Ford F-150 1998 Workshop Manual

ford :: Ford Truck F 150 2WD Pickup V8-5.4L
Prop SOHC VIN Z (1998)

> A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 )

P0500 - P0504: Testing and InspectionP0500 ( P 0500 )

For diagnosis of refer to the system experiencing the problem.P0500

Computers and Control Systems or Transmission Control System

Refer to pinpoint test DP1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle SpeedSensor (VSS)

For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection

Transfer Case

ESOF - Electronic Shift on the Fly

> A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information

> System Diagnosis > P0500 ( P 0500 ) > Page 9

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

> A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information

> System Diagnosis > P0500 ( P 0500 ) > Page 10

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

B1432 - P1820 Electronic Shift on the Fly (ESOF)

MSOF - Mechanical Shift on the Fly

B1450 - P1828 Mechanical Shift on the Fly (MSOF)

For complete Transfer Case diagnostic information,

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications

Alarm Module: Specifications

Remote Anti-Theft Personality Module Nuts ..................................................................................................................................... 7-8.1 Nm (62-72 in lb)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications > Page 16

Alarm Module: Description and Operation

The RAP module controls the anti-theft system and the keyless entry system. The RAP module communicates with the GEM to request that the interiorlights be turned ON/OFF with use of the keyless entry remote transmitter, and the GEM communicates with the RAP module to inform when the door isopened. REFER to Module Communications Network for inter-module communication.

(RAP)

The ignition lock anti-theft switch detects if the ignition key cylinder is broken or "slam pulled" during a theft. The ignition lock anti-theft switch isalways monitored by the Remote Anti-theft Personality module. This allows the alarm system to be triggered if the ignition lock anti-theft switchdetects tampering of the ignition key cylinder (even in the event that the alarm is not active at the time).

(GEM)

The door open warning lamp switch communicates with the RAP module through the Generic Electronic Module . This input to the RAP modulewill cause the anti-theft alarm to be sounded if the anti-theft alarm was armed.

The door disarm switches are attached to both the LH and RH lock cylinder. The door disarm switch must be triggered before the mechanical lockunlocks. This prevents the anti-theft alarm from activating when it should have been disarmed.

In addition to the perimeter alarm that uses the door open warning lamp switch, the RAP module also uses the ignition lock anti-theft switch and theautolock/relock feature to prevent theft of the vehicle. For a full description of the autolock/relock system, REFER to the Keyless Entry system.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications > Page 17

Alarm Module: Service and Repair
REMOVAL

1. Disconnect the battery ground cable.

Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result.CAUTION:

2. Remove the LH front door scuff plate.

3. Remove the LH cowl side trim panel.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications > Page

18

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

4. Disconnect the two Remote Anti-theft Personality module electrical connectors.(RAP)

1 Disconnect C257.
2 Disconnect C256.

If C256 is disconnected first, an inadvertent IGNTAM alarm event (AL_EVT) will be stored and the alarm will sound. The alarm must beNOTE:

disarmed by the remote unlock button or a key in the door lock cylinder to UNLOCK. To avoid this condition, disconnect (1) C257 before (2)C256 and reconnect (2) C256 before (1) C257.

5. Remove the RAP module nuts and the RAP module.

INSTALLATION

1. To install, reverse the removal procedure.

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy.The vehicle may need to be driven or more to relearn the strategy.16 km (10 mi)

^ To avoid inadvertent alarm activation, reconnect C256 first.

^NOTE:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications

Multifunction Electronic Control Module: Specifications

GEM/CTM Screws ........................................................................................................................................................................... 0.9-1.3 Nm (8-12 in lb)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications > Page 22

Multifunction Electronic Control Module: Description and Operation

(CTMs)

Central Timer Modules are equipped on two-wheel drive vehicles without power windows. All other vehicles have a Generic Electronic Module.(GEM)

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Information > Specifications > Page 23

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

NOTE: (NGS)

CTM diagnostics are not compatible with the New Generation STAR Tester; instead, the diagnostics are internal to the module. Thediagnostic mode is entered by shorting two pins of the diagnostic connector together.
The GEM inputs and outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged.

GEM Diagnostics

(SBDS)

The GEM diagnostics are accessible with the New Generation Star Tester and the Service Bay Diagnostic System . The GEM constantlymonitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a DiagnosticTrouble Code .(DTC)

There are three areas of diagnostic information useful when diagnosing the GEM.

^ DTCs A record of past or present system problems.

^ PIDs - The present state of an input or output.
^ Active Commands Gives the ability to turn on GEM outputs without activating the inputs normally associated with the function.

Ignition Switch Positions

The position of the ignition switch is very important to proper GEM operation. Often times, erratic or unexpected operation can be traced to problems onthese GEM inputs. The following is a brief description of five ignition switch positions.

When the ignition switch is in the RUN position, battery voltage should be present at the GEM/CTM RUN and RUN/ACC input terminals When theignition switch is in the ACC position, battery voltage should be present at the GEM/CTM RUN/ACC input terminal only.
When the ignition switch is in the START position, battery voltage should be present at the GEM/CTM start/clutch depressed input.

The GEM module does not have an OFF or LOCK Switch State input. The GEM will assume the OFF or LOCK position when there are no RUN, ACC,or START signals present.

