Sharp IV-S51M Installation manual

M-12071-A50
REVISION 2
Multiport EFI Engine Management Wiring Harness
M-12071-A50
REVISION 2
Installation Manual
TABLE OF CONTENTS
Section
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
Topic
Page
Introduction ....................................................................................2
Overview .........................................................................................2
Additional Necessary Ford Sensors and Components.............. 2-3
Tools Required .............................................................................. 4
Pre-Installation of Harness and Parts ..........................................4
Harness Wire Colors and Component Locations........................ 5-6
Harness Installation....................................................................... 7-9
Wiring Connections .......................................................................10-11
Enhanced Features ....................................................................... 12-13
Initial Start Up ................................................................................ 14
Troubleshooting ............................................................................ 14-15
2-Digit EEC-IV Diagnostic Trouble Code (DTC) Definitions ...... 16-17
PCM Connector Face and Usage Chart ....................................... 18
Electrical Schematic - 5.0L Mass Air ........................................... 19
FRCM Schematic ........................................................................... 20
Miscellaneous Parts List ...............................................................21
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Print Revision: Nov-2012
M-12071-A50
REVISION 2
NOTES
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Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
1.0
INTRODUCTION
This wiring harness kit is offered to allow Ford performance enthusiasts to take advantage of
fuel injection technology with ease and simplicity. This harness includes numerous features
intended to simplify the installation process. This harness kit is primarily intended for use on
5.0L (302) and 5.8L (351) engines, but will also fit 429/460 engines if used with the proper
distributor and throttle body. You may need to purchase additional support items from Ford
Racing to complete the installation of fuel injection on your engine. This will depend upon
the year and type of the engine that you start with, as well as how complete your engine is.
2.0
OVERVIEW
These instructions will guide you through the preparation and installation of all the required
steps to equip your engine with fuel injection. Please read the instructions thoroughly before
starting the installation. To insure a trouble-free installation, please read over each step that
pertains to the installation procedure. If you have any questions relating to the installation of
this harness, or need to know what parts may be compatible, please contact Ford Racing at
(800) FORD-788.
3.0
ADDITIONAL NECESSARY FORD SENSORS AND COMPONENTS
The simplicity of installing fuel injection on a Ford engine can be primarily attributed to the
EFI system utilizing a Mass Air Flow meter. When the engine is properly fit with the correct
size injectors and MAF meter, the engine can run properly without the need for a costly dyno
tune. The following components, offered separately by your local Ford dealer, can be used
to support this Ford EFI Wiring Harness.
3.1
Mass Airflow Computer for Ford-----------------------------
This mass-air flow computer will work for performance engine
assemblies and stock high-output engines and is compatible
with C-4, C-6, and AOD transmissions; Will NOT work with
computer controlled automatic transmissions.
Manual Transmission
- F3ZF-12A650-DB
Automatic Transmission
- F3ZF-12A650-FB
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M-12071-A50
REVISION 2
(Continued)
3.2
Fuel Injector
- F1ZE-9F593-C2A, 19 Lb/Hr
Many Ford 302/351 fuel injected engines are factory equipped with a set of 19# Fuel
Injectors, which will safely support approximately 275 HP. If you have made horsepower
improvements, you will need to consider larger fuel injectors.
3.3
Mass Airflow Sensor
- F1ZZ-12B579-AA
If you choose a larger injector than the factory 19 lb/hr, you will need an aftermarket
mass air meter calibrated for that size injector.
3.4
3.5
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Engine Sensors
Air Charge Temp Sensor (ACT)
Engine Coolant Temp Sensor (ECT)
Throttle Position Sensor (TPS)
Oxygen Sensor (O2), (2 Required)
BARO Sensor (BP or MAP)
EGR Position Sensor
Motorcraft # DY-674
Motorcraft # DY-303
Motorcraft # CX-1133
Motorcraft # DY-606
Motorcraft # DY-530
Motorcraft # CX-1464
Inertia Switch (Fuel Pump Cutoff)
Ford # XF3Z-9341-AA
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M-12071-A50
REVISION 2
4.0
TOOLS REQUIRED
In addition to a common assortment of sockets, wrenches and screwdrivers, you will need
the following:
A.
B.
C.
D.
E.
F.
G.
