Oct 242017
 

2005 Ford Explorer

Engine will just die

This vehicle runs well and has plenty of power, but occasionally the engine will just die. It can happen at 10 mph or 60 mph. It will crank back up and run. Appears to be an intermittent problem. Pulled two codes from the computer:
P1633 KAM (Keep Alive Memory) Voltage Too Low
P0462 Fuel Level Sensor Low Input

I don’t know that these codes have anything to do with the problem we’re having with the vehicle. I’ve checked some of the simple stuff like making sure there is plenty of fuel in the tank, and I checked the battery voltage (a good 12.6 volts).

What do you think?


I wouldn’t think that these codes have anything to do with the engine intermittently dying on you. Unfortunately this is one of the most difficult problems to diagnose. If the engine wouldn’t restart it would be as simple as just figuring out if it isn’t getting fuel or spark. But since it starts right back up it make it that much more difficult. I would guess a loose connection or a failing sensor. As for which one, difficult to tell. Unfortunately in this case it would be more cost effective to let the problem get worse in order to know exactly what to repair/replace. No need to through parts at it if you don’t have to.

What does code P1633 mean?

P1633 means that the powertrain control module (PCM) has detected low voltage on the keep alive memory circuit. This is the circuit that supplies constant battery voltage to the keep alive memory portion of the PCM so it can retain information regarding fuel control, idle control and transmission control adaptive strategies to name a few. If the battery is disconnected or voltage drops below 10.5 volts this code will be set. If the battery has not been disconnected then the circuit will need to be checked for opens or high resistance in the wire, shorts, blown fuse, high voltage r/f interference from ignition or charging system components, or the PCM being being faulty itself.

Ford Code P1633

KAM Volt Low

Code P1633 Probable Causes

  1. Sensor or solenoid faulty
  2. Connector terminal contact is damaged or corroded
  3. Wire harness – Check harness for correct voltage, open, short to ground or short to voltage
  4. Update control unit software – Check for the latest control unit update
  5. Powertrain or Engine Control Module faulty
  6. Battery voltage low

Ford Code P0462

Fuel level sensor A circuit low input

Code P0462 Probable Causes

  1. Sensor or solenoid faulty
  2. Connector terminal contact is damaged or corroded
  3. Wire harness – Check harness for correct voltage, open, short to ground or short to voltage
  4. Update control unit software – Check for the latest control unit update
  5. Powertrain or Engine Control Module faulty
  6. Battery voltage low

Sources: Justanswer, Chilton

Oct 232017
 

2006 Ford Taurus

I have been throwing parts at this car trying to fix it. It started with multiple check engine codes P0300 and a few more P03XX ones I cannot remember. But they all had to do with misfire. I replaced the plugs and the coil pack. While replacing the plugs, #5 cylinders plug was missing the tip of the plug so I know it was not firing. After replacing the parts it ran great but code P0300 came back. Checked for vacuum leaks, tested all the injectors and found one that may have been weak. Then I replaced the upper intake manifold and all the injectors along with the EGR Valve, Mass Air Flow, EGR Vacuum Solenoid, and the Cam Sensor. I figured I would have got it with all that but nope.

I now get P0402 and still P0300 so now I am thinking I will go ahead and replace the Camshaft Synchronizer and the crank sensor. Not sure what else I could be missing but I am willing to try anything at this point. If anyone has any other ideas, I am going to pull the plugs and recheck them along with the plug wires. I have rechecked the wiring positions and they are in the correct order.


In my experience with code P0402 you will need to replace 3 components. The EGR, EGR Regulator and DPF (Differential Pressure Feedback) EGR valves. You will also want to remove the valve tubes and make sure all are clean and clear of obstruction. Do the same for the ports they connect to. As for the Po300 misfire code should clear up once you take care of the EGR issues.

Exhaust Gas Recirculation (EGR) System Components — Exploded View

EGR compnent location diagram 2006 Ford Taurus

Item Part Number Description
1 14A464 Exhaust gas recirculation (EGR) vacuum regulator valve electrical connector
2 N620479 EGR vacuum regulator valve nuts (2 required)
3 9J489C EGR vacuum regulator valve
4 Vacuum tube connector-to-EGR vacuum regulator valve (part of 9E498)
5 9E498 EGR vacuum tube
6 Vacuum tube connector-to-EGR valve (part of 9E498)
7 9E444A Differential pressure feedback EGR sensor
8 14A464 Differential pressure feedback EGR sensor electrical connector
9 9D476B EGR valve gasket
10 9E444A EGR valve
11 Exhaust manifold-to-EGR valve tube fitting (part of 9D477E)
12 Exhaust manifold-to-EGR valve tube nut (part of 9D477E)
13 9D477E Exhaust manifold-to-EGR valve tube
14 W500224 EGR valve bolts (2 required)
15 9P761A Differential pressure feedback EGR sensor vacuum hoses (2 required)

Ford Code P0402

Code P0402 Description: Exhaust Gas Recirculation Flow Excessive Detected

Code P0402 Possible Causes

  1. Sensor or solenoid faulty
  2. Connector terminal contact is damaged or corroded
  3. Wire harness – Check harness for correct voltage, open, short to ground or short to voltage
  4. Update control unit software – Check for the latest control unit update
  5. Powertrain or Engine Control Module faulty
  6. Exhaust leaks or restrictions
  7. EGR components clogged, dirty or leaky
  8. EGR valve damaged/defective

 

Oct 212017
 

Ford Crown Victoria

The headlights do not always come on when operating the high/low switch. Sometimes they come on, however they don’t come on every time. I’d like to know if there is some part, other than the h/l switch that will cause this intermittent situation? Thank You for your knowledgeable response.