GEM Features and Functions

GEM Feature Matrix

The GEM controls the following features:

^ Wipers/washers.
^ Warning chimes.
^ Battery saver.
^ Illuminated entry and courtesy lamps.
^ Driver power window
^ Accessory delay.
^ 4-wheel drive

Wiper/Washer Control and Interval Timer

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Information > Specifications > Page 24

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

There are four modes of operation for the wipers: interval (standard CTM and speed-dependent GEM), LOW, HI, and wash. These modes are onlyactive with the ignition switch in the RUN or ACC position. Speed dependent wipers compensate for the extra moisture that accumulates on thewindshield at higher speeds. At higher speeds, the speed dependent feature shortens the delay between wipers when using the variable interval wiperfeature. Delays will automatically adjust at speeds between .16 and 105 km/h (10 and 65 mph)

Chime Warning

There are four warning chimes and lamps that are controlled by the GEM and CTM: headlamps operating without the ignition on (chime only), door ajar(chime and lamp), key in the ignition (chime only), and driver seat belt warning (chime and lamp).

Battery Saver

40 minutes

The battery saver feature removes extended interior lamp power drains from the battery. The GEM and CTM will keep power available for all interiorlights and hood lamp circuits for after the ignition switch is turned OFF. The battery saver timer is reset by lifting a door handle (GEM only),activating a door ajar switch, unlocking door with the keyless entry remote transmitter, or changing the ignition to RUN or ACC position. If asleep, theGEM and CTM will wake up when one of the following occurs:

^ Any door becomes ajar or is closed.
^ The key is inserted or removed.
^ The ignition switch is turned to ACC or RUN.
^ The doors are unlocked with the keyless entry remote transmitter.

Courtesy Lamps/Illuminated Entry

The GEM/CTM illuminates the interior courtesy lamps when any door is ajar. The GEM also receives a signal from the Remote Anti-theft Personality module for keyless entry illumination. All interior courtesy lamps are turned off when any of the following occur:(RAP)

^

have elapsed since the illuminated entry feature was activated.Twenty-five seconds

^ The ignition switch is turned to RUN.
^

25 km/h (15 mph) 16 km/h (10 mph)

Vehicle speed is over (a new ajar signal will turn on courtesy lamps only if the vehicle speed is less than - GEM only).

Delayed Accessory (GEM only)

ten minutes

The delayed accessory feature provides power to the power windows for after the ignition switch is moved from the RUN to the OFFposition. If during this period either door is opened, the delayed accessory relay will be de-energized.ten-minute

One-Touch Down Window (GEM only)

The power switch for the driver window control has two detents for the down window control. With the ignition switch in RUN or ACC, pressing thefirst detent (normal mode) allows manual down window control; pressing the switch farther to the second detent (auto) will cause the driver window toautomatically move to the full down position. Pressing either the up or down window switch will cancel an auto mode operation in progress.

Transfer Case (4-Wheel Drive - GEM Only)

Two types of 4-wheel drive systems are offered: the Mechanical Shift-On-the-Fly and the Electronic Shift-On-the-Fly .(MSOF) (ESOF)

RAP-Controlled Functions

The RAP module controls the door locks through three external relays located under the instrument panel relay cover:

^ Driver unlock relay.
^ All unlock relay.
^ All lock relay.

The RAP module receives input from the following components for electronic door lock system operation:

^ Keyless entry remote transmitters.
^ Door ajar output from the GEM.
^ Door unlock switches (LH/RH).
^

Brake Pedal Position switch.(BPP)

^

Digital Transmission Range sensor.(DTR)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications > Page 25

Multifunction Electronic Control Module: Service and Repair

GENERIC ELECTRONIC MODULE

REMOVAL

1. Disconnect the battery ground cable.

Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result.CAUTION:

2. Remove the cover from the instrument panel fuse junction panel.

3. Remove the lower instrument panel steering column cover.
1 Remove the lower instrument panel steering column cover bolts.
2 Remove the lower instrument panel steering column cover.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component

Information > Specifications > Page 26

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

4. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel.

5 Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts.

6. Disconnect the (A) Generic Electronic Module/Central Timer Module electrical connectors from the (B) GEM/CTM.(GEM/CTM)

7. Remove the GEM/CTM screws and the GEM/CTM.

INSTALLATION

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Information > Specifications > Page 27

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

1. To install, reverse the removal procedure.
^ Check for proper operation.

NOTE:

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptivestrategy. The vehicle may need to be driven or more to relearn the strategy.16 km (10 mi)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-15> May > 98 > ABS - Lamp

ON/DTC B1342 Stored

Electronic Brake Control Module: Customer InterestABS - Lamp ON/DTC B1342 Stored

Article No.98-9-15
05/11/98
^

BRAKES - 4WABS - ABS LAMP ILLUMINATED WITHDIAGNOSTIC TROUBLE CODE (DTC) B1342STORED IN MEMORY AND/OR CODES NOT LISTEDIN WORKSHOP MANUAL - VEHICLES BUILTTHROUGH 2/12/98

^

LAMP - ABS LAMP ILLUMINATED WITHDIAGNOSTIC TROUBLE CODE (DTC) B1342STORED IN MEMORY AND/OR CODES NOT LISTEDIN WORKSHOP MANUAL - VEHICLES BUILTTHROUGH 2/12/98

LIGHT TRUCK:1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR

ISSUEThe Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New GenerationStar (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brakecontrol module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will bemaintained.

ACTIONReplace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer tothe appropriate Workshop Manual, Section 206-09, for replacement procedures.
PART NUMBER PART NAME

F75Z-2C065-AA

Anti-lock Brake Control Module(F-150)

F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD)
F7SZ-2C065-CA

Anti-lock Brake Control Module(Expedition, Navigator)
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
980915A Diagnose And Replace 0.6 Hr.

