LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2003 >> Windstar Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - System Test DV Through JD - CNG, Flex-Fuel & Gasoline >> Test HM: Secondary Air Injection System >> Testing
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Test HM: Secondary Air Injection System: Testing

NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION  table of fault code setting condition.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P0411  HM7  HM7  HM7
P0412  HM1  HM1  HM1
P1413  HM19  HM19  HM19
P1414  HM27  HM27  HM27
P2257  HM27  HM27  HM27
P2258  HM4  HM4  HM4
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 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:
    • AIR Circuit Open Or Short To PWR
    • AIR By-Pass Solenoid Fault
    • Faulty PCM
    • Faulty Solid State Relay (SSR)
    • 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 Figure. 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. 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 Figure. 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. 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 Figure. 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. 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. 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 Figure. 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. 6) Check B+ Circuit For Open In Harness

    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 Figure. 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. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: To properly test EAIR pump, it must be capable of driving HO2S to lean.

  7. 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:
    • Faulty Electric AIR (EAIR) Pump
    • Hose From AIR Pump Leaking Or Blocked
    • 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. CAUTION: Overheating and damage may occur to EAIR pump if operated in OUTPUT TEST MODE for longer than 2 minutes.

  8. 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. 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).
    10. NOTE: On 2-valve systems, ensure air flows from both valves.

  10. 10) Check AIR Diverter Valve Integrity
    Turn ignition switch to OFF position. Disconnect air tube from diverter valve(s) outlet side. Check diverter valve outlet(s) for heat damage and repair if necessary. Using hand vacuum pump, apply 16 in. Hg (54 kPa) of vacuum to AIR diverter valve(s). Turn ignition switch to ON position. Using scan tool, enter OUTPUT TEST MODE. If air is present from AIR diverter valve(s), turn ignition switch to OFF position and check exhaust tube(s) from AIR diverter valve to exhaust manifold(s). If exhaust tube(s) from diverter valve are okay, go to next step. If air is not present from AIR diverter valve(s), turn ignition switch to OFF position and check hose from EAIR pump to AIR diverter valve(s). Replace as necessary. If hose is okay, replace appropriate AIR diverter valve(s).
    11. NOTE: An intake manifold gasket leak can cause vacuum gauge reading to remain below normal range.

  11. 11) Check Manifold Vacuum With Exhaust Manifold Disconnected
    Disconnect exhaust pipe from exhaust manifold. Install vacuum gauge to intake manifold port (if not done previously). Start engine and gradually raise engine speed to 2000 RPM. Observe vacuum gauge reading response while maintaining increased engine RPM. If manifold vacuum increases quickly to 16 in. Hg (54 kPa) as increased RPM is maintained, exhaust system is free of restrictions. Exhaust restriction is downstream of exhaust manifold. Reconnect exhaust system to exhaust manifold and go to next step. If manifold vacuum is low or slow to respond, restriction is present in exhaust manifold. Check exhaust manifold for restrictions. If restrictions are present and are unable to be removed, replace exhaust manifold.

  12. 12) Check Manifold Vacuum With Muffler & Tailpipe Assembly Disconnected For Indication Of A Restriction

    Disconnect muffler and tailpipe assembly from catalytic converter. Start engine and gradually raise engine speed to 2000 RPM. Observe vacuum gauge reading response while maintaining increased engine RPM. If vacuum gauge needle moves quickly to more than 16 in. Hg (54 kPa) with engine speed increased, restriction is in muffler and tailpipe assembly. Repair as necessary. If vacuum gauge needle does not move quickly to more than 16 in. Hg (54 kPa) with engine speed increased, restriction is in catalytic converter. Replace catalytic converter. After replacing catalytic converter, check muffler and tailpipe assembly for debris from faulty catalytic converter.

  13. 13) Check Voltage On EAIR Monitor Circuit

    Connect scan tool to Data Link Connector (DLC). Turn ignition switch to OFF position. Disconnect EAIR pump. Turn ignition switch to ON position. Using scan tool, enter OUTPUT TEST MODE. Using a DVOM, measure voltage between negative battery terminal and SAIRM circuit at EAIR pump harness connector. See Figure. If voltage is more than 10.5 volts, go to step  15). If voltage is 10.5 volts or less, go to next step.

  14. 14) Check EAIR Pump GND Circuit For Open In Harness

    Using a DVOM, measure resistance of GND circuit between EAIR pump harness connector and negative battery terminal. See Figure. If resistance is less than 5 ohms, go to step  21). If resistance is 5 ohms or more, repair open in GND circuit.

  15. 15) Check Air Hose To EAIR Pump

    Disconnect air inlet hose to EAIR pump. Check hose for cracks, binding, obstructions, water or ice (in colder climates). Drain water from air hose, repair, reposition or replace hose as necessary and go to step  17). If hose is okay, go to step  17).