5.0
Wire Strippers
Digital Volt/Ohm Meter
Solder Gun / Solder
Electrical Tape / Shrink Tubing
Drill Motor
2.5” Hole Saw
Utility Knife
PRE-INSTALLATION OF HARNESS AND PARTS
5.1
Disconnect the battery prior to doing any wiring!!
5.2
This harness has been designed to be compatible with fuel injection intake
manifolds intended for use on ‘86-’93 Mustang 5.0L engines. If used on other
applications, you may need to lengthen or move certain sensor leads.
5.3
Install the fuel injection lower intake manifold. Though not mandatory, it is advised
to remove the upper intake if it is already installed. This will help to simplify the
installation of the wiring harness onto the engine. Make sure that the ports in the
lower intake manifold are covered to prevent debris from entering the engine.
5.4
Make certain that the Air Charge Temp (ACT) and Engine Coolant Temp (ECT)
sensors are installed in the lower intake manifold.
5.5
Mount the Barometric Pressure (BP) sensor to the firewall behind the engine.
5.6
Identify where the EEC harness can pass through on the passenger side of the
firewall. You will need to determine the proper location to cut a 2½” hole into the
firewall for the harness to pass through. Check for any wires, hoses, etc. that may
become damaged by the hole saw.
NOTE: THIS HARNESS IS DESIGNED TO MOUNT THE COMPUTER IN
THE PASSENGER SIDE KICK PANEL.
5.7
Use a center punch to mark the location of the center of the hole. By using the
center punch, this will keep the drill bit from ‘walking’ while you are cutting through
the firewall.
5.8
Drill the 2½” hole into the firewall. Clean any sharp edges with a file or die grinder.
5.9
The grommet will need to be cut in order to be installed onto the harness. Using a
utility knife, carefully make one cut starting from the inside of the grommet and
cutting outwards. It is always safest to pull the knife away from you while cutting.
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M-12071-A50
REVISION 2
6.0
HARNESS WIRE COLORS AND CONNECTOR LOCATIONS
BK = Black
BR = Brown
DB = Dark Blue
DG = Dark Green
Connector #
GY = Gray
LB = Light Blue
LG = Light Green
O = Orange
Connects to
PK = Pink
P = Purple
R = Red
T = Tan
W = White
Y = Yellow
Wire Colors
1................................ Fuel Injector #1……………………………….. R, T
2……………………… Fuel Injector #2……………………………….. R, W
3……………………… Fuel Injector #3……………………………….. R, BR/Y
4……………………… Fuel Injector #4……………………………….. R, BR/LB
5……………………… Fuel Injector #5……………………………….. R, T/BK
6……………………… Fuel Injector #6……………………………….. R, LG/O
7……………………… Fuel Injector #7……………………………….. R, T/R
8……………………… Fuel Injector #8……………………………….. R, LB
9……………………… Throttle Position Sensor (TPS)……………… BR/W, GY/R, GY/W
10……………………. Idle Air Control (IAC) Solenoid……………….R, W/LB
11……………………. Engine Coolant Temp (ECT) Sensor………. GY/ R, LG/R
12……………………. Mass Air Flow (MAF) Meter…………………. R, BK, T/LB, LB/R
13……………………. Air Charge Temp (ACT) Sensor……………. GY/R, GY
14……………………. SPOUT Connector……………………………. R, PK
15……………………. Thick Film Ignition (TFI) Module……………..O/R, T/Y, R/LG,
R/LB, PK, GY/O
16……………………. Coil…………………………………………….. R/LG, T/Y
17……………………. System Ground (DIRECTLY to battery!!)….. Black
18……………………. 12V SUPPLY (USE AN INLINE FUSE!!)….. Red
19……………………. A/C Clutch Connector……………………….. BK/Y, BK/W
20……………………. Barometric Pressure (BAP) Sensor………… BR/W, GY/R, LG/BK
21……………………. Left Oxygen (O2) Sensor……………………. GY/Y, BK/W, R/BK
22……………………. Right Oxygen (O2) Sensor………………….. GY/Y, BK/W, GY/LB
23……………………. Inertia Switch Connector……………………. PK, PK/BK
24……………………. Self Test Connector…………………………. PK/LG, LB/O, GY/R, W/P
25……………………. 15-Pin Disconnect……………………………. PK/LG, R/LB, BK, T/Y
PK, DG/Y, P, R/LG
26……………………. Fuse Relay Control Module (FRCM)………. ---------------------------------27……………………. 60-Pin Connector, PCM……………………... ---------------------------------28.............................. EGR Vacuum Regulator (EVR)..................... R, BR/PK
29.............................. EGR Position Sensor (EGR)......................... BR/W, GY/R, BR/LG
30.............................. Electric Fan Lead (See Page 13).................. O
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M-12071-A50
REVISION 2
6.1 Harness Layout
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-6-
M-12071-A50
REVISION 2
7.0
HARNESS INSTALLATION
.