ABS Module - F-Series,Expedition, And Navigator

DEALER CODING

CONDITION
BASIC PART NO. CODE
2C065 42

OASIS CODES: 206000, 301000

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-9-15 > May > 98

> ABS - Lamp ON/DTC B1342 Stored

Electronic Brake Control Module: All Technical Service BulletinsABS - Lamp ON/DTC B1342 Stored

Article No.98-9-15
05/11/98
^

BRAKES - 4WABS - ABS LAMP ILLUMINATED WITHDIAGNOSTIC TROUBLE CODE (DTC) B1342STORED IN MEMORY AND/OR CODES NOT LISTEDIN WORKSHOP MANUAL - VEHICLES BUILTTHROUGH 2/12/98

^

LAMP - ABS LAMP ILLUMINATED WITHDIAGNOSTIC TROUBLE CODE (DTC) B1342STORED IN MEMORY AND/OR CODES NOT LISTEDIN WORKSHOP MANUAL - VEHICLES BUILTTHROUGH 2/12/98

LIGHT TRUCK:1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR

ISSUEThe Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New GenerationStar (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brakecontrol module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will bemaintained.

ACTIONReplace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer tothe appropriate Workshop Manual, Section 206-09, for replacement procedures.
PART NUMBER PART NAME

F75Z-2C065-AA

Anti-lock Brake Control Module(F-150)

F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD)
F7SZ-2C065-CA

Anti-lock Brake Control Module(Expedition, Navigator)
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
980915A Diagnose And Replace 0.6 Hr.

ABS Module - F-Series,Expedition, And Navigator

DEALER CODING

CONDITION
BASIC PART NO. CODE
2C065 42

OASIS CODES: 206000, 301000

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control

Module: > 03-10-3 > May > 03 > Fuel System (CNG/LPG) - No Start Condition

Fuel Injector Driver Module (CNG): All Technical Service BulletinsFuel System (CNG/LPG) - No Start Condition

Article No.03-10-3
05/26/03
^

DRIVEABILITY - BI-FUEL CNG/LPG LOW FLOW INJECTOR SERVICE KIT WITHOUT COOLANT LOCK-OFF

^

DRIVEABILITY - CRANK NO START - BI-FUEL CNG/LPG VEHICLES - LOW FLOW INJECTOR SERVICE KIT WITHOUT COOLANT LOCK-OFF

FORD:1996-2000 CONTOUR1996-2003 F-1501997 F-250 LD1998-1999 E SERIES2000-2001 SUPER DUTY F SERIES
Article 02-10-5 is being republished in its entirety to update the model line and model year coverage.

ISSUESome 1996-2002 B-Fuel CNG F-150, E-250/350, 1996-2000 Contour, 2000-2003 B-Fuel LPG F-150 and 2000-2001 Super Duty F Series vehicles(without coolant lock-off) may exhibit a no start condition. This may be caused by stuck Low Flow Injectors on the Compuvalve possibly due to fuelcontamination. To avoid the replacement of the Compuvalve when only the Low Flow Injectors have failed, the Low Flow Injectors have been releasedseparately for service.

ACTIONIf diagnosis leads to a failed Low Flow Injector, refer to the following removal and installation procedure to replace the Low Flow Injector assembly.
SERVICE PROCEDURE

WARNING

WHEN SERVICING FUEL RELATED COMPONENTS, ELIMINATE ALL SOURCES OF IGNITION (E.G. TORCHES, HEATERS, ANDLIGHTED TOBACCO). FLAMMABLE MIXTURES MAY BE PRESENT AND CAN IGNITE, RESULTING IN DAMAGE AND/OR INJURIES.THE FUEL SYSTEM LINE PRESSURE MUST BE RELIEVED BEFORE ANY COMPONENT CAN BE REMOVED. REMOVAL OFCOMPONENTS WITHOUT PRESSURE RELIEF CAN CAUSE AN UNCONTROLLED RELEASE OF PROPANE OR NATURAL GAS ANDMAY RESULT IN DAMAGE AND/OR INJURIES.

PRELIMINARY PREPARATION

1.

Relieve system line pressure and remove the Compuvalve from the vehicle. Refer to Service Manual GFIP162 for the 1996 CNG Bi-Fuel modelyear and Service Manual GFIP173 for the 1998 CNG Bi-Fuel model year. Bi-Fuel vehicles for the 1999 through 2003 Bi-Fuel CNG model yearsand 2000 through 2003 Bi-Fuel LPG model years. Refer to the Ford Truck/Car Workshop Manual Section 303-04D.

NOTE

ONCE THE SYSTEM IS DISCONNECTED, COVER ALL OPEN HOSE FITTINGS AND ELECTRICAL CONNECTIONS TO AVOIDCONTAMINATION.

2. Ensure that all loose debris is removed from the injector area, to avoid contamination during removal.

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Other Service Bulletins for Electronic Brake Control Module: > 03-10-3 > May > 03 > Fuel System (CNG/LPG) - No Start Condition > Page 47

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

3. Place the Compuvalve flat on a work bench (with injectors facing up).

NOTE

ENSURE THAT THE BENCH SURFACES ARE CLEAN AND DIRT FREE. BENCHES SHOULD BE COVERED TO AVOID SCRATCHINGCOMPONENT SURFACES.

REMOVAL OF LOW FLOW INJECTOR ASSEMBLY

NOTE

DURING THE REMOVAL OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROM ENTERINGTHE FUEL FLOW OPENINGS.

1. Carefully cut cable tie (1) securing the Low Flow Injector Assembly (A) harness and discard cable tie (Figure 1).

2. Remove the two mounting screws (2) securing the Injector Fuel Rail (3) to the Compuvalve (4) and discard screws (Figure 1).

3.

4. Remove 0-ring (5) from Compuvalve (4) and discard 0-ring (Figure 1).

NOTE

IF THE COMPUVALVE IS LEFT UNINSTALLED FOR AN EXTENDED PERIOD OF TIME, USE A CLEAN LINT-FREE CLOTH TOCOVER ALL EXPOSED OPENINGS TO AVOID CONTAMINATION.