  16. 16) Check Solid State Relay Output

    Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Reconnect AIR by-pass solenoid. Reconnect PCM harness connector. Ensure SSR is connected. Turn ignition switch to ON position. Using scan tool, enter OUTPUT TEST MODE. Access AIR and AIRM PIDs from PID/DATA MONITOR & RECORD menu. Compare AIR and AIRM PID readings. If both PID readings indicate ON, replace SSR. If either PID value indicates OFF, fault may be intermittent. Go to TEST Z, step 2) to check for intermittent faults. If no intermittent faults are found, replace PCM.
    17. NOTE: Water contamination in EAIR pump will shorten life of pump.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 17) to step 19). No test procedures have been omitted.

  17. 17) Check Air Pump For Water
    Turn ignition switch to OFF position. Disconnect EAIR pump air hoses and harness connector. Carefully tilt EAIR pump at various angles to check for water. If water is present, replace EAIR pump. If water is not present proceed as follows:
    • If fuse was replaced in step  6), testing is complete.
    • On all others, go to step  9).
    18. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  18. 19) For KOEO, KOER & Continuous Memory DTC P1413: Check B+ Circuit Voltage To Solid State Relay
    DTC P1413 indicates SAIRM circuit is low (EAIR pump OFF) although PCM is commanding EAIR pump ON. Possible causes are:
    • B+ Circuit Open
    • EAIRM Circuit Open Or Short To GND
    • Faulty PCM
    • Faulty EAIR Pump
    • Faulty Solid State Relay (SSR)

    Turn ignition switch to OFF position. Disconnect SSR harness connector. Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and B+ circuit at SSR harness connector. See Figure. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, go to step  26).

  19. 20) Check VPWR Voltage To SSR

    Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and VPWR circuit at SSR harness connector. See Figure. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, go to TEST B, step 5) (LS V6), or repair open in VPWR circuit between PCM power relay and SSR (all others).

  20. 21) Check Voltage On EAIR Monitor (SAIRM) Circuit

    Turn ignition switch to OFF position. Ensure scan tool is connected to Data Link Connector (DLC). Reconnect SSR harness connector. Disconnect EAIR pump connector. Turn ignition switch to ON position. Using scan tool, enter OUTPUT TEST MODE. See OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS. Access AIRM PID. If AIRM PID value indicates ON, remain in OUTPUT TEST MODE and go to step  25). If AIRM PID value indicates OFF and DTC P0411 is present, replace EAIR pump, remain in OUTPUT TEST MODE and go to next step.

  21. 22) Check SAIRM Circuit Voltage To PCM

    Ensure ignition switch is in ON position. Using scan tool, access AIRM PID from PID/DATA MONITOR & RECORD menu. If AIRM PID value indicates ON, replace PCM. If AIRM PID value indicates OFF, go to next step.

  22. 23) Check EAIR Driver & SAIRM Circuits For Open In Harness

    Turn ignition switch to OFF position. Disconnect SSR and EAIR pump harness connectors. Using a DVOM, measure resistance of EAIR driver circuit and SAIRM circuit between PCM harness connector and SSR harness connector. Using a DVOM, measure resistance of SAIRM circuit between SSR harness connector and EAIR pump harness connector. See Figure. If any 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.

  23. 24) Check EAIRM Circuit For Short To Ground

    Using a DVOM, measure resistance between EAIRM and PWR GND circuits at PCM harness connector. See Figure. If resistance measurement is more than 10 k/ohms, replace SSR. If resistance measurement is 10 k/ohms or less, repair short between circuits.

  24. 25) Check EAIRM Circuit Voltage To PCM

    Reconnect EAIR pump and PCM harness connectors. Turn ignition switch to ON position. Ensure scan tool is still in OUTPUT TEST MODE and all outputs are selected ON. Using scan tool, access AIRM PID. If AIRM PID value indicates ON, replace PCM. If AIRM PID value indicates OFF, repair open in EAIR circuit.

  25. 26) Check B+ Circuit For Open In Harness

    Using a DVOM, measure resistance of B+ circuit between SSR harness connector and SSR dedicated B+ circuit fuse. See Figure. If resistance is less than 5 ohms, replace SSR dedicated fuse. If resistance is 5 ohms or more, repair open in B+ circuit.
    26. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  26. 27) For KOEO, KOER & Continuous Memory DTC P1414 & P2257: Check EAIRM Circuit For Open In Harness
    DTC P1414 indicates SAIRM circuit is high (EAIR pump is ON) although PCM is commanding EAIR pump OFF. Possible causes are:
    • SAIRM Circuit Open
    • EAIR Circuit Shorted To PWR
    • Faulty Solid State Relay (SSR)
    • Open EAIR Pump GND
    • Faulty EAIR Pump
    • Faulty PCM

    Turn ignition switch to OFF position. Disconnect EAIR pump, SSR harness connector and PCM connector(s). Using a DVOM, measure resistance of SAIRM circuit between PCM harness connector and EAIR pump harness connector. See PCM CONNECTOR IDENTIFICATION and Figure. If resistance is 5 ohms or more, repair open in SAIRM circuit. If resistance is less than 5 ohms, go to next step.