7.1 Lay the harness onto the lower intake manifold
being careful to position it according to the layout
of the engine. Fuel Injectors #1, 2, 3, and 4 are
on the right (Passenger, USA) side of the engine
compartment. You may attach the fuel injector
connectors at this time.
7.2
Attach the connector for the TFI
Module located on the distributor.
(Page 6, Connector #15)
7.3
Attach the connector for the ACT
Sensor. This is usually located at
the front of the lower intake manifold
in the top of the #5 intake runner.
(Page 6, Connector #13)
7.4
Attach the connector for the ECT Sensor. This is generally located on the right
side of the engine towards the front. (Page 6, Connector #11)
7.5
Route the leads for the Oxygen (O2) Sensors behind the engine towards the left
and right oxygen sensors being careful to insure that the harness will not lie
against any portion of the exhaust pipe. If the harness can freely touch any portion
of the exhaust pipes, it should be tied back using ‘zip-ties’ or another suitable
substitute. The connectors can be attached to the O2 sensors at this time.
(Page 6, Connector #21 and Connector #22)
7.6
Attach the connector to the BAP Sensor. (Page 6, Connector #20)
7.7
Route the wiring with the battery leads around the left (Driver, USA) side of the
engine compartment. DO NOT HOOK UP THE BATTERY AT THIS TIME! The
harness has been designed to mount the Coil in the fender well on this side. You
may attach the connector to the Coil at this time. (Page 6, Connector #16)
7.8
If you are using a Ford A/C compressor, you may attach the connector for it at this
time. The harness should have enough slack to route the lead under the
compressor and up to the connector. This will help keep it away from the fan belt.
(Page 6, Connector #19)
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M-12071-A50
REVISION 2
7.9
Route the EEC Harness 60-Pin Connector, the 9-Pin Connector, the Inertia Switch
Connector, the Self Test Connector, and the FRCM Connector through the hole in
the firewall referred to on Page 4 (Sections 5.6 – 5.8). Place the grommet around
the harness and carefully position the groove of the grommet so that it ‘straddles’
the sheet metal in the hole of the firewall. Do NOT attach the 60-Pin Connector to
the computer at this time.
CAUTION: DO NOT ROUTE THE HARNESS NEAR A HEAT SOURCE,
SHARP EDGES, OR MOVING PARTS.
7.10 Install the upper intake manifold and vacuum hoses. DO NOT CONNECT a
vacuum line to the BARO Sensor! This must be open to atmosphere.
7.11 Install the throttle body and EGR Spacer. At this time, you should also attach the
EGR Position Sensor and EVR connector. (Page 6, Connector #28 & #29)
NOTE:
It has been our experience that some individuals prefer to delete the
EGR Position Sensor to achieve a “cleaner looking engine assembly.”
You should be aware that the use of an EGR System is MANDATORY
for proper engine function. If you choose to delete this system, you
MUST have the computer reprogrammed for this purpose! Otherwise,
the vehicle computer will run in a ‘Limp-Home Mode’, causing an
excessively rich running condition, and retarded ignition timing,
resulting in overall poor performance.
7.12 Attach the connector for the TPS. This sensor is located at the end of the throttle
shaft on the throttle body. (Page 6, Connector #9)
7.13 Attach the connector to the IAC Solenoid. This connects at the end of the long
cylinder located on the side of the throttle body. (Page 6, Connector #10)
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M-12071-A50
REVISION 2
7.14 As previously stated, this harness is
designed to mount the computer in
the passenger side kick panel. If
space is tight, you may choose to
mount the computer under the dash.
NOTE: The computer should be
mounted
with
the
connector located at the
bottom to avoid trapping
water.
