Ford F150 Pickup. Instruction - part 1520

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Continuous Oil Flow To VCT Piston Chamber  

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VCT Solenoid Valve Stuck Open  

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Camshaft Advance Mechanism Binding (VCT Unit)  

Start engine. Perform KOER ON-DEMAND SELF-TEST. If KOER DTC P0010, P0012, P0021, 
P0022, P1381, P1383, P1386 or P01388 is present, go to next step. If KOER DTC P0010, P0012, P0021, 
P0022, P1381, P1383, P1386 or P01388 is not present, fault may be intermittent. Go to TEST Z, step 1). 

12) Check Camshaft Timing 
 
Check camshaft timing. See appropriate article in ENGINES. Repair as necessary. If camshaft timing is 
okay, variable camshaft timing mechanism is seized and unable to move. Repair or replace VCT unit. 
Clear DTCs and repeat QUICK TEST procedures to ensure all EEC-V systems are working properly and 
DTCs are no longer present.  

TEST HM: SECONDARY AIR INJECTION SYSTEM 

Diagnostic Aids 

Perform this test when instructed during QUICK TEST or if directed by other test procedures. This test is used 
to diagnose the following:  

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Wiring Harness Circuits: (AIRB, B+, EAIR, EAIR MONITOR & GND)  

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Solid State Relay (SSR)  

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Electric Secondary Air Injection (AIR) Pump. See Fig. 250.  

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Secondary Air Injection (AIR) By-Pass Solenoid  

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Powertrain Control Module (PCM)  

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Secondary Air Injection (AIR) Diverter Valve  

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Vacuum Supply & Hoses  

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Air Silencer  

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Secondary Air Injection (AIR) Check Valve  

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Partial Restricted Exhaust  

NOTE:

After each service or repair procedure has been completed, reconnect all 
components. Clear DTCs and repeat QUICK TEST procedures to ensure all EEC-
V systems are working properly and DTCs are no longer present.

 

2003 Ford Pickup F150 

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

  

Fig. 249: Identifying Electric AIR Circuit & Connector Terminals 
Courtesy of FORD MOTOR CO. 

Fig. 250: Identifying Electric AIR Pump Components 
Courtesy of FORD MOTOR CO. 

Testing 

 

2003 Ford Pickup F150 

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

  

1) For KOEO, KOER & Continuous Memory DTC P0412: Check B+ Voltage To Solid State Relay
DTC P0412 indicates secondary air injection system AIR circuit fault. Possible causes are: 

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AIR Circuit Open Or Short To PWR  

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AIR By-Pass Solenoid Fault  

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Faulty PCM  

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Faulty Solid State Relay (SSR)  

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Faulty AIR Pump  

Turn ignition switch to OFF position. Disconnect SSR harness connector. Turn ignition switch to ON 
position. Using a DVOM, measure voltage between negative battery terminal and B+ circuit at SSR 
harness connector. See Fig. 249. If voltage is more than 10.5 volts, supplied voltage is okay. Go to next 
step. If voltage is 10.5 volts or less, go to step 6). 

2) Check EAIR Circuit For Open In Harness 
 
Turn ignition switch to OFF position. Disconnect AIR by-pass solenoid. Temporarily remove secondary 
air injection system dedicated fuse. Disconnect PCM connector(s). Inspect connector for loose, damaged 
or corroded terminals. Repair as necessary. Using a DVOM, measure resistance of SAIR circuit between 
PCM harness connector, SSR harness connector and secondary AIR by-pass solenoid harness connector. 
See Fig. 249. If either resistance measurement is 5 ohms or more, repair open in affected circuit. If all 
resistance measurements are less than 5 ohms, go to next step. 

3) Check SAIR Circuit For Short To PWR Or GND With Disconnected AIR By-Pass Solenoid 
 
Using a DVOM, measure resistance between SAIR circuit, and VPWR circuit at PCM harness connector, 
and negative battery terminal. See Fig. 249. If both resistance measurements are more than 10 k/ohms, go 
to next step. If either resistance measurement is 10 k/ohms or less, repair short between affected circuits. 

