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xdfairmont79

xg pano-xh 4.0ltr and t5 conversion

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my old xg pano gave up the ghost, stupid auto stays in third nop matter what i change or fix. the solenoids are fucked and it has 309,000 on the clock anyway.. so ive found a xh with GOOD running gear, fully gasketed 4.0ltr with 200,000 kays, and a nice feeling and sounding t5, lsd etc. so xh's are ugly and xg panelvans are awesome. so, plan is to swap it all over, i think the 4ltr in the xh is an xg one anyway.. old styl inlet manifold and rocker cover. probably rebuilt engine.. either way. will the crossmember fit? is it the same as xf and xg? or will i need to find another? and what are any other things to look out for?

 

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stupid auto stays in third nop matter what i change or fix. the solenoids are fucked and it has 309,000 on the clock anyway..

 

So it's stuck in limp home mode?

I would take a gander at the fault codes first, before doing anything drastic.

 

XG's are the same as ED falcons.

To check fault codes -

 

diagplug.jpg

 

Top Row:

A-Engine STI

B-Transmission STI

C-ABS STI

D-Air Bag memory Clear

E-Engine STO

F-Transmission STO

G-ABS STO

H-Not Used

I-Not Used

J-Not Used

K-Fuel Pump.

Bottom Row:

L-Engine Ground

M-Transmission Ground

N-ABS ground

O-Not Used

P-Not Used

Q-BCM Serial data

R-Tacho

S-Not Used

T-B+ (12 Volts).

 

The Self Test Codes can be read using either a Multimeter, or an LED, and consists of a number of Pulses outputted on the Engine STO Pin, and the Vehicle Diagnostic connector (The STO Out Pin is the 5th Pin from the left, on the upper row).

These codes can be deciphered by using the format,

  • 1/2 Second On Time for Each Digit,
  • 2 Seconds Off Time Between Digits,
  • 4 Seconds Off Time Between Codes,
  • 6 Seconds Off Time Before and After the 1/2 Second separator pulse.

     

    To Perform a Key On/Engine Off (KOEO) Self Test,

  • 1. With the Ignition Switch Off, Connect the Engine STI Input to ground, (The STI Input is the First pin from the left, upper row, connect this to the Pin directly below it)
  • 2. Connect a LED, Multimeter, Lamp, or Buzzer to the STO Pin, and ground. (The STO Pin is the 5th Pin from the Left, on the upper Row.)
  • 3. Turn the Ignition Switch to On, But DO NOT START the Engine
  • 4. Observe the Codes.

    These codes will be displayed in the following sequence,

    1. On Demand Codes - Hard Faults

    2. Separator Code - Numeral 10

    3. Memory Codes - Intermittent Faults.

     

    To Perform a Key On/Engine Running Self Test,

  • 1. With the Ignition Switch Off, Connect the Engine STI Input to ground,
  • 2. Turn the Ignition Switch to start, and start the Engine
  • 3. Observe the Codes.

    These codes will be displayed in the following sequence,

    1. On Demand Codes - Hard Running Faults

    2. Separator Code - Numeral 10

    During a Separator Code, the Throttle should be goosed (Pressed and released) if performing a Cylinder Balance Test (V8).

    This will cause the Engine to hold the selected RPM, and Test.

     

    Cylinder Balance Test - V8

    When this test the EEC-V Module selectively shuts off fuel to each of the cylinders, one at a time, and measures the drop in RPM.

    If this Drop is outside the normal limits, it will at the completion of the test, output a fault code for that cylinder.

    This code will be in the format "10" for Cylinder 1, "20 for Cylinder 2, etc.

    If all cylinders are OK, the EEC-V Will give a code "90"

    See the Key On, Engine Running Self test for more information.

     

    Electric Thermo Cooling Fan Test

    This test will switch on the Thermo Fans when the Key On, Engine Off (KOEO) Self Test is performed.

    To activate, carry out a KOEO Self test, and when the codes are being displayed, place the Transmission in to gear to turn the Thermo Fans On, and Place the Transmission into neutral to stop Fan operation.

    If both fans do not operate, then there is a problem with their operation.

     

    Erasing Memory Codes

    Turn the ignition key OFF for a period of 10 seconds, then On.

    Activate the (KOEO) Self Test,

    As soon as the Diagnostic codes are being displayed, simply remove the Ground to the Self Test Input.

 

You need to run the KOEO and then the KOER in sequence and allow 20 seconds of Key off before trying to read the codes again.

The best connector to use to attach wires to the plugs are old fashioned (not modular) telephone plugs spade connectors (if you can't get to d**k Smiths, Altronics, Jaycar etc you should be able to salvage some complete with already crimped on wires from an old phone plug).