7.15 Once you have determined a suitable location to mount the computer, you may
attach the 60-Pin connector using a 10mm socket. MAKE SURE THAT THE
BATTERY LEADS ARE NOT CONNECTED WHILE ATTACHING THE
COMPUTER OR IT COULD BE DAMAGED! (Page 6, Connector #27)
7.16 The Fuse/Relay Control Module (FRCM) should be mounted in an area that can
be easily accessed. This is where the fuses are located for the EEC Power Relay,
the Fuel Pump Relay, and the Wide Open Throttle (WOT) Cutout Relay.
Additionally, you will need to access the FRCM if you wish to perform a ‘Key On
Engine Running’ (KOER) diagnostic test. (See Section 9.1 on Page 11 for more
information on the FRCM)
7.17 Mount the fuel pump Inertia Switch somewhere
on the vehicle’s body near the computer. It
should be mounted upright with the RESET
button at the top. A generous length of wire has
been included to allow you every opportunity to
mount the Inertia Switch and take advantage of
this safety feature. It is important to mount this to
a solid surface that will allow it to ‘trigger’ in the
unfortunate event of a collision. The purpose of
the Inertia Switch is to interrupt the voltage leading to the fuel pump and to prevent
it from continuing to run in the case of a ruptured fuel line. It is possible to trigger
the Inertia Switch if the vehicle hits an abnormally hard bump. The Inertia Switch
can easily be reset by depressing the plunger. Because you may need to reset the
Inertia Switch, you should mount it somewhere that you can access it if necessary.
(Page 6, Connector #23)
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M-12071-A50
REVISION 2
8.0
WIRING CONNECTIONS
This harness has been designed to simplify the installation process of fuel injection. There
are numerous enhancements intended to require minimal effort by the installer. With the
exception of the main battery leads, all of the required harness connections have been
located in a central location within a single 9-Pin Disconnect located near the computer.
Additionally, all of the fuses, relays, and enhanced features have been conveniently located
in the Fuse/Relay Control Module (FRCM).
8.1
Locate the Single 9-Pin Disconnect (Page 6, Connector #25). This EFI Wiring
Harness kit includes a mate to this connector which includes 8 wiring pigtails. This
is where you will need to make the connections for the harness.
8.2
You may use the diagram on page 11 as a reference for the following connections:
A. Pin 1 (Pink/Green Wire), and Pin 2 (Pink Wire): These two wires will need to
go to the “Check Engine” light. This is a mandatory connection and is required
for the computer to do an initial ‘Self Test’ upon starting the engine.
B. Pin 3 (Red/Blue Wire): Connect this wire to a 12V ‘START’ source, meaning
that voltage is present only when the starter is cranking. This connection is
used to tell the computer and the TFI module when the engine is being started,
and will initiate a different strategy in the computer when voltage is applied.
C. Pin 4 (Black Wire): Connect this wire to a ground source. A body ground is
acceptable for this connection, though you should make sure that the area is
free from rust or paint. This connection is for grounding the case of the
computer and also for grounding the shielded wires leading to the TFI Module.
D. Pin 6 (Green/Yellow Wire): This wire connects to the positive side of the fuel
pump. Connect the negative side of the fuel pump to a ground source. If you
are using a fuel pump which can draw more than 20 amps, you should use an
external fuel pump relay, and use this wire as the trigger wire to that relay.
E. Pin 7 (Purple Wire): If your engine is equipped with air conditioning, connect
this wire to the dash control A/C switch. This wire should have power when the
A/C is on. This will engage the A/C compressor clutch, and send a signal to the
computer to maintain proper idle speed to compensate for the increased load
which will be imposed on the engine from the A/C compressor.
F. Pin 8 (Red/Green Wire): Connect this wire to a SINGLE SOURCE which will
have 12 Volts when the key is in both the ‘Start’ (cranking) AND in the ‘Run’
positions. This is the primary circuit which will provide power to all of the relays
and to the ignition system.
G. Pin 9 (Tan/Yellow Wire): This wire is the tachometer lead. This is not a
mandatory connection.
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M-12071-A50
REVISION 2
8.3
The final connections to be made will be the Main Power Supply and the Ground
Wire. This harness has been designed for use with the battery mounted in the front
of the engine compartment on the Left (Driver, USA) side. If your battery is in a
different location, you should lengthen these wires using a 10 gauge wire and run
them DIRECTLY to the battery. These extensions should be soldered. By running
these wires directly to the battery, this will insure a proper ground, and eliminate
many potential problems. TAKE THE TIME TO DO IT RIGHT!