INSTALLATION OF LOW FLOW INJECTOR ASSEMBLY
Assembly Preparation

1. Ensure all mating surfaces between Compuvalve (4), Injector Fuel Rail (3) and Low Flow Injectors (6) & (7) are clean (Figure 1).

NOTE

TO CLEAN, GENTLY WIPE SURFACES USING A CLEAN LINT-FREE CLOTH.

2. Ensure that lubricant is on both the inlet and outlet 0-rings of the new Low Flow Injectors (6) & (7) and on 0-ring (5) (Figure 1).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-3 > May > 03 > Fuel System (CNG/LPG) - No Start Condition > Page 48

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Remove the Low Flow Injector Assembly (A) and Injector Fuel Rail (3) from Compuvalve (4). Discard Low Flow Injector assembly (A) and setaside the Injector Fuel Rail (3) (Figure 1).

NOTE

IF REQUIRED, APPLY A THIN FILM OF NON-SILICONE BASED LUBRICANT FOR 0-RINGS (E.G. PARKER 0-LUBE).

3.

Before installing the Low Flow Injector Assembly (A), ensure that the orientation of injector # 1 (6) (with shorter wire) and of injector # 2 (7)(with longer wire) are positioned as shown (Figure 1).

Assembly Installation

NOTE

DURING THE INSTALLATION OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROMENTERING THE FUEL FLOW OPENINGS.

1. Press the outlet of the Low Flow Injectors (6) & (7) into Compuvalve (4) (Figure 1).

2.

Route wires under the outlet portion of the Low Flow Injectors (6) & (7) 50 that the wires will not become pinched between Compuvalve (4) andthe Injector Fuel Rail (3) (Figure 1)

3. Install 0-ring (5) into Compuvalve (4) as shown (Figure 1).

4. Press Injector Fuel Rail (3) onto the inlet of Low Flow Injectors (6) & (7) (Figure 1).

5. Apply Loctite 272 to the threads of mounting screws (2) (Figure 1).

6.

Line up the two holes in the Injector Fuel Rail (3) with the mounting holes in the Compuvalve (4) and install with mounting screws (2). Torque to2-2.5 N.m (18-22 Lb-in) (Figure 1).

CAUTION

ENSURE THAT INJECTOR WIRES ARE NOT PINCHED UNDER INJECTORS OR INJECTOR FUEL RAIL.

7. Insert cable tie (1) through the cable tie holder (8) and gently tighten Low flow Injector Assembly (A) harness (Figure 1).

8.

When complete, install Compuvalve (4) to the vehicle and leak test all removed components and fittings. Refer to Service Manual GFIP162 for the1996 CNG Bi-Fuel model year and Service Manual GFIP173 for the 1998 CNG Bi-Fuel model year. For Bi-Fuel vehicles for the 1999 through2003 CNG Bi-Fuel model years and 2000 through 2003 LPG Bi-Fuel model years, refer 10 Workshop Manual Section 310-00C.

Parts Block

OTHER APPLICABLE ARTICLES: 03-10-4, 02-10-4SUPERSEDES: 02-10-5WARRANTY STATUS: INFORMATION ONLYOASIS CODES: 206000, 601300, 602300, 603300, 607000, 607400, 608000, 609000, 609400, 611000, 611500

Disclaimer

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control

Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition

Fuel Injector Driver Module (CNG): All Technical Service BulletinsFuel System (LPG) - No Start Condition

Article No03-10-4
05/26/03

DRIVEABILITY - BI-FUEL LPG LOW FLOW INJECTOR SERVICE ASSEMBLY WITH COOLANT LOCK-OFF

FORD:1998-1999 E SERIES, F-150, F-250
Article 02-10-6 is being republished in its entirety to update the model coverage.

ISSUESome 1998-1999 B-Fuel LPG vehicles (With Coolant Lock off) may exhibit a no start condition. This may be caused by stuck Low Flow Injectors on theCompuvalve possibly due to fuel contamination. To avoid the replacement of the Compuvalve when only the Low Flow Injectors have tailed, the LowFlow Injectors have been released separately for service.

ACTIONIf diagnosis leads to failed Low Flow Injectors, refer to the following removal and installation procedure to replace the Low Flow Injector assembly.
SERVICE PROCEDURE

WARNING

WHEN SERVICING FUEL RELATED COMPONENTS, ELIMINATE ALL SOURCES OF IGNITION (E.G. TORCHES, HEATERS, ANDLIGHTED TOBACCO). FLAMMABLE MIXTURES MAY BE PRESENT AND CAN IGNITE, RESULTING IN DAMAGE AND/OR INJURIES.THE FUEL SYSTEM LINE PRESSURE MUST BE RELIEVED BEFORE ANY COMPONENT CAN BE REMOVED. REMOVAL OFCOMPONENTS WITHOUT PRESSURE RELIEF CAN CAUSE AN UNCONTROLLED RELEASE OF PROPANE AND MAY RESULT INDAMAGE AND/OR INJURIES.

PRELIMINARY PREPARATION

1.

Relieve system line pressure and remove the Compuvalve from the vehicle. Refer to Service Manual GFIP163 for the 1998 LPG Bi-Fuel modelyear. For 1999 model year Bi-Fuel LPG vehicles refer to the Ford Truck Workshop Information Section 303-04E.

NOTE

2. Ensure that all loose debris is removed from the injector area, to avoid contamination during removal.

3. Place the Compuvalve flat on a work bench (with injectors facing up).

NOTE

ENSURE THAT THE BENCH SURFACES ARE CLEAN AND DIRT FREE. BENCHES SHOULD BE COVERED TO AVOID SCRATCHINGCOMPONENT SURFACES.