  27. 28) Check EAIR Pump For Open

    Using a DVOM, measure resistance between both EAIR pump terminals. If resistance is 0.5-5.0 ohms, go to next step. If resistance is not 0.5-5.0 ohms, replace EAIR pump.

  28. 29) Check SAIRM Circuit For Short To PWR In Harness

    Turn ignition switch to ON position. Using a DVOM, measure voltage between chassis ground and SAIRM circuit at PCM harness connector. See Figure. If voltage is more than 10.5 volts, repair short to PWR in SAIRM circuit. If voltage is 10.5 volts or less, SAIRM circuit is okay. Go to next step.

  29. 30) Check Solid State Relay Output

    Reconnect all connectors. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. See OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS. Access AIR and AIRM PIDs. Observe PID values. If both PID values indicate ON, replace SSR. If either PID value indicates OFF, replace PCM.
    NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 30) to step 32). No test procedures have been omitted.

  30. 32) Check Vacuum Hose Integrity

    Turn ignition switch to OFF position. Remove vacuum hose between intake manifold and AIR diverter valve(s). Check hose for cracks, blockage, restrictions, kinks, poor connections, obstructions or water or ice (in colder climates). Replace or repair hose as necessary. If hose is okay, go to next step.

  31. 33) Check AIR By-Pass Solenoid Electrical Operation

    Ensure scan tool is connected to DLC. Disconnect air by-pass solenoid connector. Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. Connect DVOM between both AIR by-pass solenoid harness connector terminals. See Figure. Observe DVOM voltage reading while cycling outputs first ON, and then OFF. If voltage reading cycles more than 0.5 volt, remain in OUTPUT TEST MODE and go to next step. If voltage reading does not cycle more than 0.5 volt, turn ignition switch to OFF position and go to step  35).

  32. 34) Check AIR By-Pass Solenoid For Mechanical Operation

    Ensure scan tool is in OUTPUT TEST MODE. Reconnect AIR by-pass solenoid harness connector. Disconnect source vacuum hose from AIR by-pass solenoid. Connect hand vacuum pump to vacuum source side of AIR by-pass solenoid. Apply 16 in. Hg (54 kPa) to AIR by-pass solenoid. Observe DVOM while cycling outputs ON and OFF. If vacuum does not release as outputs are cycled ON and OFF, replace AIR by-pass solenoid. If vacuum releases as outputs are cycled ON and OFF, repair vacuum hose between AIR by-pass solenoid and intake manifold vacuum tree. If hose is okay, go to TEST Z, step 2) .

  33. 35) Check Air By-Pass Solenoid Resistance

    Turn ignition switch to OFF position. Disconnect AIR by-pass solenoid harness connector. 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.

  34. 36) Check VPWR Circuit For Open In Harness

    Turn ignition switch to ON position. Using a DVOM, measure voltage between negative battery terminal and VPWR circuit at AIR by-pass solenoid harness connector. See Figure. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit. On LS V6, ensure dedicated B+ circuit fuse is okay.

  35. 37) Check EAIR Circuit For Open In Harness

    Turn ignition switch to OFF position. Disconnect SSR and PCM connector(s). Using a DVOM, measure resistance of EAIR circuit between PCM harness connector, AIR by-pass solenoid harness connector and SSR harness connector. See PCM CONNECTOR IDENTIFICATION and Figure. If any resistance measurement is 5 ohms or more, repair open in EAIR circuit. If both resistance measurements are less than 5 ohms, go to next step.

  36. 38) Check EAIR Circuit For Short To Ground In Harness

    Turn ignition switch to OFF position. Using a DVOM, measure resistance between EAIR and PWR GND circuits at PCM harness connector. See PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. See PCM CONNECTOR IDENTIFICATION and Figure. If resistance measurement is more than 10 k/ohms, go to next step. If resistance measurement is 10 k/ohms or less, repair short between circuits.

  37. 39) Check EAIR Circuit For Short To PWR In Harness

    Using a DVOM, measure resistance between EAIR, and PWR and VREF circuits at PCM harness connector. See PCM PWR GND, SIG RTN & VREF TERMINAL IDENTIFICATION table. See PCM CONNECTOR IDENTIFICATION and Figure. If resistance is more than 10 k/ohms, replace PCM. If resistance is 10 k/ohms or less, repair short between circuits.
scientia non olet · About LEMON Manuals