A. Connect the Red 12 Gauge wire to the positive side of the battery THROUGH
AN INLINE FUSE rated at 50 amps. IF YOU DO NOT USE AN INLINE FUSE,
YOU RUN THE RISK OF FIRE SHOULD THE CIRCUIT EVER SHORT! (This
wire may have the appearance of being smaller than a conventional 12 gauge
wire. This is because it is ‘TXL’ type wire and the sheathing is thinner.) (Page
6, Connector #18)
B. Connect the Black 12 Gauge wire DIRECTLY to the negative side of the
battery. (This wire may have the appearance of being smaller than a
conventional 12 gauge wire. This is because it is ‘TXL’ type wire and the
sheathing is thinner.) (Page 6, Connector #17)
8.4
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9-Pin Disconnect Layout:
Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
9.0
Enhanced Features
This harness has been carefully designed and developed primarily off of feedback derived
from performance enthusiasts who wanted a simple, yet fully functional, wiring solution for
their Street-Rods. A lot of careful thought and effort has been utilized to make this harness
very simple to install. One heavily favored option is that all necessary relays and fuses have
been packaged into a single location, referred to as the Fuse Relay Control Module. Quite
simply, this harness is cleanest and simplest wiring harness on the market.
9.1
Fuse Relay Control Module (FRCM): This is the central location where all of the
fuses and relays have been placed to minimize the bulk of wiring for a much
cleaner appearance under the hood. There are a number of additional features
which have been included within the FRCM:
A. LED Indicators: These have been included to assist in any potential trouble
shooting that may be required. When power is being passed through the relay,
the LED indicator will light GREEN.
B. Simple 1 Connector Hookup: With the exception of the main battery leads,
all of the required harness connections have been located in a single
connector. This ‘9-Pin Disconnect’ is conveniently located under the dash near
the computer for ease of installation to the necessary power and ground
connections.
The mating connector houses the wiring leads where all of the connections are
to be made. This feature allows the EFI Wiring Harness to be easily
disconnected from the vehicle without disrupting the solder joints if the engine
ever needs to be removed from the vehicle for any reason.
C. Dual Mode Self-Test Compatibility: With previous wiring harnesses, it has
been required to hook up a NEUTRAL SENSING switch if a diagnostic test
procedure was desired during a Key On Engine Running (KOER) mode. This
circuit has been integrated into the FRCM to eliminate the need for these
additional components and to save time on wiring this circuit.
Technical Tidbit: By default, the computer automatically assumes that the
vehicle is in gear. If the computer cannot determine if the vehicle is in neutral, it
will generate a code 67, and will not allow a diagnostic scan while the engine is
running. The FRCM has integrated a circuit which can be used to simulate the
vehicle being in neutral by simply depressing the yellow button located in the
upper left corner of the FRCM box, labeled “PUSH TO TEST”. By depressing
this button, this will complete a circuit between pin 30 and pin 46 in the
computer, simulating the signal the computer would normally receive when the
vehicle is in neutral. When this circuit is engaged, you will also have the ability
to do a ‘Cylinder Balance Test’. For a more thorough description of diagnostic
test procedures, refer to a Ford Powertrain Diagnostics/ Emissions Control
manual. This circuit can be reset to default by simply turning off the key.
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M-12071-A50
REVISION 2
D. Optional Electric Cooling Fan Control, By default, the factory Ford computer
(PCM) has no provisions to control an electric cooling fan. However, some
aftermarket ‘chip’ tuners are able to introduce this function via pin 41 at the
PCM, which is normally an unused pin.

If you will be using a 'chip-tuned' PCM to control an electric cooling fan, you
will need to attach the 10ga Orange wire (Page 6, Item #30) to the 12V+
side of the electric cooling fan. You will also need to provide the ground
cable for the fan, and it too should be a 10ga wire attached directly to the
chassis.
o

NOTE: If the electric cooling fan being used is rated in excess of 35
amps, you should use the Orange wire to trigger an external relay
for use with that fan.