REMOVAL OF LOW FLOW INJECTOR ASSEMBLY

NOTE

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F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

ONCE THE SYSTEM IS DISCONNECTED, COVER ALL OPEN HOSE FITTINGS AND ELECTRICAL CONNECTIONS TO AVOIDCONTAMINATION.

DURING THE REMOVAL OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROM ENTERINGTHE FUEL FLOW OPENINGS.

1. Carefully cut cable tie (1) securing the Low Flow Injector Assembly (A) harness and discard cable tie (Figure 1).

2. Remove nut (2) and solenoid casing (3) and set aside (Figure 1).

3. Remove Coolant Lock-off Solenoid (4) from core tube (5) (Figure 1).

NOTE

LEAVE THE RUBBER SPACER (6) IN PLACE ON CORE TUBE (5) AFTER REMOVING COOLANT LOCK-OFF SOLENOID (4) (FIGURE1).

4. Remove the two mounting screws (7) securing the Injector Fuel Rail (8) to the Compuvalve (9) and discard screws (Figure 1)

5.

Remove the Low Flow Injector Assembly (A) and Injector Fuel Rail (8) from Compuvalve (9). Discard Low Flow Injector Assembly (A) and setaside the Injector Fuel Rail (8) (Figure 1).

6. Remove 0-ring (10) from Compuvalve (9) and discard 0-ring (Figure 1).

NOTE

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition > Page 54

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

IF THE COMPUVALVE IS LEFT UNINSTALLED FOR AN EXTENDED PERIOD OF TIME, USE A CLEAN LINT-FREE CLOTH TOCOVER ALL EXPOSED OPENINGS TO AVOID CONTAMINATION.

INSTALLATION OF LOW FLOW INJECTOR ASSEMBLY
Assembly Preparation

1. Ensure all mating surfaces between Compuvalve (9), Injector Fuel Rail (8) and Low Flow Injectors (11) & (12) are clean (Figure 1).

NOTE

TO CLEAN, GENTLY WIPE SURFACES USING A CLEAN LINT-FREE CLOTH.

2. Ensure there is lubricant on the inlet and outlet 0-rings of the new Low Flow Injectors (11) & (12) and to 0-ring (11) (Figure 1).

NOTE

IF REQUIRED, APPLY A THIN FILM OF NON-SILICON BASED LUBRICANT (E.G. PARKER 0-LUBE).

3.

Before installing the Low Flow Injector assembly (A), ensure that the orientation of injector # 1 (11) (with shorter wire) and of injector # 2 (12)(with longer wire) are positioned as shown (Figure 1).

Assembly Installation

NOTE

DURING THE INSTALLATION OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROMENTERING THE FUEL FLOW OPENINGS.

1. Press the outlet of the Low Flow Injectors (11) & (12) into Compuvalve (9) (Figure 1).

2.

Route wires under the outlet portion of the Low Flow Injectors (11) & (12) 50 that the wires will not become pinched between Compuvalve (9)and the Injector Fuel Rail (8) (Figure 1).

3. Install 0-ring (10) into Compuvalve (9) as shown (Figure 1).

4. Insert Coolant Lock-off Solenoid (4) onto core tube (5) (orient solenoid as shown) (Figure 1).

5. Press Injector Fuel Rail (8) onto the inlet of Low Flow Injectors (11) & (12) (Figure 1).

6. Apply Loctite 272 to the threads of mounting screws (7) (Figure 1).

7.

Line up the two holes in the Injector Fuel Rail (8) with the mounting holes in the Compuvalve (9) and install with mounting screws (7). Torque to2-2.5 N.m (18-22 Lb-in) (Figure 1).

CAUTION

ENSURE THAT INJECTOR WIRES ARE NOT PINCHED UNDER THE INJECTORS OR THE INJECTOR FUEL RAIL.

8. Place solenoid casing (3) over Coolant Lock-off Solenoid (4) and tighten down with nut (2). Torque nut to 5-6 N.m (45-55 Lb-in).

9. Insert cable tie (1) through the cable tie holder (13) and tighten (Figure 1).

10.

When complete, install Compuvalve (9) to the vehicle and leak test all removed components and fittings. Refer to Service Manual GFIP163 for the1998 LPG Bi-Fuel model year. For the 1999 LPG Bi-Fuel model year refer to the Ford Truck Workshop Manual Section 310-00C.

OTHER APPLICABLE ARTICLES: 02-10-4, 03-10-3SUPERSEDES: 02-10-6WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 601300, 602300, 603300, 607000, 607400, 608000, 609000, 609400, 611000, 611500

Disclaimer

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition > Page 60

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

1. Carefully cut cable tie (1) securing the Low Flow Injector Assembly (A) harness and discard cable tie (Figure 1).

2. Remove the two mounting screws (2) securing the Injector Fuel Rail (3) to the Compuvalve (4) and discard screws (Figure 1).

3.

4. Remove 0-ring (5) from Compuvalve (4) and discard 0-ring (Figure 1).

NOTE

IF THE COMPUVALVE IS LEFT UNINSTALLED FOR AN EXTENDED PERIOD OF TIME, USE A CLEAN LINT-FREE CLOTH TOCOVER ALL EXPOSED OPENINGS TO AVOID CONTAMINATION.

INSTALLATION OF LOW FLOW INJECTOR ASSEMBLY
Assembly Preparation

1. Ensure all mating surfaces between Compuvalve (4), Injector Fuel Rail (3) and Low Flow Injectors (6) & (7) are clean (Figure 1).

NOTE

TO CLEAN, GENTLY WIPE SURFACES USING A CLEAN LINT-FREE CLOTH.