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For 92 XG utes/vans (pre-smartlock OHC engines)
 
FORD FALCON EA - EBl 3.9L (P Engine) 1988 - 92 EEC IV Engine Management System
Includes Utility, Van, Fairmont, Fairlane NA & NC, LTD DA & DC6 (Models with Multi Point Injection)

Fault Codes

The Fault Codes are organised into Two Groups.
1. One Set of Fault Codes are displayed in the "Key On, Engine Off" (KOEO) Mode.
2. The Other Set of Fault Codes are displayed in the "Key On, Engine Running" (KOER) Mode.

If, the Vehicle has the Battery disconnected for a period of time, OR
If any of the Engine Management Components are replaced;
The Keep Alive Memory WILL be affected and will have Incorrect Settings.
The ECM will need its KAM reassigned in order to relearn its program.
 

Fault Code Identification

There are altogether Five Service Code Types.
1. Fast Codes
(These appear very fast and are of NO value unless you are using a Data Scanner.)
2. ECM Identification Code
3. Hard Codes
(Current Faults.)
4. Separator Codes
5. Memory Codes
(Faults stored in memory from the Previous 20 Engine Warm-up / Run Cycles).


Intermittent Fault Codes
For checking of Faults that may be of an Intermittent Nature.
Connect LED Test Lamp to the Diagnostic Connector
Do NOT connect the Self Test Jumper.

Proceed to;
Wiggle all Connectors.
Wiggle all associated Wiring Harnesses.
Operate all Moving Sensors.

If a Fault is detected by the ECM.
It will cause the LED to Glow or Flash.
The Fault Codes will be written to the ECM.
Extract Codes by the following steps.

The Fault Codes will appear in this Sequence:
KOEO Mode:
Fast Codes
Hard Codes
Separator Code (10)
Memory Codes

KOER Mode:
ECM ID Code
Fast Codes
Hard Codes.


The Fault Codes can be read by use of:

1. An Analogue Multimeter (Set to 0 to 20 Volts DC)
2. A Digital Multimeter with a Bar Graph on the display (Set to 0 to 20 Volts DC)
3. A Test Light.

The Fault Codes are read as Pulses or Strong Fluctuations of the Multimeter Needle.
Each Pulse is 0.5 Seconds long.
The Interval between Tens and Single Units is 2.0 Seconds.
The Interval between Fault Codes is 4.0 Seconds.

After the Hard Codes have been displayed;
There is an Interval of 6.0 Seconds.

Followed by a Separator Code.

After the Separator Code;
There is an Interval of 6.0 Seconds

The Memory Codes are then displayed.
(KOEO Mode only).
(Again, there is an Interval of 4.0 Seconds between Codes).

Code Repeat
The Hard Codes and Memory Codes will ONLY be repeated Once.

To activate the Self Test again;
Switch Ignition OFF for more than 15 Seconds.



Fault Code Erasure
Disconnect Jumper Wire (Self Test Input) between Diagnostic Connectors.
Turn Ignition OFF for 10 Seconds
Connect Jumper Wire (Self Test Input) between Diagnostic Connectors
While Fault Codes are Flashing;
Remove Jumper Wire.

Retest Codes for successful Erasure.
Code 11 (System Pass)
Should be seen on both Hard and Memory Codes.

Fault Code Extraction
Connect Test Equipment to Diagnostic Connectors.

Ignition to ON
Read KOEO Codes
Ignition to OFF
Start Engine
Read KOER Codes
 
Fault Code Table -

Code # Circuit and Status
10 Separator Code

11 System Pass

12 Fast Idle RPM
Out of Range

13 Low Idle RPM
Out of Range

14 PIP Signal
Out of Range

15 ROM or KAM Test Fail

16 RPM Too Low for Fuel Test

19 ECM Power Supply Low
(MPFI)

20 ECM ID
3.9 MPFI Manual

21 ECT Sensor
Out of Range

22 MAP Sensor
Out of Range

23 TP Sensor
Out of Range

24 Air Temperature Sensor
Out of Range

30 ECM ID
3.9 MPFI Automatic

40 ECM ID
3.9 CFI Manual

41 Oxygen Sensor Signal Low

42 Oxygen Sensor Signal High

50 ECM ID
3.9 CFI Automatic

51 ECT Sensor Voltage too High

52 Power Steering Switch Open

53 TP Voltage too High

54 ACT Voltage too High

55 ECM Power Supply LOW
CFI

58 Idle Tracking Switch - Out of Range
CFI - KOER

60 ECM ID
3.2 CFI Manual

61 ECT Voltage too Low

63 TP Voltage too Low

64 ACT Voltage too Low

67 A/C is ON or Neutral / Park Switch in Gear

68 Idle Tracking Switch - Out of Range
CFI - KOEO

70 ECM ID
3.2 CFI Automatic

78 Interrupted Power Supply to Key Circuit

85 Canister Purge Signal
Out of Range

87 Fuel Pump Relay Signal
Out of Range

99 Idle Speed Compensation
Not in Memory

 

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OR for 93-96 XG utes/vans -

 

FORD FALCON EBII & ED 4.0L (H Engine) 1993-94 EEC IV Engine Management System
FORD FAIRLANE NC & NCII, LTD DC & DCII 1993-94 and XG Utility and Van 1993-96

Fault Codes

The Fault Codes are organised into Two Groups.