If you will NOT be using an electric fan, the cooling fan wire(s) can be cut
back and taped off. Additionally, if the PCM has not been modified for this
feature, be aware that there is no concern that the Orange wire will have
any voltage present, and should not be at risk of shorting out.
FRCM LAYOUT
(Schematic on page 20)
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M-12071-A50
REVISION 2
10.0
INITIAL START UP
The following information is offered assuming you have adhered to each of the previous
steps of this installation manual. This would include making certain that the main power
leads are hooked up, the PCM & FRCM are connected, and all of the required connections
within the ‘9 Pin Disconnect’ have been made.
10.1 Check all fluid levels, electrical and fluid connections. It is recommended to prime
the oil pump to insure adequate delivery of oil to all moving parts for initial start up.
10.2
Pressurize the fuel system. This can be done by turning the key on and off
several times to fully prime the system. Inspect the entire fuel system (from tank
to engine) for leaks. If any leaks are found, do not proceed further until these
have been corrected.
10.3
Start Engine. Check for leaks and/or noises that may indicate a problem. If no
leaks or noises are present, prepare to set initial timing.
10.4
When setting the ignition timing, be certain to unplug the SPOUT connector
(Page 6, Connector #14) which is located near the TFI module at the distributor.
Loosen the distributor hold-down bolt. Set initial timing to factory setting of 10°
BTDC. Tighten the distributor hold-down bolt, and verify timing is still correct.
Reinstall the SPOUT connector; timing should advance approximately 8-10
degrees at idle.
CAUTION: Be certain to run the vehicle in a well ventilated area.
11.0
TROUBLESHOOTING
We have taken great strides to help insure a trouble-free installation, but If you do encounter
a “No Start” condition, please check each of the following:
11.1
Check to be certain that the circuit breaker provided on the red main positive
lead wire (Page 6, Connector #18) has not been tripped. This can be reset by
simply pushing the black button located on the side of the circuit breaker near
the copper colored terminal.
11.2
If the fuel pump does not prime, check the Inertia Switch to
be certain that the “Reset Switch” is depressed. (Page 6,
Connector #23)
11.3
Confirm that the green LED’s for the ”EEC Relay” and “Fuel Pump Relay” within
the FRCM are lit when the key is turned on. Note: If the engine is not rotating (by
either cranking or running), the fuel pump relay will only activate for 1 second
when the key is first turned on.
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M-12071-A50
REVISION 2
(Troubleshooting - Continued)
11.4
Verify that you have connected the black ground wire (Page 6, Connector #17)
DIRECTLY to the negative side of the battery. Do NOT attach this connection to
any other ground source. The entire EFI system is dependent upon this ground.
Be sure to solder any splices that may have been required if this connection
needed to be lengthened.
11.5
Inspect the engine for vacuum leaks. Vacuum leaks will allow air to enter the
engine without being monitored by the mass air meter, which will cause the PCM
to ‘think’ that the engine is receiving less air than it actually is, causing a lean
condition.
11.6
Verify that you are using a quality Mass Air Flow meter. This sensor is the single
most important sensor in the entire EFI system and is a common culprit of idle
surge and low speed drivability problems. Ford Racing offers MAF meters that
exceed OEM quality; refer to section 3.3 (on page 3) for more information.
11.7
Verify proper fuel pressure within the system. Ford EFI systems normally require
39-42 psi at the fuel rail. An IN-TANK fuel pump is highly recommended as this
will help to eliminate the potential for cavitation (vapor bubbles) in the fuel supply
line. If you still choose to use an externally mounted fuel pump, you should be
ABSOLUTELY CERTAIN that it is gravity fed, meaning the fuel pump does not
have to ‘pull’ the fuel to it. If the fuel pump creates a vacuum in the inlet of the
fuel pump, the fuel can easily ‘flash’ to a vapor, creating tiny vapor bubbles
within the inlet of the fuel pump. When these vapor bubbles pass through the
pump to the ‘high pressure’ side, they do not go away; they are merely
compressed. Once these vapor bubble are expelled through the fuel injectors,
they are no longer under pressure and they will expand, displacing the fuel that
is needed by the engine, and generally causing a lean condition. This problem is
commonly characterized by becoming worse as the engine warms, and/or during
warm weather which usually consists driving over hot pavement which reflects
heat towards the fuel tank.