2. Ensure that lubricant is on both the inlet and outlet 0-rings of the new Low Flow Injectors (6) & (7) and on 0-ring (5) (Figure 1).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition > Page 61

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Remove the Low Flow Injector Assembly (A) and Injector Fuel Rail (3) from Compuvalve (4). Discard Low Flow Injector assembly (A) and setaside the Injector Fuel Rail (3) (Figure 1).

NOTE

IF REQUIRED, APPLY A THIN FILM OF NON-SILICONE BASED LUBRICANT FOR 0-RINGS (E.G. PARKER 0-LUBE).

3.

Before installing the Low Flow Injector Assembly (A), ensure that the orientation of injector # 1 (6) (with shorter wire) and of injector # 2 (7)(with longer wire) are positioned as shown (Figure 1).

Assembly Installation

NOTE

DURING THE INSTALLATION OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROMENTERING THE FUEL FLOW OPENINGS.

1. Press the outlet of the Low Flow Injectors (6) & (7) into Compuvalve (4) (Figure 1).

2.

Route wires under the outlet portion of the Low Flow Injectors (6) & (7) 50 that the wires will not become pinched between Compuvalve (4) andthe Injector Fuel Rail (3) (Figure 1)

3. Install 0-ring (5) into Compuvalve (4) as shown (Figure 1).

4. Press Injector Fuel Rail (3) onto the inlet of Low Flow Injectors (6) & (7) (Figure 1).

5. Apply Loctite 272 to the threads of mounting screws (2) (Figure 1).

6.

Line up the two holes in the Injector Fuel Rail (3) with the mounting holes in the Compuvalve (4) and install with mounting screws (2). Torque to2-2.5 N.m (18-22 Lb-in) (Figure 1).

CAUTION

ENSURE THAT INJECTOR WIRES ARE NOT PINCHED UNDER INJECTORS OR INJECTOR FUEL RAIL.

7. Insert cable tie (1) through the cable tie holder (8) and gently tighten Low flow Injector Assembly (A) harness (Figure 1).

8.

When complete, install Compuvalve (4) to the vehicle and leak test all removed components and fittings. Refer to Service Manual GFIP162 for the1996 CNG Bi-Fuel model year and Service Manual GFIP173 for the 1998 CNG Bi-Fuel model year. For Bi-Fuel vehicles for the 1999 through2003 CNG Bi-Fuel model years and 2000 through 2003 LPG Bi-Fuel model years, refer 10 Workshop Manual Section 310-00C.

Parts Block

OTHER APPLICABLE ARTICLES: 03-10-4, 02-10-4SUPERSEDES: 02-10-5WARRANTY STATUS: INFORMATION ONLYOASIS CODES: 206000, 601300, 602300, 603300, 607000, 607400, 608000, 609000, 609400, 611000, 611500

Disclaimer

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition > Page 66

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

1. Carefully cut cable tie (1) securing the Low Flow Injector Assembly (A) harness and discard cable tie (Figure 1).

2. Remove nut (2) and solenoid casing (3) and set aside (Figure 1).

3. Remove Coolant Lock-off Solenoid (4) from core tube (5) (Figure 1).

NOTE

LEAVE THE RUBBER SPACER (6) IN PLACE ON CORE TUBE (5) AFTER REMOVING COOLANT LOCK-OFF SOLENOID (4) (FIGURE1).

4. Remove the two mounting screws (7) securing the Injector Fuel Rail (8) to the Compuvalve (9) and discard screws (Figure 1)

5.

Remove the Low Flow Injector Assembly (A) and Injector Fuel Rail (8) from Compuvalve (9). Discard Low Flow Injector Assembly (A) and setaside the Injector Fuel Rail (8) (Figure 1).

6. Remove 0-ring (10) from Compuvalve (9) and discard 0-ring (Figure 1).

NOTE

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Other Service Bulletins for Electronic Brake Control Module: > 03-10-4 > May > 03 > Fuel System (LPG) - No Start Condition > Page 67

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

IF THE COMPUVALVE IS LEFT UNINSTALLED FOR AN EXTENDED PERIOD OF TIME, USE A CLEAN LINT-FREE CLOTH TOCOVER ALL EXPOSED OPENINGS TO AVOID CONTAMINATION.

INSTALLATION OF LOW FLOW INJECTOR ASSEMBLY
Assembly Preparation

1. Ensure all mating surfaces between Compuvalve (9), Injector Fuel Rail (8) and Low Flow Injectors (11) & (12) are clean (Figure 1).

NOTE

TO CLEAN, GENTLY WIPE SURFACES USING A CLEAN LINT-FREE CLOTH.

2. Ensure there is lubricant on the inlet and outlet 0-rings of the new Low Flow Injectors (11) & (12) and to 0-ring (11) (Figure 1).

NOTE

IF REQUIRED, APPLY A THIN FILM OF NON-SILICON BASED LUBRICANT (E.G. PARKER 0-LUBE).

3.

Before installing the Low Flow Injector assembly (A), ensure that the orientation of injector # 1 (11) (with shorter wire) and of injector # 2 (12)(with longer wire) are positioned as shown (Figure 1).

Assembly Installation

NOTE

DURING THE INSTALLATION OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROMENTERING THE FUEL FLOW OPENINGS.

1. Press the outlet of the Low Flow Injectors (11) & (12) into Compuvalve (9) (Figure 1).

2.

Route wires under the outlet portion of the Low Flow Injectors (11) & (12) 50 that the wires will not become pinched between Compuvalve (9)and the Injector Fuel Rail (8) (Figure 1).

