Computer will not go into diagnostic mode on 91-93 model 5.0 Mustangs
How it is supposed to work:
The grey/red wire (pin 46) is signal ground for the computer. It provides a dedicated
ground for the EGR, Baro, ACT, ECT, & TPS sensors as well as the ground to put the
computer into self test mode.
If this ground is bad, none of the sensors mentioned will work
properly. That will severely affect the car's performance. You will have hard starting, low power
and drivability problems. Since it is a dedicated ground, it passes through the computer on its
way to the computer main power ground that terminates at the battery pigtail ground. It should
read less than 1.5 ohms when measured from anyplace on the engine harness with the battery
pigtail ground as the other reference point for the ohmmeter probe.
What sometimes happens is that the test connector grey/red wire gets jumpered to power
which either burns up the wiring or burns the trace off the pc board inside the computer.
That trace connects pins 46 to pins 40 & 60. Only an experienced electronics technician can open
the computer up & repair the trace if it burns up and creates an open circuit.
The STI (Self Test Input ) is jumpered to ground to put the computer into test mode. Jumpering
it to power can produce unknown results, including damage to the computer. The ohm test
simply verifies that there are no breaks in the wiring between the test connector and the computer input.
How to test the wiring :
With the power off, measure the resistance between the computer test ground
(grey/red wire) on the self test connector and battery ground. You should see less than
1.5 ohms.
If that check fails, remove the passenger side kick panel and disconnect the computer
connector. There is a 10 MM bolt that holds it in place. Measure the resistance between
the grey/red wire and pin 46 on the computer wiring connector : it should be less than
1.5 ohms. More that 1.5 ohms is a wiring problem. If it reads 1.5 ohms or less, then the
computer is suspect. On the computer, measure the resistance between pin 46 and pins
40 & 60: it should be less than 1.5 ohms. More that that and the computer’s internal
ground has failed, and the computer needs to be replaced.
See http://www.stangnet.com/mustang-forums/749974-computer-issue.html#post7490537 for Joel5.0’s fix for the computer internal signal ground.
If the first ground check was good, there are other wires to check. Measure the
resistance between the STI computer self test connector (red/white wire) and pin 48 on
the computer main connector: it should be less than 1.5 ohms. More that 1.5 ohms is a
wiring problem
The following is a view from the computer side of the computer connector.
Diagram courtesy of Tmoss & Stang&2birds
Check out the diagram and notice all the places the grey/red wire goes. Almost every
sensor on the engine except the MAF is connected to it.
See the following website for some help from Tmoss (diagram designer) & Stang&2Birds
(website host) for help on 88-95 wiring
Mustang FAQ - Wiring & Engine Info
Grounds
Grounds are important to any electrical system, and especially to computer controlled engines.
In an automobile, the ground is the return path for power to get back to the alternator and battery.
1.) The main power ground is from engine block to battery: it is the power ground for the starter & alternator.
2.) The secondary power ground is between the back of the intake manifold and the driver's side firewall. It is often missing or loose. It supplies ground for the alternator, A/C compressor clutch and other electrical accessories such as the gauges.
Any car that has a 3G or high output current alternator needs a 4 gauge ground wire running from the block to the chassis ground where the battery pigtail ground connects. The 3G has a 130 amp capacity, so you wire the power side with 4 gauge wire. It stands to reason that the ground side handles just a much current, so it needs to be 4 gauge too.
The picture shows the common ground point for the battery , computer, & extra 3G alternator ground wire as described above in paragraph 2. A screwdriver points to the bolt that is the common ground point.
The battery common ground is a 10 gauge pigtail with the computer ground attached to it.
Picture courtesy timewarped1972
Correct negative battery ground cable.
3.) The computer has its own dedicated power ground that comes off the ground pigtail on the battery ground wire. Due to its proximity to the battery, it may become corroded by acid fumes from the battery.
In 86-90 model cars, it is a black cylinder about 2 1/2" long by 1" diameter with a black/lt green wire.
In 91-95 model cars it is a black cylinder about 2 1/2" long by 1" diameter with a black/white wire.
You'll find it up next to the starter solenoid where the wire goes into the wiring harness.
4.) All the sensors have a common separate ground. This includes the TPS, ACT, EGE, BAP, & VSS sensors.
5.) The O2 sensor heaters have their own ground (HEGO ground) coming from the computer. This is different and separate from the O2 sensor ground. It is an orange wire with a ring terminal on it. It is located in the fuel injector wiring harness and comes out under the throttle body. It gets connected to a manifold or bolt on back of the cylinder head.
6.) The TFI module has 2 grounds: one for the foil shield around the wires and another for the module itself. The TFI module ground terminates inside the computer.
7.) The computer takes the shield ground for the TFI module and runs it from pin 20 to the chassis near the computer.
8.) The computer's main power ground (the one that comes from the battery ground wire) uses pins 40 & 60 for all the things it controls internally.
See http://assets.fluke.com/appnotes/automotive/beatbook.pdf for help for help troubleshooting voltage drops across connections and components. .
Extra grounds are like the reserve parachute for a sky diver. If the main one fails, there is always your reserve.
The best plan is to have all the grounds meet at one central spot and connect together there. That eliminates any voltage drops from grounds connected at different places. A voltage drop between the computer ground and the alternator power ground will effectively reduce the voltage available to the computer by the amount of the drop.