11.8
Perform a diagnostic test via the Self Test Connector. If you do not have an EFI
Scan Tool available, it is also possible to perform this test using a simple jumper
wire at the Self Test Connector. With the ignition switch in the OFF position,
hook up a jumper wire from the GY/RD wire (359) in the 6-pin connector to the
W/P wire (209) in the 1-pin connector. When the key is turned to the RUN
position, after about 15 seconds, the 'Check Engine' light will begin to flash
indicating which codes are present in the PCM.
Once all codes are reported, the codes will repeat
once again. These are the Key On Engine Off
(KOEO) codes. Wait approximately 10 seconds
after the KOEO test, and there will be a single
flash, followed by another set of DTC codes which
will follow. These are the 'Continuous' codes.
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Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
12.0
2-Digit EEC-IV DIAGNOSTIC TROUBLE CODE (DTC) DEFINTIONS — Passenger Car
DIAGNOSTIC TROUBLE CODES
(DTC's)
DEFINITIONS
11 - O, R, C
System PASS
12 - R
Cannot control rpm during KOER Self-Test high rpm check
13 - R
Cannot control rpm during KOER Self-Test low rpm check
14 - C
PIP circuit failure
15 - O
PCM Read Only Memory (ROM) test failed
15 - C
PCM Keep Alive Memory (KAM) test failed
16 - R
Rpm too low to perform HO2S test
18 - R
SPOUT circuit open
18 - C
IDM circuit failure/SPOUT circuit grounded
19 - O
Failure in PCM internal voltage
21 - O, R
ECT out of Self-Test range
22 - O, R, C
MAP/BARO out of Self-Test range
23 - O, R
TP out of Self-Test range
24 - O, R
ACT out of Self-Test range
26 - O, R
MAF out of Self-Test range
29 - C
Insufficient input from the Vehicle Speed Sensor (VSS)
31 - O, R, C
EVP circuit below minimum voltage
32 - O, R, C
EVP voltage below closed limit
33 - R, C
EGR valve opening not detected
34 - O, R, C
EVP voltage above closed limit
35 - O, R, C
EVP circuit above maximum voltage
41 - R
HO2S circuit indicates system lean (right HO2S)
41 - C
No HO2S switch detected (right HO2S)
42 - R
HO2S circuit indicates system rich (right HO2S)
44 - R
Secondary Air Injection system inoperative (right side)
45 - R
Secondary Air Injection upstream during Self-Test
46 - R
Secondary Air Injection not bypassed during Self-Test
51 - O, C
ECT indicated -40°C (-40°F)/circuit open
53 - O, C
TP circuit above maximum voltage
54 - O, C
IAT indicated -40°C (-40°F)/circuit open
56 - O, C
MAF circuit above maximum voltage
61 - O, C
ECT indicated 123°C (254°F)/circuit grounded
63 - O, C
TP circuit below minimum voltage
64 - O, C
ACT indicated 123°C (254°F)/circuit grounded
Ford Racing Technical Support (800)FORD-788
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M-12071-A50
REVISION 2
66 - C
MAF circuit below minimum voltage
67 - O
Park/Neutral Position (PNP) switch circuit open - or A/C ON
during Self-Test
77 - R
Brief WOT not sensed during Self-Test/Operator error
79 - O
A/C on/Defrost on during Self-Test
81 - O
Secondary Air Injection Diverter (AIRD) solenoid circuit failure
82 - O
Secondary Air Injection Bypass (AIRB) solenoid circuit failure
84 - O
EGR Vacuum Regulator (EVR) circuit failure
85 - O
Canister Purge (CANP) circuit failure
87 - O,C
Fuel pump primary circuit failure
91 - R
HO2S circuit indicates system lean (left HO2S)
91 - C
No HO2S switching detected (left HO2S)
92 - R
HO2S circuit indicates system rich (left HO2S)
94 - R
Secondary Air Injection system inoperative (left side)
95 - O,C
Fuel pump secondary circuit failure
96 - O,C
Fuel pump secondary circuit failure
98 - R
Hard fault is present - FMEM mode
NO DTC's *
Unable to initiate Self-Test or unable to output DTC's *
DTC's NOT LISTED