3. Install 0-ring (10) into Compuvalve (9) as shown (Figure 1).

4. Insert Coolant Lock-off Solenoid (4) onto core tube (5) (orient solenoid as shown) (Figure 1).

5. Press Injector Fuel Rail (8) onto the inlet of Low Flow Injectors (11) & (12) (Figure 1).

6. Apply Loctite 272 to the threads of mounting screws (7) (Figure 1).

7.

Line up the two holes in the Injector Fuel Rail (8) with the mounting holes in the Compuvalve (9) and install with mounting screws (7). Torque to2-2.5 N.m (18-22 Lb-in) (Figure 1).

CAUTION

ENSURE THAT INJECTOR WIRES ARE NOT PINCHED UNDER THE INJECTORS OR THE INJECTOR FUEL RAIL.

8. Place solenoid casing (3) over Coolant Lock-off Solenoid (4) and tighten down with nut (2). Torque nut to 5-6 N.m (45-55 Lb-in).

9. Insert cable tie (1) through the cable tie holder (13) and tighten (Figure 1).

10.

When complete, install Compuvalve (9) to the vehicle and leak test all removed components and fittings. Refer to Service Manual GFIP163 for the1998 LPG Bi-Fuel model year. For the 1999 LPG Bi-Fuel model year refer to the Ford Truck Workshop Manual Section 310-00C.

OTHER APPLICABLE ARTICLES: 02-10-4, 03-10-3SUPERSEDES: 02-10-6WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 601300, 602300, 603300, 607000, 607400, 608000, 609000, 609400, 611000, 611500

Disclaimer

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 68

Electronic Brake Control Module: Specifications
TORQUE SPECIFICATIONS

Rear Wheel Anti-Lock Control Module Screws ......................................................................................................................... 2-3 Nm (17-26 inch lbs.)4-Wheel Anti-Lock Control Module Screws .............................................................................................................................. 4-5 Nm (36-44 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 69

Electronic Brake Control Module: Locations

Instrument Panel View

The Rear Anti-Lock Brake System Module is located behind right side of the instrument panel.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS)

Electronic Brake Control Module: Service and RepairFour Wheel Anti-Lock Brake System (4WABS)

Removal

1. Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.CAUTION:

Disconnect the battery ground cable.

2. Disconnect the anti-lock brake control module electrical connectors.

3. Disconnect the pump motor electrical connector from the anti-lock brake control module.

4. Remove the anti-lock brake control module.
1 Remove the screws.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel

Anti-Lock Brake System (4WABS) > Page 72

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

2 Remove the anti-lock brake control module.

Installation

1. When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptiveNOTE:

strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
To install, reverse the removal procedure.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 73

Electronic Brake Control Module: Service and RepairRear Antilock Brake System (RABS)

Removal

1. Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.CAUTION:

Disconnect the battery ground cable.

2. Remove the instrument panel cluster panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair

3. Remove the anti-lock brake control module,
1 Disconnect the anti-lock brake control module electrical connector.
2 Remove the bolts.
3 Remove the anti-lock brake control module.

Installation

1. When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptiveNOTE:

strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn, the strategy.
To install, reverse the removal procedure.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation

Audible Warning Device Control Module: Description and Operation

The Generic Electronic Module and Central Timer Module control the following warnings and chimes:(GEM) (CTM)

^ Driver safety belt not fastened (warning lamp and repetitive chime).
^ Key-in-ignition (repetitive chime).
^ Headlamp-on warning (repetitive chime).

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 78

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

^ Door ajar (warning lamp and single tone).

The following four distinct chime rates are used to indicate warning:

^ Safety belt warning chime is one chime per second.
^ Key-in-ignition warning is two chimes per second.
^ Headlamp-on warning is four chimes per second.
^ Door ajar warning is a single chime.

Safety Belt Warning Chime

The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime will sound when the driver safety belt is notfastened when the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position.

The safety belt warning chime will stop sounding when:

^ The safety belt is fastened.
^ The ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position.
^

The chime has sounded for six seconds.

The safety belt warning chime inputs are:

^ Ignition switch START position (battery potential on the START [clutch depressed] input).
^ Ignition switch RUN position (battery potential on RUN and RUN/ACC inputs).
^ Driver safety belt switch (grounded when not fastened, open circuit when fastened).

Door Ajar Warning Chime

one second

The door ajar warning chime warns that a door has become ajar. The door ajar warning chime is a single tone with the duration of . Thechime will sound when:

^ GEM: Driver or passenger door initially becomes ajar while the ignition switch is in the RUN position.
^ CTM: Passenger door initially becomes ajar while the ignition switch is in the RUN position.

The door ajar warning chime inputs are:

^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs).
^ Door ajar switches (open circuit with door closed, grounded with door ajar).

Key-In-Ignition Warning Chime

The key-in-ignition chime warns that the key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when:

^ GEM: Driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the key is in the ignition.
^ CTM: Driver door is ajar, the ignition switch is in the OFF/LOCK, ACC or RUN position and the key is in the ignition.

The key-in-ignition warning chime will stop sounding when:

^ The driver door is closed.
^ The key is removed from the ignition.
^ GEM: Ignition switch is switched to the RUN position.

The key-in-ignition warning chime inputs are:

^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs).
^ Ignition switch ACC position (battery potential on RUN/ACC input only).
^ Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out).
^ LH door ajar switch (open circuit with door closed, grounded with door ajar).

Headlamps Warning Chime

The headlamps warning chime warns that the headlamps are on while the driver door is ajar. The headlamps warning chime will sound when all thefollowing conditions are met:

^ The driver door is ajar.
^ The headlamp switch is in the PARK or HEAD position.
^ The ignition switch state is in the OFF/LOCK position.
^ Key-out.

