Service Manual: SYSTEM WIRING DIAGRAMS - F350 SUPER …

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2005 Ford Pickup 6.0L Eng F350 Super Duty Service Manual: SYSTEM WIRING DIAGRAMS - F350 SUPER DUTY

ENGINE PERFORMANCE > 6.0L DIESEL

Fig 1: 6.0L Diesel, Engine Performance Circuit (1 of 5)

HOT AT ALL TIMES

FUSE 5 50A

HOT AT ALL TIMES

FUEL INJECTOR CONTROL MODULE POWER RELAY

FUSE 18 10A

FUSE 15 15A

HOT AT ALL TIMES

FUEL HEATER RELAY

BATTERY JUNCTION BOX (BJB) (LEFT REAR OF ENGINE COMPT)

GROUND GROUND GROUND POWER RELAY FUEL DELIVERY

IGNITION POWER RELAY

PCM COMM CYLINDER ID

GROUND POWER RELAY POWER RELAY POWER RELAY

GROUND POWER RELAY CTRL

CAN BUS 2H CAN BUS 2L DRAIN WIRE

1 BLK/PNK

574

2 BLK/PNK

574

3 BLK/PNK

574

4 DK GRN/LT GRN

876

5 LT GRN/YEL

54

6

7 VIO/ORG

1717

8 WHT/BLK

814

9 PNK/YEL

878

10 DK BLU/ORG

56

(PINS 11-21 NOT USED)

22 BLK/PNK

574

23 DK GRN/LT GRN

876

24 DK GRN/LT GRN

876

25 DK GRN/LT GRN

876

26 BLK/PNK

574

27 RED/YEL

3098

28

29

30 RED/LT GRN

69

31 LT BLU/WHT

70

32 BLK

48

C1388C

(AT LEFT REAR OF ENGINE COMPT) G101 BLK/PNK S195

RED/LT GRN

1 LT GRN/YEL

7

FUEL INJ 4 OPEN GND

2 LT GRN/WHT

3

FUEL INJ 1 OPEN GND

3 TAN/YEL

11

FUEL INJ 7 OPEN GND

4 RED/YEL

15

FUEL INJ 6 OPEN GND

5 WHT/LT BLU

2

FUEL INJ 1 CLOSE GND

6 YEL/LT GRN

6

FUEL INJ 4 CLOSE GND

7 BRN

14

FUEL INJ 6 CLOSE GND

8 LT GRN/RED

10

FUEL INJ 7 CLOSE GND

(PINS 9-16 NOT USED)

17 LT GRN/BLK

12

FUEL INJ 7 OPEN PWR

18 LT GRN/ORG

9

FUEL INJ 7 CLOSE PWR

19 WHT/BLK

4

FUEL INJ 1 OPEN PWR

20 DK BLU

1

FUEL INJ 1 CLOSE PWR

21 RED/LT GRN

16

FUEL INJ 6 OPEN PWR

22 RED/BLK

13

FUEL INJ 6 CLOSE PWR

23 WHT/PNK

33

FUEL INJ 4 OPEN PWR

24 ORG/LT BLU

5

FUEL INJ 4 CLOSE PWR

C1388A

FUEL INJ 5 OPEN GND FUEL INJ 2 OPEN GND FUEL INJ 8 OPEN GND FUEL INJ 3 OPEN GND FUEL INJ 5 CLOSE GND FUEL INJ 2 CLOSE GND FUEL INJ 8 CLOSE GND FUEL INJ 3 CLOSE GND

FUEL INJ 2 OPEN PWR FUEL INJ 2 CLOSE PWR

FUEL INJ 3 OPEN PWR FUEL INJ 3 CLOSE PWR

FUEL INJ 5 OPEN PWR FUEL INJ 5 CLOSE PWR

FUEL INJ 8 OPEN PWR FUEL INJ 8 CLOSE PWR

1 TAN/LT GRN 2 LT BLU/RED 3 WHT/RED 4 ORG/LT GRN 5 LT BLU/BLK 6 ORG/YEL 7 BLK/LT GRN 8 WHT/VIO (PINS 9-16 NOT USED) 17 WHT/LT BLU 18 WHT 19 BLK/PNK 20 DK GRN/VIO 21 DK BLU/ORG 22 DK GRN/LT GRN 23 RED/LT BLU 24 YEL/WHT C1388B

23 19 31 27 22 18 30 26

20 17 28 25 24

21 32 29

FUEL INJECTION CONTROL MODULE (FICM) (TOP LEFT REAR OF ENGINE)

S120

S102

G100 (AT LEFT REAR OF ENGINE COMPT)