4) For KOEO, KOER & Continuous Memory DTC P2258: Check AIR By-Pass Solenoid Resistance
 
Ensure AIR by-pass solenoid is disconnected. Using a DVOM, measure resistance between both AIR by-
pass solenoid terminals. If resistance is 50-100 ohms, go to next step. If resistance is not 50-100 ohms, 
replace AIR by-pass solenoid. 

5) Check SAIR Circuit For Short To PWR Or GND With SSR Reconnected 
 
Ensure AIR by-pass solenoid is disconnected. Reconnect SSR harness connector. Using a DVOM, 
measure resistance between SAIR, PWR GND and VPWR circuits at PCM harness connector. See PCM 
CONNECTOR IDENTIFICATION and Fig. 249. If any resistance is 10 k/ohms or less, replace SSR. If 
all resistance measurements are more than 10 k/ohms, reconnect all connectors and go to step 9) (DTC 
P0411), or go to step 16) (all others). 

6) Check B+ Circuit For Open In Harness 

NOTE:

For additional testing information, see DIAGNOSTIC AIDS.

 

2003 Ford Pickup F150 

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

  

 
Ensure SSR is disconnected. Using a DVOM, measure resistance of B+ circuit between SSR harness 
connector and secondary AIR system dedicated fuse output terminal. See Fig. 249. If resistance is less 
than 5 ohms, check VPWR circuit for short to GND. Replace dedicated fuse, reconnect SSR and go to 
step 8). If resistance is 5 ohms or more, repair open in B+ circuit. Reconnect SSR and reinstall dedicated 
fuse. 

7) For KOEO, KOER & Continuous Memory DTC P0411: Visually Inspect Electric AIR Pump 
Hoses & Air Silencer 
DTC P0411 indicates secondary air injection system does not detect the presence of air in exhaust when 
introduced by secondary air injection system. Possible causes are: 

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Faulty Electric AIR (EAIR) Pump  

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Hose From AIR Pump Leaking Or Blocked  

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AIR By-Pass Solenoid Leak/Blocked, Stuck Open Or Closed  

Check EAIR pump air hoses from pump to AIR diverter valves for binding, cracks, obstructions, water or 
ice (in colder climates). Check for damaged exhaust system. Check AIR silencer for obstructions. Repair 
as necessary. If all components and hoses are okay, go to next step. 

8) Check EAIR Pump Operation 
Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, 
enter OUTPUT TEST MODE. If EAIR pump operates, turn ignition switch to OFF position and go to 
step 17) to check EAIR pump for water contamination. If EAIR pump does not operate, fault may be 
intermittent. Go to TEST Z, step 2) and check for intermittent faults. If no intermittent faults are found, 
go to step 13). 

9) Check For Vacuum At AIR Diverter Valves 
 
Ensure ignition switch is turned to OFF position. Connect scan tool to Data Link Connector (DLC). 
Connect a vacuum gauge to AIR diverter valve(s) control vacuum hose. Using a hand vacuum pump, 
apply 16 in. Hg (54 kPa) of vacuum to intake manifold side of AIR by-pass solenoid vacuum supply 
hose. Turn ignition switch to ON position. Using scan tool, enter OUTPUT TEST MODE. Vacuum 
should be present on vacuum gauge. If vacuum is present, go to next step. If vacuum is not present, go to 
step 32). 

NOTE:

For additional testing information, see DIAGNOSTIC AIDS.

NOTE:

To properly test EAIR pump, it must be capable of driving HO2S to lean.

CAUTION: Overheating and damage may occur to EAIR pump if operated in 

OUTPUT TEST MODE for longer than 2 minutes.

NOTE:

On 2-valve systems, ensure air flows from both valves.

 

2003 Ford Pickup F150 

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