The headlamps warning chime will stop sounding when any one of the conditions above are removed. The headlamps warning chime inputs are:

^ Ignition switch OFF/LOCK (open circuit on all ignition inputs).
^ Headlamp switch (battery potential when in PARK or HEAD position, open circuit when in OFF position).
^ Driver door ajar switch (open circuit with door closed, grounded with door ajar).
^ Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out).

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 79

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Safety Belt Warning Lamp

The safety belt warning lamp warns that the safety belt is not fastened. The safety belt warning lamp illuminates when it is grounded and turns off whenthe circuit is open. The safety belt warning lamp will illuminate when the safety belt is not fastened and the ignition switch is turned from the OFF/LOCKor ACC to the RUN or START position.
The safety belt warning lamp will turn off when:

^ The safety belt is fastened.
^ The ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position.
^

After the lamp is illuminated for 61 seconds.

The safety belt warning lamp inputs are:

^ Ignition switch START position (battery potential when in START).
^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs).
^ Driver safety belt switch (grounded when not fastened, open circuit when fastened).

Door Ajar Warning Lamp

The door ajar warning lamp warns that a door is ajar. The door ajar warning lamp illuminates when it is grounded. The door ajar warning lamp will beilluminated when any door initially becomes ajar while the ignition switch is in the RUN or START position.

The door ajar warning lamp will turn off when all doors are closed or the ignition switch is turned to the OFF/LOCK or ACC position. The door ajarwarning lamp inputs are:

^ Ignition switch START position (battery potential when in START).
^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs).
^ Door open warning lamp switches (grounded with door ajar, open circuit with door closed).

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection

Speedometer Module: Testing and Inspection

Refer to Instrument Panel/Testing and Inspection/Procedures.

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram Information and Instructions

Battery Discharge Protection Relay: Diagram Information and Instructions

How to Find and Use These Diagrams

Diagrams are presented in three main categories:

- Power Distribution Diagrams

- System Diagrams

- Grounds Diagrams

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 88

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 89

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Sample Power Distribution Diagram

Power Distribution Diagrams

Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires,connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of adiagram page. Circuits that go from one diagram page to another will be marked with large arrow heads.
The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution.

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 90

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Sample System Diagram

System Diagrams

Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) isshown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at theground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads.

Management, Radio/Stereo, etc.

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 91

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Sample Grounds Diagram

Grounds Diagrams

Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuitsof different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in thesame manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will bemarked with large arrow heads.
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution.

Symbol Identification

ELECTRICAL SYMBOLS

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 92

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Electrical Symbols

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 93

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Electrical Symbols

VACUUM SYMBOLS

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 94

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Vacuum Symbols

Wire Color Code Identification

BK

BL

BR
: Black: Blue: Brown: Dark BlueDB

DG
GY
GN

LB

LG
PK

O

P

R

T

V

W

: Dark Green: Gray: Green: Light Blue: Light Green: Pink: Orange: Purple: Red: Tan: Violet: White: YellowY

Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking ofthe wire.

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram Information and Instructions > Page 95

Battery Discharge Protection Relay: Electrical Diagrams

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Diagram

Information and Instructions > Page 96

F 150 2WD Pickup V8-5.4L Prop SOHC VIN Z (1998)

Courtesy Lamps

Generic Electronic Module

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Diagrams > Page 97

Battery Discharge Protection Relay: Description and Operation
Battery Saver Relay

The following components are under the control of the battery saver relay:

Delayed accessory relay.
Overhead interior lamp with map lamps.
Underhood lamp switch.
Glove box lamp switch.
Overhead interior lamp switch.
Interior lamp relay coil.

The battery saver relay becomes active (relay coil is energized) when the GEM is in awake mode and is deactivated (relay coil is de-energized) insleep mode.

The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since last active input. At that time, the relay will be deactivated and power to the above circuits will terminate.

Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode,the GEM will deactivate all outputs and will monitor select inputs.
Logical characteristics of the GEM battery saver mode are as follows:

Feature Inputs:

Sleep/Awake mode status.

Feature Outputs:

Battery saver relay control (Open circuit in sleep mode, grounded when awake).

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications

Daytime Running Lamp Control Unit: Specifications

Daytime Running Lamps Control Module Bolt ............................................................................................................................. 2.5-3.1 N.m (22-28 Lb/In)

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 101

Daytime Running Lamp Control Unit: Service and Repair
REMOVAL

1. Remove the daytime running lamps control from the radiator support.
1 Remove the bolt.
2 Disconnect the electrical connector.
3 Remove the daytime running lamps control module.

INSTALLATION

1. To install, reverse the removal procedure.

> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Testing and Inspection

Exterior Lighting Relay: Testing and Inspection
Relay Component Test

Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay tobe tested from the power distribution box, fuse junction panel or individual connector.

Terminals

Micro ISO Relay

5 ohms
5 ohms

Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is or less between terminal 2 and anyother terminal, replace the relay. If resistance is greater than , continue the test. Use two jumper wires to connect relay terminals 1 and 3 directlyto the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replacethe relay. If battery voltage is indicated, connect the third jumper wire to terminal 2 and ground the jumper wire to chassis ground. Check for voltage atterminal 5. If battery voltage is not indicated, replace the relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Testing and Inspection

Horn Relay: Testing and Inspection

Horn Relay Terminal Location
Check Relay Continuity

1. Measure the resistance between relay terminal 85 and all other terminals. If any resistance is or less, replace the relay. Otherwise, continue5 ohms

with the test.

Apply Power to the Relay

2. Use jumper wires to apply battery voltage to terminals 30 and 85. Measure voltage at terminal 87A. If the voltage is less than , replace the 10 volts

relay. Otherwise, continue with the test.

Check Relay Operation