Fuel System/Engine Controls - MIL ON/DTC P0191 Set
TSB 07-4-703/07/05
MIL ON WITH DTC P0191 - FUEL RAIL PRESSURE SENSOR CIRCUIT PERFORMANCE
FORD:
2005-2006 Five Hundred, Freestyle
MERCURY:
2005-2006 Montego
This article supersedes TSB 06-18-12 to update the the Service Procedure date code format.
ISSUE
Some 2005-2006 Freestyle, Five Hundred, and Montego vehicles may exhibit intermittent malfunction indicator light (MIL) on with diagnostic trouble code (DTC) P0191 for fuel rail pressure sensor circuit performance. Other DTCs and/or driveability concerns may also be present.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If the concern is a hard fault and can be verified, perform normal diagnostics by following revised on-line Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint tests.
For Intermittent Concerns:
NOTE
IF CONCERN IS FOUND AT ANY POINT WHILE PERFORMING SPECIFIC CHECKS BELOW, IT IS NOT NECESSARY TO PERFORM REMAINING CHECKS/REPAIRS.
1. A possible short of the VREF signal internal to the EGR system module (ESM) may result in less than 5 volts on the VREF signal line. To check for internal ESM short, check resistance between Pin-2 (VREF) and Pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less than 2000 ohms, replace ESM following Workshop Manual (WSM), Section 303-08.
2. Inspect main engine harness to powertrain control module (PCM) rub through on the A/C line at back right of engine compartment. Repair as necessary.
3. Inspect fuel rail pressure and temperature sensor located at top right of engine for broken or cracked vacuum port. Replace as necessary following WSM, Section 303-14.
4. Inspect inertia fuel shutoff (IFS) located in front passenger foot well for loose or disconnected wiring/connector and build date code on switch. If switch was built before November 2005 (5 L XXX) replace switch. Date code is visible without removing switch and is located near top of switch. (Figure 1)
a. Format is Year (4=2004, 5=2005, 6=2006) Month (A=Jan, B=Feb, C=Mar "I" is not used) Day (1-31) Shift (X or Y). On all vehicles, reroute inertia switch wiring behind/under carpet pad and install cable tie over connector. (Figure 1)
5. If vehicle is built before 8/16/2006, review Freeze Frame Data for fuel level indication (FLI) and fuel rail pressure (FRP). If FLI was 25% or less and FRP reading was below 20 PSI, concern may be due to jet pump performance under high demand. Replace fuel pump module, which contains integral jet pump, following WSM, Section 310-01.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
070407A 2005-2006 Freestyle, Five 0.9 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace Exhaust Gas
Recirculation System
Module (Do Not Use With
12650D, 12650D12,
12650D30, 9756A, 9350E)
070407B 2005-2006 Freestyle, Five 0.5 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace The Fuel Rail
Pressure And Temperature
Sensor (Do Not Use With
12650D, 12650D12,
12650D30, 9756A, 9350E)
070407C 2005-2006 Freestyle, Five 0.5 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace The Inertia
Fuel Shutoff (IFS) Switch
(Do Not Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)
070407D 2005-2006 Freestyle: 1.5 Hrs.
Check Diagnostic Trouble
Codes And Replace The
Fuel Pump, Includes Time
To Remove And Install
The Fuel Tank (Do Not
Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)
070407E 2005-2006 Five Hundred, 1.3 Hrs.
Montego: Check Diagnostic
Trouble Codes And
Replace The Fuel Pump,
Includes Time To Remove
And Install The Fuel Tank
(Do Not Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)
MT070407 Claim Additional Labor Actual
Time Required As Actual Time
Time Or Use SLTS
Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
9H307 42
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