1. One Set of Fault Codes are displayed in the "Key On, Engine Off" (KOEO) Mode.
2. The Other Set of Fault Codes are displayed in the "Key On, Engine Running" (KOER) Mode.

See Keep Alive Memory.

Fault Code Identification

There are altogether Four Service Code Types.
1. Fast Codes
(These appear very fast and are of NO value unless you are using a Data Scanner.)
2. Hard Codes
(Current Faults.)
3. Separator Codes
4. Memory Codes
(Faults stored in memory from the Previous 20 Engine Warm-up / Run Cycles).
 

 

Intermittent Fault Codes

 

For checking of Faults that may be of an Intermittent Nature.

Connect LED Test Lamp between ENG STO and Ground on the Diagnostic Connector.

Do NOT connect the Self Test Jumper.

Proceed to;

Wiggle all Connectors.

Wiggle all associated Wiring Harnesses.

Operate all Moving Sensors.

If a Fault is detected by the ECM.

It will cause the LED to Glow or Flash.

The Fault Codes will be written to the ECM.

Extract codes by the following steps.


The Fault Codes will appear in this Sequence:

KOEO Mode:

Fast Codes

Hard Codes

Separator Code (10)

Memory Codes

KOER Mode:

Fast Codes

Hard Codes.



The Fault Codes can be read by use of:
1. An Analogue Multimeter (Set to 0 to 20 Volts DC)
2. A Digital Multimeter with a bar graph on the display (Set to 0 to 20 Volts DC)
3. A Test Light.

The Fault Codes are read as Pulses or Strong Fluctuations of the Multimeter Needle.

Each Pulse is 0.5 Seconds long.

The Interval between Tens and Single Units is 2.0 Seconds.

The Interval between Fault Codes is 4.0 Seconds.

After the Hard Codes have been displayed;

There is an Interval of 6.0 Seconds.

Followed by a Separator Code.

After the Separator Code;

There is an Interval of 6.0 Seconds

The Memory Codes are then displayed.

(KOEO mode only).

(Again, there is an Interval of 4.0 Seconds between Codes).



Code Repeat

The Hard Codes and Memory Codes will ONLY be repeated Once.

To activate the Self Test again;

Switch Ignition OFF for more than 15 Seconds.

Fault Code Erasure

1. Turn ignition off for at least 10 seconds.

2. Reactivate Fault Code Extraction.

3. As soon as any Code is Displayed:
Disconnect Jumper Wire to STI at the Diagnostic Connector.

Fault Code Extraction



There are some Significant Changes to the Procedures used on Previous Models.

Engine to Operating Temperature

NO Electrical Load

Use a Jumper Wire with Very Small Female Ends to connect;

The ENG STI Terminal to the ENG GND Terminal on the Diagnostic Connector.

Connect the Positive Lead of:

1. A Low Wattage Test Lamp, OR

2. An Analog Multimeter, OR

3. A Digital Multimeter with Bar Graph OR

4. An Oscilloscope

To the Battery Positive Terminal.

Connect The Negative Probe to the ENG STO Terminal on the Diagnostic Connector.

When the Ignition is turned ON.

The Test Instrument will start flashing out the Fault Codes in the following order:



Codes appear in Standard Ford Format:

2 Flashes

Pause

3 Flashes

Is Fault Code 23.

(TPS Out of Range)

KOEO Test (Key ON Engine OFF)

A. Fast Codes including Module Identification Code.
B. Hard Fault Codes
(Problems the ECU has determined currently exist)
C. Separator Code 10
(One Flash)
D. Memory Fault Codes
(Problems that have appeared in the last 50 start/stop cycles but may not be currently there)



KOER Test (Key ON Engine Running)

Disconnect Jumper Wire.

Run Engine for 2 Minutes at 1500 RPM to warm Oxygen Sensor.

Allow to Idle.

Reconnect Jumper Wire.



