Visual. REFER to the Workshop Manual Section 303-03, Engine Cooling, The Engine
Overheats or No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index to
diagnose any cooling system concerns that are present.
Verify correct coolant level
and coolant concentration
REFER to the Workshop Manual Section 303-03, Engine Cooling, Cooling System
Draining, Filling and Bleeding for correct coolant concentrations and fill procedures.
Mass Air Flow (MAF)
Sensor
GO to Pinpoint Test DC.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Fuel Delivery System
GO to Pinpoint Test HC.
Secondary Ignition System
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
Engine Oil Quality
Visual.
Additional Testing
GO to Pinpoint Test Z.
Chart 10
— Poor Fuel Economy
Note: Driving styles may have a significant influence on fuel economy. Verify the concern before
starting an in-depth diagnosis. If available, use the integrated diagnostic system (IDS) fuel
economy test to verify a concern is present. The following external factors may contribute
to poor fuel economy:
• stop and go driving
• incorrect axle ratio
• incorrect tire pressure and size
• road/weather conditions
• vehicle loads (such as trailer towing)
• aftermarket add-ons
• extended winter warm-up conditions
• short run operations
• high speed driving
• customer expectations
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-15
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Check the following PIDs:
— LONGFT1/LONGFT2
(value between -20 and
+20%)
— VPWR (value between
10.5 and 17.0 volts, and
within 0.5 volt of battery
voltage)
LONGFT1/LONGFT2 value low (-):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
rich.
LONGFT1/LONGFT2 value high (+):
Continue diagnosis. Concentrate checks in areas that would cause the engine to run
lean.
VPWR not between 10.5 and 17.0 volts:
REFER to the Workshop Manual Section 414-00, Charging System and carry out the
Inspection and Verification to continue diagnosis.
VPWR between 10.5 and 17.0 volts, but not within 0.5 volt of battery voltage:
CHECK the B+ voltage to the PCM power relay. CHECK the VPWR circuit between
the PCM and the PCM power relay. CHECK the PWR GND circuits.
Verify the engine operates
at normal temperature.
Visual. REFER to the Workshop Manual Section 303-03, Engine Cooling, Symptom
Chart to diagnose any cooling system concerns that are present.
Secondary Ignition System
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Fuel System
GO to Pinpoint Test HC.
Exhaust System
GO to Pinpoint Test HF.
Variable Camshaft Timing
(VCT) System
GO to Pinpoint Test HK.
Transmission Fluid Level
Visual.
Automatic Transmission
REFER to the Workshop Manual Section 307-01, Automatic Transaxle/Transmission,
Diagnosis By Symptom to continue diagnosis.
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
Additional Checks:
— Correct PCM VID block
information. Refer to
Section 2, Flash
Electrically Erasable
Programmable Read
Only Memory (EEPROM)
to carry out the Making
Changes to the VID
Block procedure.
— Brake drag
— Base engine concerns
— Incorrect PCV valve
— Contaminated MAF
sensor
— Intake air system
REFER to the applicable Workshop Manual section.
Additional Testing
GO to Pinpoint Test Z.
Chart 11
— Emissions Compliance
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-16
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
Emissions Related Systems
REFERENCE (Section 5 Pinpoint Test unless noted)
GO to Pinpoint Test EM.
Chart 12
— Warning Indicators: Check Fuel Cap Indicator, Malfunction Indicator Lamp (MIL), Power Take
Off (PTO), Temperature Warning Indicator or Gauge (applications with cylinder head
temperature [CHT] sensor only), Transmission Control Indicator Lamp (TCIL), Powertrain
Malfunction Indicator (Wrench)
— PTO Concerns: Not Working Correctly
Note:
— If the symptom is both a MIL on and exhaust emission test failure, GO directly to Chart
11.
— If the engine is a no start, GO directly to Chart 3.
— If the engine runs rough at idle, GO directly to Chart 1.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Verify the fuel filler cap is
correctly tightened or the
capless fuel tank filler pipe
is correctly sealed.
Visual.
Check Fuel Cap Indicator
— Never/always on
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, to diagnose the check fuel cap indicator is never/always on or
to diagnose the CHECK FUEL CAP warning is inoperative.
MIL
— Always on when the
engine is running (no
DTCs present)
— Never on (including
during indicator prove
out)
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, and carry out the Inspection and Verification to continue
diagnosis.
PTO
— PTO indicator
never/always on
— PTO not working
correctly
GO to Pinpoint Test FB.
Temperature Warning
Indicator or Gauge
(applications with CHT
sensor only)
— Engine cooling system
— Indicator circuits
For an engine that is overheating, REFER to the Workshop Manual Section 303-03,
Engine Cooling to diagnose the engine overheating symptom. Be aware that since a
PCM DTC is not present, the PCM is not attempting to activate the indicator.
For an engine operating at normal temperature, GO to Pinpoint Test DL.
(Continued)
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-17
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
TCIL
— Always on when the
engine is running (no
DTCs present)
— Never on
For E-Series, GO to Pinpoint Test TB.
For all others, REFER to the Workshop Manual Section 413-01, Instrumentation,
Message Center, and Warning Chimes.
Powertrain Malfunction
Indicator (Wrench)
— Never/always on
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, to diagnose the wrench indicator is never/always on or to
diagnose the POWERTRAIN MALFUNCTION warning is inoperative.
Additional Testing
GO to Pinpoint Test Z.
Chart 13
— Automatic Transmission (A/T) Shift Concerns: Upshift, Downshift, Engagement
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Transmission
REFER to the Workshop Manual Section 307-01, Automatic Transaxle/Transmission,
Shift Point Road Test to continue diagnosis.