DTC's displayed are not applicable to the vehicle being tested
KEY: O = Key On Engine Off (KOEO)
R* = Engine Running (ER)
C = Continuous Memory
Some of the above codes can be expected and should not be a cause for concern. These are
commonly referred to as 'Soft Codes' which indicates that a fault may be present, but that the
PCM will not activate the 'Check Engine' light, nor will it enter into Fault Mode Engine
Management (FMEM), or 'Limp Home Mode'. These codes typically include the following:













29
33
44
45
46
67 (KOER Is not possible when this code is present, See page 12, Section C)
81
82
85
87
94
95
96
* Please refer to Page 12, Section C, for help on performing Engine Running (ER) Diagnostics
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Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
13.0
PCM CONNECTOR FACE AND USAGE CHART
Ford Racing Technical Support (800)FORD-788
- 18 -
M-12071-A50
REVISION 2
14.0
ELECTRICAL SCHEMATIC - 5.0L Mass Air
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Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
15.0
FRCM Schematic
Ford Racing Technical Support (800)FORD-788
- 20 -
M-12071-A50
REVISION 2
16.0
MISCELLANEOUS PARTS LIST
Description
Part Number
Starter Solenoid (Diode Suppressed) ……………………………….. E9TZ-11450-B
Ignition Coil ...………………………………………………………….. E73Z-12029-A
Fuel Rail, 5.0L …………………………………………………………. F2ZZ-9F792-AS
Fuel Rail, 5.8L …………………………………………………………. F2TZ-9F792-C
Fuel Filter ………………………………………………………………. E7DZ-9155-A
Barbed Fuel Filter Fitting (5/16”) ……………………………………... N806187-S190
Barbed Fuel Filter Fitting (3/8”) ………………………………………. N806796-S190
Fuel Filter Duck Bill Clip (5/16”) ……………………………………… N802239-S
Fuel Filter Duck Bill Clip (3/8”) ……………………………………….. N802241-S
Fuel Line Fitting, male, Pressure Line ………………………………. N806207-S190
Fuel Line Fitting, male, Return Line …………………………………. 390417-S190
Fuel Line Fitting, female, Pressure Line …………………………….. N806205-S190
Fuel Line Fitting, female, Return Line ……………………………….. 390417-S190
Distributor, Non Roller (Flat Tappet) Cam Compatible, 5.0L ……… E5TZ-12127-B
Distributor, Non Roller (Flat Tappet) Cam Compatible, 5.8L ……… E7TZ-12127-D
MSD Distributor, Roller Cam Compatible, 5.0L …………………….. PN 8456
MSD Distributor, Roller Cam Compatible, 5.8L …………………….. PN 8452
Quantity
(4)
(6)
(6)
(4)
(12)
(4)
(4)
(1)
(6)
(6)
(4)
(2)
(4)
(1)
(6)
(3)
(1)
Description
Part Number
Fuel Injector Rail Bolts ……………………………….. 56073-S2
Flywheel Bolts (Manual) ……………………………... F1ZZ-6379-A
Flywheel Bolts (Automatic) ………………………….. D2AZ-6379-B
Motor Mount Bolts ……………………………………. 391099-S100
Lower Intake Manifold Bolts …………………………. 388058-S
T-5 Transmission to Bellhousing Bolts ……………...N605935-S2
Cylinder Head Smog Plugs …………………………. F4ZZ-6E086-A
Distributor Hold-Down and Bolts ……………………. M-12270-A302
Valve Cover Bolts (Stamped Steel style) …………...390819-S2
Valve Cover Bolts (Cast Aluminum style) ………….. 390820-S8
GT40 Upper to Lower Mounting Bolts (Short) …….. 390395-S32
GT40 Upper to Lower Mounting Bolts (Long) ……... 390658-S8
EFI Cover Bolts ……………………………………….. 57357-S2
EFI Throttle Cable ……………………………………. E6ZZ-9A758-A
Pressure Plate Bolts …………………………………..N602549-S51M
Pressure Plate Dowel Pins ………………………….. D1FZ-6397-B
K&N Conical Filter ……………………………………. RU-3130
Alternator Harness for 1987-93 Mustang 5.0L Alternator ……... F3TZ-14305-F
- Green/Red Wire, 12V Key On
- Yellow/White Wire, 12V Constant
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Ford Racing Technical Support (800)FORD-788
M-12071-A50
REVISION 2
NOTES
Ford Racing Technical Support (800)FORD-788
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Print Revision: Nov-2012