A Fast codes
B* Turn steering wheel 180° in both directions
C Separator code # 10
D* Snap throttle to 50% and return (Goose Test)
E Hard Fault Codes - Current problems detected by ECU (No Memory Codes)

* Immediate action required by technician



This Test cannot proceed if;

A Code 67 appeared in KOEO Hard Faults.

(Ignore Flickering Test Instrument - Fast Codes).

Fault Code Table

ECM Identification Codes (Vehicles Without Smartlock)

Code #.......................... Description
30 Multipoint SWB (2.92 Axle)

40 Multipoint SWB (3.27 Axle)

50 Multipoint LWB, Wagon, Ute and Van.

ECM Part Numbers (Vehicles with Smartlock)
Ford Part #................. Description
91DA 12A650 BX Multipoint SWB (2.92 Axle)

91DA 12A650 CX Multipoint SWB (3.27 Axle)

91DA 12A650 KX Multipoint LWB, Wagon, Ute and Van.



The last letter in the part number (X) can be any letter!

Code # Circuit and Status
10 Separator Code

11 System Pass

12 High RPM Idle Check Fail

13 Low RPM Idle Check Fail

14 Unsteady PIP Signal during Idle Test

15 Bad ROM / KAM Data

16 RPM Too Low to run Fuel Test

19 Internal EEC-IV
Power too Low

21 ECT Circuit

22 MAP Sensor Circuit

23 TPS Sensor Out Of Range

Possible Symptoms:
Late and harsh transmission shifts.
No torque converter lock up.

Possible Cause:
Short circuit in wiring to TPS.
TPS mounting screws loose, worn or faulty TPS.


24 ACT Sensor Circuit

26 Trans Oil Temp Sensor Out Of Range
Possible Symptoms:
High transmission oil temperature.
Lock up in 3rd and 4th gears except under very low speed and light throttle.
Economy light on dash will flash when ECM is in "overheat" mode.

Transmission shifts will be firm until transmission obtains normal
operating temperature.

Possible Cause:
The voltage measured by the ECM from the temperature input terminals
has been out of range.
Loose connection, short circuit to ground in wiring or temperature sensor.
Blocked or restricted transmission oil cooler, no external oil cooler
fitted to vehicle for towing.


27 Shift Lever Position Input Fault
Possible Symptoms:

No torque converter lock up. Manual select will not be available.
Transmission may downshift on rough roads.

Possible Causes:
Open or short circuit inside inhibitor switch or wiring.
Dirty terminal connector on inhibitor switch.
Incorrect linkage adjustment.

36 Shaft Speed Signal Fault (speedo sensor)
Possible Symptoms:
All transmission shifts will be controlled by the gear lever.
Skip downshifts will be disabled and downshifts will only occur at low speeds.

No converter lock up.
No speedometer operation.
Transmission may only operate in 1st gear or limp mode.

Possible Cause:
Open or short circuit in speedo transducer.
Dirty, loose or disconnected terminals at speedo transducer.

41 HEGO always Lean
(Oxygen Sensor)

42 HEGO always Rich
(Oxygen Sensor)

44 Smartlock Enable Code not present

51 ECT Voltage too High

52 Power Steering Switch Open

(Ignore on Utes & Vans)

53 TPS Voltage too High

54 ACT Voltage too High

57 Power / Economy Switch Circuit

61 ECT Voltage too Low

63 TPS Voltage too Low

64 ACT Voltage too Low

67 Air Conditioning Input Fault

72 No Dynamic MAP Change

73 No Dynamic TPS Change

77 Goose Test NOT Performed

78 Transmission Battery Circuit


85 CANP Output Check Fail

87 Fuel Pump Output Circuit Fail

95 Solenoid 5 Fault (variable pressure control)

96 PCS Solenoid Fault (pressure control)


98 ON/OFF Solenoid Fault Circuit
Possible Symptoms:
Transmission in limp mode
(3rd gear only, no converter lock up, high line pressure).

Possible Cause:
Blown fuse or faulty relay.
Loose or dirty battery terminals.

High resistance at transmission and engine earth leads.
Wiring harness fallen onto exhaust manifold.
Faulty or disconnected wiring harness on transmission.
Disconnected ECM connector or bent ECM pins.
Low battery voltage.
High battery voltage (regulator or alternator fault).
Shorted S5 solenoid.
Loose wires on solenoids.
Faulty ECM.

99 Throttle Not Learnt
Possible Symptoms:
The transmission operates from default throttle calibrations.

At zero throttle settings the ECM may calculate the throttle to be open
further than it actually is, causing poor shifts and late shifts.
Torque converter lock up may be in 3rd or 4th gear when throttle is closed.
(Provided vehicle speed is high)

Possible Cause:
Incorrect idle speed.
ECM left without power supply for a long period of time.
New ECM has been installed in vehicle.

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