Additional Tests
GO to Pinpoint Test Z.
Chart 14
— Instrumentation: Tachometer Inoperative, Speedometer/Odometer Inoperative, Boost Gauge
Indicates Higher Than Normal Boost, Fuel Gauge Inoperative
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Tachometer Inoperative
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, to diagnose the incorrect tachometer indication.
Speedometer/Odometer
Inoperative
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, to diagnose the inoperative speedometer/odometer.
Boost Gauge (for vehicles
equipped with a
supercharger)
— Indicates higher than
normal boost
For supercharger bypass control concerns, GO to Pinpoint Test KJ.
For charge air cooler (CAC) system concerns, GO to Pinpoint Test KP.
Fuel Gauge Inoperative
— Fuel gauge always
indicates full or empty
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes, to diagnose the incorrect fuel gauge indication.
Instrumentation
REFER to the Workshop Manual Section 413-01, Instrumentation, Message Center,
and Warning Chimes.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-18
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
Chart 15
— Oil System Concerns: High Oil Consumption, Leaks
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Positive Crankcase
Ventilation (PCV) System
GO to Pinpoint Test HG.
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Additional Checks
— External leaks
— Correct dipstick
— Correct oil viscosity
— Turbocharger System
Visual.
Chart 16
— Cooling System Concerns: Electric Cooling Fan(s) Does Not Operate (Low, High or Variable
Speed), Cooling Fan Clutch Does Not Operate
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Electric Cooling Fan
For Crown Victoria/Grand Marquis, Flex, Fusion/Milan/MKZ, Edge/MKX, MKS, MKT,
Taurus, and Town Car, GO to Pinpoint Test KN.
For all others, GO to Pinpoint Test KF.
Cooling Fan Clutch
GO to Pinpoint Test HV.
Cooling System
REFER to the Workshop Manual Section 303-03, Engine Cooling to diagnose the
cooling system concern.
Chart 17
— Cooling System Concerns: Electric Cooling Fan(s) Always Runs
Note: This chart is only intended to diagnose an electric cooling fan that always runs with a cool
engine and the A/C and defroster off.
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-19
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Cooling Fan
For Crown Victoria/Grand Marquis, Flex, Fusion/Milan/MKZ, Edge/MKX, MKS, MKT,
Taurus, and Town Car, GO to Pinpoint Test KN.
For all others, GO to Pinpoint Test KF.
Cooling System
REFER to the Workshop Manual Section 303-03, Engine Cooling, The Engine
Overheats to diagnose the cooling system concern.
Chart 18
— Exhaust System Concerns: Visible Smoke
Note: Black smoke indicates a rich fuel mixture, blue smoke indicates burning oil, and white
smoke indicates water in the combustion chamber.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Base Engine
REFER to the Workshop Manual Section 303-00, Engine System and carry out the
Inspection and Verification to continue diagnosis.
Fuel Delivery System
— Black smoke
GO to Pinpoint Test HC.
Ignition System
— Black smoke
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, GO to Pinpoint Test JB.
Positive Crankcase
Ventilation (PCV) System
— Blue smoke
REFER to the Workshop Manual Section 303-00, Engine System for a description of
the Oil Consumption Test.
Turbocharger System
— Blue smoke
REFER to the Workshop Manual Section 303-04, Fuel Charging and Controls Turbocharger for the Oil Consumption Test.
Chart 19
— Fuel System Concerns: Odor, Engine Compartment
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
EVAP System
Visual.
Fuel System
Visual. GO to Pinpoint Test HC.
2011Powertrain Control/Emissions Diagnosis, 8/2010
3-20
Symptom Charts
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
Chart 20
— Engine Noise (under hood)
Note: Attempt to identify the source of the noise. If the noise is from a source other than those
listed below, refer to No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index
(for noise such as spark knock) or the applicable Workshop Manual section to continue
diagnosis.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Secondary Ignition System
— Snap noise that may be
due to secondary ignition
arcing.
For vehicles equipped with a coil pack ignition system, GO to Pinpoint Test JC.
For all others, CHECK the condition of the spark plug boots.
Turbocharger System
REFER to the Workshop Manual Section 303-04, Fuel Charging and Controls Turbocharger to diagnose the turbocharger noise.
Chart 21
— Exhaust System Concerns: Odor (Sulfur or Rotten Egg Smell)
Note: A slight sulfur smell may be normal. Catalysts with less than 8,000-16,000 kilometers
(5,000-10,000 miles), either from a new vehicle or new catalyst, are likely to have a sulfur
smell due to the highly active state of new catalysts. Installing a new catalyst may actually
make the symptom worse.
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Check for any driveability or
exhaust smoke symptoms.
REFER to No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index for
direction to repair other symptoms.
Fuel Delivery System
GO to Pinpoint Test HC.
Fuel Source
Talk with the customer. Sulfur content can vary in different fuels. Suggest trying a
different fuel source.
Chart 22
— Starting Concerns: No Crank
2011Powertrain Control/Emissions Diagnosis, 8/2010
Symptom Charts
3-21
No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless noted)
Add-on Anti-Theft Devices
Visual. CHECK with the customer.
Anti-Theft
REFER to the Workshop Manual Section 419-01, Anti-Theft and diagnose the vehicle
does not start symptom.
Base Engine
— Starting system
REFER to the Workshop Manual Section 303-06, Starting System and diagnose the
engine does not crank symptom.
2011Powertrain Control/Emissions Diagnosis, 8/2010