RED/LT GRN 1

RED/LT GRN 2

DK BLU 1

(ENGINE CONTROL SENSOR & FUEL CHARGE HARN, NEAR BREAKOUT TO LEFT REAR OF ENGINE)

BLK 2

LT GRN/YEL A

PNK/YEL B

DK BLU/ORG C

RED/LT GRN D

LT BLU/WHT E

FICM TO PCM CONNECTIONS (TO DIAGRAM 5 OF 5)

S250

FUEL HEATER (LEFT SIDE OF VEHICLE UNDERBODY

G100

(AT LEFT REAR OF ENGINE COMPT)

NCA

NCA

NCA

NCA

NCA

NCA

NCA

NCA

S194

G110

(AT TOP REAR OF ENGINE)

204615

FUEL INJECTOR 8

(LEFT REAR OF ENGINE)

FUEL INJECTOR 5

(TOP RIGHT REAR OF ENGINE)

FUEL INJECTOR 3

(TOP RIGHT OF ENGINE)

FUEL INJECTOR 2

(TOP LEFT OF ENGINE)

FUEL INJECTOR 4

(TOP LEFT SIDE OF ENGINE)

FUEL INJECTOR 6

(TOP LEFT REAR OF ENGINE)

FUEL INJECTOR 1

(TOP RIGHT SIDE OF ENGINE)

FUEL INJECTOR 7

(TOP OF RIGHT CYLINDER BANK)

... 1/17/2016

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Page 2 of 5

Fig 2: 6.0L Diesel, Engine Performance Circuit (2 of 5)

HOT AT ALL TIMES

ACC

START

LOCK

RUN

OFF

IGNITION SWITCH

RED/ LT GRN

S258

CENTRAL JUNCTION BOX (CJB)

(BEHIND LOWER LEFT SIDE OF DASH)

PCM POWER

DIODE

HOT AT ALL TIMES

PCM POWER RELAY

FUSE 22 20A

HOT AT ALL TIMES

FUEL PUMP RELAY

FUSE 40 20A

HOT AT ALL TIMES

FUSE 10 10A

BATTERY JUNCTION BOX (BJB) (LEFT REAR OF ENGINE COMPT)

RED/ LT GRN RED/LT GRN 1

S182

RED/ LT GRN

S162

(LEFT REAR OF ENGINE COMPT) G100

RED/LT GRN 2

(ENDS IN HARNESS)

CTO A/C RELAY

TR0-N2 START RLY CNTRL FUEL PUMP RELAY

PTO RPM TR0-P

A/C PRESS SW BCPSW

GROUND GROUND

PTO DLC CAN H DLC CAN L WATER IN FUEL A/C PRESS SW PARK BRAKE STOPLAMP SW INERTIA SW

APS2 MAF SENSOR

VSO GROUND SPEED CTRL SW APPS 3 SIG APPS 1 SIG START INTLCK BRAKE PRESS SW APPS 2 RTN GEN/BATT SPEED CTRL SW CUSTOMER ACC SIGNAL RETURN IGNITION

VSS

CLTCH PED DEACT TOW/HAUL SW APPS 2 SIG BARO PRESS PROG SIG VBATT MAP SENSOR MAF SENSOR IAT SENSOR PTO VREF REF VOLTAGE IGNITION

1 LT GRN/WHT

76

2 PNK/YEL

331

3 RED/WHT

463

4 PNK

329

5 LT BLU/ORG

926

6 ORG/YEL

2246

7 YEL/WHT

1857

8 TAN/LT GRN

439

9 VIO/LT GRN

2248

10 LT BLU/YEL

875

11 BLK/WHT

570

S117

12 ORG

2242

13 WHT

1908

14 BLK

1909

15 RED

643

16 TAN/LT GRN

440

17 LT GRN/RED

162

18 RED/LT GRN

810

19 PNK/BLK

787

20 BLK/WHT

3014

21 TAN/LT BLU

968

22 WHT/ORG

679

23 BLK/WHT

570

24 BLK 25 WHT/RED

133 3015

CRUISE CONTROL

26 YEL/WHT

3835

27 LT BLU/YEL

92

(M/T)

28 BLK/YEL

307

29 GRY/BLK

3013

30 VIO

3090

31 LT BLU/BLK 32 ORG/BLK

151 2247

CRUISE CONTROL

33 GRY/RED

359

34 RED

361

35 GRY/BLK

679

(OR TAN/BLU) 36 TAN/WHT

306 (M/T) 224 (A/T)