When looking at the diagram it appears the only options would be the wiring, the switch or the Lighting Control Module. If equipped with DRL (Daytime Running Lights) there is the addition of the DRL Module.

Headlights

Headlights without DRL wiring diagram

(best viewed in Chrome or Firefox)
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Headlights with DRL wiring diagram

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Oct 182017
 

Ford Ranger

Diagnosed a bad throttle position sensor. Installed a new one. Ran great for about a minute. Went back to running rough. Installed another new tps. Again it ran good for about a minute. Then it ran rough again. With the voltmeter I confirmed I had good 12 volt power going in. On the third wire I confirmed a good ground loop. But on the signal wire it should read 0.9 volts on closed throttle and 5.0 volts on wide open throttle. It gave 0.3 volts closed throttle to wide open throttle. Could my signal wire be grounded somewhere? Or could my computer be fried?


Throttle Position Sensor

tps connector diagram 2003 Ford Ranger

Testing for short or open in wiring harness

Check TP Circuit for open in harness
  • Turn ignition switch to off position. Leave TP sensor disconnected. Disconnect PCM connector(s). Inspect connector for loose, damaged or corroded terminals, and repair as needed.
  • Using a digital multi-meter, measure resistance of TP circuit between PCM harness connector and TP sensor connector.
  • If resistance is less than 5 ohms go to next step below. If resistance is 5 ohms or more, repair open in TP circuit.
Check TP Circuit for short to SIG RTN or PWR GND in harness
  • Ensure PCM is disconnected. Disconnect scan tool from Data Link Connector.
  • Using a Digital multi-meter, measure resistance between TP circuit, and SIG RTN and PWR GND circuits at PCM harness connector. If either resistance measurement is 10k/ohms or less, repair short between circuits.
  • If both resistance measurements are more than 10k/ohms, replace the PCM.

 

 

Oct 092017
 

2002 Ford Mustang

I need to see which color wires and what holes they plug in on engine wiring harness that control fuel injectors, coils, etc. It has 25 to 30 pins.


I shall provide you with the engine wiring diagram in 3 parts. (best viewed with Chrome or Firefox)

Engine Wiring Diagram 2002 Ford Mustang GT

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2002-ford-mustang-gt-engine-controls-2-of-3
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Oct 022017
 

2002 Ford F250

Hi, I have a 2002 f250 V10 crew cab. When I go over rough road the front end can pull and move me over in the lane. The front end has been checked and new shocks installed but it still does it and when I Hit freeway bumps it hits real hard. If I install air bags in the coil springs will it help the ride and steering?


Air bags are not going to help the ride or the steering. It would make the ride stiffer. I would have the tires and alignment checked. Also check for a loose steering gear box. If your tires are oversized (not stock size) this may also cause the vehicle to want to shoot to one side of the road or the other.

Oct 022017
 

1992 Ford F150

Fuel pump will not prime


If your truck utilizes a mechanical fuel pump follow the testing procedure listed below. These trucks (1990 – 1996) employ a single, high pressure pump which is part of the modular, In-Tank Reservoir (ITR) assembly. Besides the pump, the ITR consists of a venturi jet pump, a supply check valve and a shuttle selector valve. All this is mounted on the fuel gauge sender flange. The sending unit is separate from the ITR module.

When the fuel system is opened allowing the pressure to bleed off will require the system to be primed once reassembled. This can be achieved by cycling the ignition switch on and off. The ignition key needs to be moved to the “ON” position for 5 seconds and then moved to “OFF” for 5 seconds. This needs to be repeated a minimum of 10 times. If fuel pressure has not built up, check for fuel leaks first. Then test your fuel pump relay function. Next test your fuel pump.

 

fuel pump diagram 1992 Ford F150

Mechanical Fuel Pump Testing

CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

Incorrect fuel pump pressure and low volume (flow rate) are the two most likely fuel pump troubles that will affect engine performance. Low pressure will cause a lean mixture and fuel starvation at high speeds and excessive pressure will cause high fuel consumption and carburetor flooding.

To determine that the fuel pump is in satisfactory operating condition, tests for both fuel pump pressure and volume should be performed.

The test are performed with the fuel pump installed on the engine and the engine at normal operating temperature and at idle speed.

Before the test, make sure that the replaceable fuel filter has been changed at the proper mileage interval. If in doubt, install a new filter.