37 WHT

3012

38 DK BLU/LT GRN

356

39 VIO

107

40 DK GRN

1683

41 LT GRN/BLK

358

42 LT BLU/RED

967

43 GRY

743

44 ORG/RED

2245

45 BRN/WHT

351

46 RED

361

C1381B

POWERTRAIN CONTROL MODULE (PCM) (LEFT SIDE OF

(NOT USED)

ENGINE COMPT)

(ENGINE CONTROL SENSOR HARN,

NEAR BREAKOUT TO C128)

S150

RED

S123 (IN ENGINE CONTROL SENSOR HARN, NEAR BREAKOUT FOR C1298)

A/C SYSTEM

STARTING SYSTEM

(NOT USED) A/C SYSTEM

LT BLU/YEL BLK/WHT

S106

(LEFT REAR OF ENGINE COMPT) G100

G101 (AT LEFT REAR OF

ENGINE COMPT)

A/C SYSTEM

PNK/BLK

S118 (IN ENGINE CONTROL HARN, NEAR BREAKOUT

FOR POWERTRAIN CONTROL MODULE)

STARTING SYSTEM

(IN ENGINE CONTROL HARN, NEAR BREAKOUT FOR G101)

S114

ABS SYSTEM

S170

INERTIA FUEL SHUTOFF SWITCH (AT RIGHT KICK PANEL)

(ENDS IN HARNESS)

PNK/BLK S234 (IN BODY MAIN HARN, NEAR C278)

(IN BACK-UP LIGHT SWITCH TO REAR LIGHT FEED HARN, NEAR BREAKOUT FOR AUTOMATIC TRANSMISSION MODULE)

S139

BLK/ ORG

(IN ENGINE CONTROL SENSOR HARN, UNDER BATTERY JUNCTION BOX)

TAN (AT LEFT REAR OF

ENGINE COMPT)

G100

S250

S221 (MAIN HARN, AT BREAKOUT

FOR C2186)

S223 (IN MAIN HARN, NEAR BREAKOUT FOR C218)

RED/WHT 1

RED 2

WHT 3

BLK 4

RED 5

LT GRN/RED 6

RED/LT GRN 7

BLK/YEL 8

VIO 9

GRY/RED 10

(OR TAN/BLU) TAN/WHT 11 VIO 12

204616

INTAKE AIR TEMPERATURE

SENSOR (LATE PRODUCTION)

(LEFT SIDE OF ENGINE COMPT, BEHIND AIR CLEANER)

MASS AIRFLOW SENSOR (IN AIR INTAKE TUBE)

MANIFOLD ABSOLUTE PRESSURE SENSOR

(AT REAR OF FIREWALL)

BAROMETRIC ABSOLUTE PRESSURE

SENSOR

(BEHIND LEFT SIDE OF DASH)

M

FUEL PUMP (NEAR LEFT SIDE OF TRANSMISSION)

1

3

2

ACCELERATOR PEDAL POSITION SENSOR

(ON ACCELERATOR PEDAL SUPPORT)

... 1/17/2016

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Page 3 of 5

Fig 3: 6.0L Diesel, Engine Performance Circuit (3 of 5)

(BEHIND RIGHT SIDE OF DASH)

FOUR WHEEL DRIVE

CONTROL

MODULE

(ON PARK BRAKE ASSEMBLY)

PARKING BRAKE

SWITCH

(ON LEFT FRAME RAIL)

WATERIN-FUEL SENSOR

HOT IN RUN

FUSE 12 2A

BATTERY JUNCTION BOX (BJB) (LEFT REAR OF ENGINE COMPT)

HOT AT ALL TIMES

FUSE 34 10A

3 C270A

HOT AT ALL TIMES

FUSE 45 10A

CENTRAL JUNCTION BOX (CJB) (BEHIND LOWER LEFT SIDE OF DASH)

8 C270A

S278

G300 (UNDER LEFT SIDE OF DASH)

S110 (ENGINE CONTROL HARN, NEAR BREAKOUT

FOR POWERTRAIN

CONTROL MODULE)

HEADLIGHTS SYSTEM

(W/ DRL)

BRAKE PRESSURE SWITCH (ON BRAKE MASTER CYLINDER)

S112 (ENGINE CONTROL HARN, NEAR BREAKOUT FOR POWERTRAIN CONTROL MODULE)

S208

BRAKE PEDAL POSITION SWITCH (ABOVE BRAKE PEDAL)

S205

S271

RED/WHT 1

RED 2

WHT 3

BLK 4

RED 5

LT GRN/RED 6

RED/LT GRN 7

LT GRN/ RED

(W/ DRL)

S174

LT GRN/RED

(ENGINE CONTROL SENSOR HARN, AT BREAKOUT FOR G100)

S278

BLK/YEL 8

VIO 9

(MAIN HARN, AT BREAKOUT FOR INSTRUMENT

CLUSTER)

GRY/RED 10

(OR TAN/BLU) TAN/WHT 11

VIO 12

(IN MAIN HARN, AT BREAKOUT

FOR (DLC)) S220

(IN MAIN HARN, NEAR BREAKOUT

FOR (DLC))

S213

COMPUTER DATA LINES

SYSTEM

WHT BLK

WHT

BLK

(IN ENGINE CONTROL SENSOR

HARN, NEAR BREAKOUT TO C135)

S142

(IN ENGINE CONTROL SENSOR HARN, NEAR BREAKOUT TO G300) S140 WHT

BLK

MALFUNCTION INDICATOR LAMP

204617

HS CAN (+)

HS CAN

(-)

INSTRUMENT CLUSTER

DATA LINK CONNECTOR (BEHIND LEFT SIDE OF DASH)

COMPUTER DATA LINES SYSTEM

RED 1

RED/YEL 2

DK BLU 3

RED 4

GRY 5

BLK 6

ORG 7

(OR TAN/BLU) TAN/WHT 8

NCA NCA S197

(ENGINE CONTROL SENSOR & FUEL CHARGE HARN, AT BREAKOUT FOR C1381C)

CRANKSHAFT POSITION SENSOR

(LOWER RIGHT SIDE OF ENGINE)

CAMSHAFT POSITION SENSOR

(ON LOWER FRONT CENTER OF ENGINE)

... 1/17/2016

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Page 4 of 5

Fig 4: 6.0L Diesel, Engine Performance Circuit (4 of 5)

TORQSHIFT TRANSMISSION

PRESSURE CONTROL

(PC-A) SOLENOID

SHIFT SOLENOID PRESSURE CONTROL A

(SSPC-A)

SHIFT SOLENOID PRESSURE CONTROL B

(SSPC-B)

SHIFT SOLENOID PRESSURE CONTROL C

(SSPC-C)

SHIFT SOLENOID PRESSURE CONTROL D

(SSPC-D)

SHIFT SOLENOID PRESSURE CONTROL E

(SSPC-E)

TORQUE CONVERTER

CLUTCH SOLENOID

TRANSMISSION FLUID

TEMPERATURE SENSOR

TRANSMISSION RANGE SENSOR

ASSEMBLY

(TR-P)

HOT IN RUN

FUSE 24 15A

20 C270A

CENTRAL JUNCTION BOX (CJB) (BEHIND LOWER LEFT SIDE OF DASH)

S235

(IN BACK-UP LIGHT SWITCH TO REAR LIGHT FEED

HARN, NEAR BREAKOUT FOR TRANSMISSION)

S129

WHT/VIO 2 NCA

TAN/WHT 1 NCA

TOW/HAUL SWITCH

RED 1

RED/YEL 2

DK BLU 3

RED 4

GRY 5

BLK 6

ORG 7

(OR TAN/BLU) TAN/WHT 8

TAN/WHT A/T

TAN/LT BLU M/T

204618

CENTRAL JUNCTION BOX (CJB)

(BEHIND LOWER LEFT SIDE OF DASH)

REVERSING LAMP RELAY

POWERTRAIN CONTROL MODULE (LEFT SIDE OF ENGINE COMPT)

RED 1

RED/YEL 3

TAN/LT BLU 4

CLUTCH PEDAL POSITION SWITCH

(M/T) (ABOVE CLUTCH PEDAL)

DK BLU 2

RED 3

GRY 4

BLK 5

ORG 6

S128

(IN BACK-UP LIGHT SWITCH TO REAR LIGHT FEED HARN, NEAR BREAKOUT FOR TRANSMISSION)

S127

PNK/WHT 1 BLK/WHT 3

H DK BLU/YEL 2

OUTPUT SHAFT SPEED SENSOR

(TOP OF TRANSMISSION)

(IN BACK-UP LAMP SWITCH TO REAR LAMP FEED HARN, NEAR BREAKOUT FOR C1107)

H

TURBINE SHAFT SPEED SENSOR

SPEED SENSOR

ASSEMBLY

(LEFT SIDE OF

H

TRANSMISSION)

INTERMEDIATE SHAFT

SPEED

SENSOR

... 1/17/2016

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Page 5 of 5

Fig 5: 6.0L Diesel, Engine Performance Circuit (5 of 5)

VARIABLE GEOMETRIC

TURBO ACTUATOR

(TOP REAR CENTER OF

ENGINE) INJECTION PRESSURE REGULATOR

W/ DUAL GENERATORS

SECONDARY GENERATOR GENERATOR

RIGHT GLOW PLUG BANK

3

1

7

5

RED 1

DK BLU 2

RED 3

GRY 4

BLK 5

ORG 6

S193 (IN ENGINE HARN, TOP LEFT OF ENGINE)