Pressure Test

  1. Remove the air cleaner assembly. Disconnect the fuel inlet line of the fuel filter at the carburetor. Use care to prevent fire, due to fuel spillage. Place an absorbent cloth under the connection before removing the line to catch any fuel that might flow out of the line.
  2. Connect a pressure gauge, a restrictor and a flexible hose between the fuel filter and the carburetor.
  3. Position the flexible hose and the restrictor so that the fuel can be discharged into a suitable, graduated container.
  4. Before taking a pressure reading, operate the engine at the specified idle rpm and vent the system into the container by opening the hose restrictor momentarily.
  5. Close the hose restrictor, allow the pressure to stabilize and note the reading. The pressure should be 5 psi. (34.5 kPa).
    If the pump pressure is not within 4–6 psi (27.6–41.4 kPa) and the fuel lines and filter are in satisfactory condition, the pump is defective and should be replaced.

If the pump pressure is within the proper range, perform the test for fuel volume.

Volume Test

  1. Operate the engine at the specified idle rpm.
  2. Open the hose restrictor and catch the fuel in the container while observing the time it takes to pump 1 pint. 1 pint should be pumped in 20 seconds. If the pump does not pump to specifications, check for proper fuel tank venting or a restriction in the fuel line leading from the fuel tank to the carburetor before replacing the fuel pump.
Sep 192017
 

2008 Ford Escape

08 escape when warm outside car shifts good but in winter when i first takeoff car hesitates for about 5 seconds before going into gear then is fine


First thing to check would be the transmission fluid level. Also check for any signs of a transmission fluid leak. Next checking for dirty fluid and finally checking and or replacing the solenoids in the transmissions valve body.

Sep 142017
 

Ford F250

Hard Start

I have had slow start problems since I bought this truck. I thought I had it fixed a couple of times. The first time was adding fuel additive, which led me to think I just had dirty injectors. The second I changed the glow plugs and harness, but that only lasted a short time, and I think i might have moved an airbubble and just got lucky on the few good starts it had. Am I on the right track? Would air in the fuel lines cause it to hard start?


Yes. Air in the fuel lines will make it difficult to start and may even cause the engine to die.

Fuel Delivery Problems

To start and run properly, injector timing has to be accurate. A quick visual inspection will tell you if the timing marks are lined up. Refer to the vehicle manufacturer’s timing procedure if you suspect timing is off or the pump has been replaced recently. On newer diesels with electronic injection pumps or direct injection, you’ll need a scan tool to make any changes.

Any air in the fuel can also be a cause of hard starting or a no start condition. Air can make the engine die after it starts, and make restarting difficult. Air can enter the system through any break in the fuel line or via a bleedback condition.

Determine if air is the problem

To determine if air is the problem, install a clear return hose on the return side of the injection pump. Crank the engine and observe the line. Air bubbles in the fuel would tell you air is entering the inlet side of the pump. The injection pump itself is usually not the source of the air leak, so check the fuel lines and pump.

A worn or clogged pump can also make an engine hard to start. If the condition has been getting steadily worse accompanied by a loss of power, and the engine has a lot of miles on it (more than 75,000), the underlying cause may be a pump that needs to be replaced.

Before condemning the pump, though, check the fuel filters. Clogged filters can cause fuel restrictions that prevent the pump from doing its job properly. The primary water separator/fuel filter usually needs to be changed about every 30,000 to 40,000 miles, and the secondary filter about every 20,000 to 30,000 miles. Newer fuel systems with a single filter usually require service about once a year. If the filter has been neglected, chances are it may be restricted or plugged.

Source: http://www.autotap.com/techlibrary/diagnosing_light_duty_diesels.asp

Sep 122017
 

2004 Ford Explorer

I have replaced the fuel pump and fuel drive module. The car runs good at idle speed but lugs down on acceleration and has no power. What else could it be? It is a 2004 Ford Explorer 4.6l Eddie Bauer edition.


If there are any check engine light codes that would be the place to start. Have a fuel pressure gauge? You can attach it and see if the fuel pressure drops on acceleration. If that checks out, move on to the fuel pressure sensor(fuel pressure regulator).

Fuel Charging and Controls

The fuel charging controls consist of the following:

  • fuel injection supply manifold
  • electronic throttle body
  • The fuel injectors
  • fuel pressure and temperature sensor
  • fuel pulse damper

The fuel injection supply manifold:

  • delivers fuel to the individual fuel injectors.
  • receives fuel from the fuel supply line.

The electronic throttle body:

  • controls air supply to the upper intake manifold by electronically positioning the throttle plate.
  • is not adjustable.
  • cannot be cleaned.
  • is serviced as a complete assembly only.

The fuel injectors:

  • are electrically operated by the powertrain control module (PCM).
  • atomize the fuel as the fuel is delivered.
  • are deposit-resistant.
  • each have an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold.

The fuel pressure and temperature sensor:

  • measures the pressure and temperature of the fuel in the fuel supply manifold and sends these signals to the PCM.
  • uses intake manifold vacuum as a pressure reference.

The fuel pulse damper:

  • reduces fuel system noise caused by the pulsing of the fuel injectors.

Fuel pressure sensor replacement

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