RED

COOLING FANS

SYSTEM

RED/ORG DK BLU BRN/PNK

(ENGINE CONTROL SENSOR & FUEL CHARGE HARN,

NEAR BREAKOUT FOR C1064)

S192

S190

LEFT GLOW PLUG BANK

4

2

8

6

HOT AT ALL TIMES

FUSE LINK F 12 GAUGE

GRAY

FUSE LINKG 12 GAUGE GRAY

(TOP RIGHT FRONT OF ENGINE) GLOW PLUG

CONTROL MODULE

160 180

38 S147

120 140

361

DK BLU/WHT 1 RED 2

BLK/ORG 3 4 5

PNK/LT GRN 6 BLK/PNK 7 8 RED 9 C1301B

GLOW PLUG 6 GLOW PLUG 8 BATTERY

GLOW PLUG 2 GLOW PLUG 4

IGNITION

150 170

38

110 130 1086 1277

DK GRN/WHT 1 RED/LT BLU 2 BLK/ORG 3 4 5 WHT/LT GRN 6 RED/LT GRN 7 VIO/ORG 8 WHT/LT GRN 9 C1301A

GLOW PLUG 5 GLOW PLUG 7 BATTERY

GLOW PLUG 1 GLOW PLUG 3 PCM CONTROL PCM MONITOR

(NOT USED) (NOT USED) (NOT USED)

(NOT USED) (NOT USED)

1183 552

1086 1185

229

WHT/YEL YEL/RED VIO/ORG

YEL BLK RED/ORG BLK BLK

1 CHARGE

2 IPR CONTROL

3 GLOW PLUG SYS

4 CHARGE (2ND)

5 6

FAN CLUTCH 7 8

3670 41 43

RED/WHT BLK/LT BLU

DK BLU BLK BLK

9 EGR TEMP SEN

10 TURBO ACT

11 TURBO ACT

12 13

228

DK BLU 14

(NOT USED) (NOT USED)

BLK 15 BLK 16

1277 WHT/LT GRN 17

(NOT USED)

BLK 18

54

LT GRN/YEL 19

56 DK BLU/ORG 20

(NOT USED)

BLK 21

360

BRN/PNK 22

33

WHT/PNK 23

(NOT USED)

BLK 24

359

GRY/RED 25

70

LT BLU/WHT 26

553

VIO/LT BLU 27

878

PNK/YEL 28

812

DK BLU/LT GRN 29

349

DK BLU 30

50

RED 31

3076

YEL/WHT 32

34

LT BLU/ORG 33

(NOT USED) (NOT USED)

BLK 34 BLK 35

351

BRN/WHT 36

69

RED/LT GRN 37

(NOT USED) (NOT USED)

(NOT USED) 350

BLK 38 BLK 39 BLK 40 GRY 41

48

BLK 42

49

ORG 43

354

LT GRN/RED 44

42

RED/WHT 45

352

BRN/LT GRN 46

C1381T

FAN CLUTCH

GLOW PLUG

FICM DELIVERY FICM CYL ID

COOLING FAN EGR VALVE

SIGNAL RETURN CAN BUS 2L EBP SENSOR FICM COMM ICP SENSOR CKP SENSOR CMP SENSOR COOLANT TEMP EGR VALVE

REF VOLTAGE CAN BUS 2H

CKP SENSOR GROUND CMP SENSOR EOT SENSOR ACT SENSOR FAN CLUTCH

COOLING FANS

SYSTEM

POWERTRAIN CONTROL MODULE (PCM)

(LEFT SIDE OF ENGINE COMPT)

204619

EGR VALVE ACTUATOR

(AT TOP OF ENGINE)

EXHAUST BACK

PRESSURE SENSOR

(LEFT FRONT OF ENGINE)

EGR TEMPERATURE

SENSOR

(EARLY PRODUCTION)

(TOP FRONT OF ENGINE)

INJECTION CONTROL PRESSURE SENSOR

(TOP LEFT REAR OF ENGINE)

ENGINE COOLANT TEMPERATURE SENSOR

(ON FRONT OF ENGINE)

ENGINE OIL TEMPERATURE

SENSOR

(LEFT RIGHT OF ENGINE)

MANIFOLD AIR TEMPERATURE

SENSOR

(TOP LEFT FRONT OF

ENGINE)

A

E

D

C

B

FICM TO PCM CONNECTIONS

(FROM DIAGRAM

1 OF 5)

... 1/17/2016

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