31S10T0 engine peformance theory and operation 2006

FCS-14569 REF Updated January, 2006 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • • • • • Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts • • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Do not smoke while working on the vehicle To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2002 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division March, 2002 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time Complete servicing my vehicle in a Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns I bring to your attention timely and professional manner Expectation “Fix It Right The First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST – Self Study – FordStar Broadcasts – Ford Multimedia Training (FMT) – Instructor Led New Model – Self Study – FordStar Broadcasts – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS INTRODUCTION Engine Performance Curriculum Goals Intro Planned Training Pathway Intro Engine Performance Curriculum Overview Intro How to Complete the Curriculum Intro Course Description Intro Course Length Intro Target Audience Intro Course Prerequisites Intro Course Structure Intro Course Objectives Intro Classroom Multimedia Training (CMT) Intro PC-Assisted Activities Intro Evaluation Strategy Intro Day One Flowchart Intro Day Two Flowchart Intro Day Three Flowchart Intro Day Four Flowchart Intro 10 DIAGNOSTIC PROCESS REVIEW Student Objectives 1-1 SSCC Process 1-2 Diagnostic Process 1-7 Diagnostic Tests 1-17 Electronic PC/ED Worksheet 1-23 On-Vehicle Worksheet 1-24 IGNITION SYSTEM DIAGNOSIS AND TESTING Student Objective 2-1 Ignition Concerns 2-2 Misfire Diagnosis 2-4 COP Misfire Diagnosis 2-8 No Start Condition Diagnosis 2-13 Ignition Bench Worksheet 2-14 Ignition COP On-Vehicle Worksheet 2-15 Ignition HDR On-Vehicle Worksheet 2-16 FUEL SYSTEM DIAGNOSIS AND TESTING Student Objective 3-1 Fuel Delivery System 3-2 Fuel Control 3-8 Fuel Economy Test 3-22 Fuel System – Bench Worksheet 3-23 Fuel System – On-Vehicle Worksheet 3-24 PCM WIRING AND CIRCUITS REVIEW Student Objective 4-1 PCM Inputs 4-2 PCM Outputs 4-11 PCM Power and Ground 4-18 Diagnosis and Testing September, 2003 TOC-1 TABLE OF CONTENTS AIR INLET DIAGNOSIS AND TESTING Student Objective 5-1 IAC Valve 5-2 Controlled Air Inlet Systems 5-5 PASSIVE ANTI-THEFT SYSTEM (PATS) Student Objective Basic PATS Integrated PATS (IPATS) Engine Performance Concerns Unrelated to PATS 6-1 6-2 6-3 6-4 EMISSIONS SYSTEM DIAGNOSIS AND TESTING Student Objective 7-1 Positive Crankcase Ventilation (PCV) 7-2 Exhaust Gas Recirculation (EGR) 7-5 Thermostat Heater Control 7-10 Catalysts 7-13 Evaporative Emissions (EVAP) System 7-16 EVAP Worksheet 7-24 OBD Test Modes Worksheet 7-25 EGR / IAC Worksheet 7-26 DAY THREE WORKSHEETS Worksheet (WDS EVAP Diagnosis – Hands-on) Worksheet (MIL ON – PC Assisted) Worksheet (Runs Very Rough at Idle – Hands-on) Worksheet (Crank/No Start CMT) WS3-3 WS3-4 WS3-6 WS3-8 DAY FOUR WORKSHEETS Worksheet (No Start – Hands-on) WS4-2 Worksheet (Engine Runs Rough – PC Assisted) WS4-6 Worksheet (Hesitation on Acceleration – Hands-on) WS4-8 Worksheet (Engine Runs Rough – CMT) WS4-10 TOC-2 April, 2002 Diagnosis and Testing INTRODUCTION ENGINE PERFORMANCE CURRICULUM GOALS The goal of the Engine Performance Curriculum is to provide you with the necessary training to enable you to ”Fix it right the first time – on time.” This Engine Performance Diagnosis and Testing classroom course provides you with hands-on practice as it relates to diagnosis and testing Planned Training Pathway Ford Motor Company has identified the skills and knowledge necessary to meet the Engine Performance Curriculum goals The Planned Training Pathway is a sequence of courses that are designed to provide students with these skills and knowledge Engine Performance Curriculum Overview The Engine Performance Curriculum consists of all of the following types of courses: Web-based – These courses are self-paced You are responsible for learning the material on your own time The courses are posted on the Internet and you are given the appropriate access codes Classroom – The classroom courses allow for application of the skills and knowledge learned in the prerequisite courses through hands-on, real-world scenarios Diagnosis and Testing January, 2006 Intro INTRODUCTION How to Complete the Curriculum To successfully complete the Engine Performance Curriculum, you must take the following sequence of courses: Ignition Theory and Operation – Code Ignition SystemCourse Theory and31S01W0 Operation Fuel and Air Theory and Operation – Course Code 31S02W0 Exhaust/Emission Theory and Operation – Course Code 31S03W0 Fuel, Air, Ignition and Emission Relationships – Course Code 31S04W0 OBD II Monitors – Course Code 31S05W0 Engine Performance Theory and Operation – Course Code 31S07T0 Driveability Diagnostic Process – Course Code 31S06W0 Driveability Diagnostic Routines – Course Code 31S08W0 Engine Performance Diagnosis and Testing – Course Code 31S10T0 Diagnosis and Testing of OBD II Vehicles – Course Code 31S12W0 Advanced Engine Performance Diagnosis and Testing – Course Code 31S15T0 Intro January, 2006 Diagnosis and Testing INTRODUCTION Course Description This course is designed to provide you with hands-on application of guided diagnosis and testing of driveability concerns The course emphasizes the SSCC process as well as critical thinking skills Although you work together in groups, each technician is responsible for completing their own worksheets The course includes instructor lecture, instructor-led group discussion, student activities, and student hands-on workstations Course Length This is a four-day, hands-on classroom course Course Structure The Engine Performance Diagnosis and Testing classroom course includes the following: • Instructor-led Discussion – You are asked to complete review questions that address content previously covered in the WBT courses Instructor-led group discussions focus on critical thinking skills and specific concepts that are critical when following a diagnostic process to identify a faulty component or circuit • Instructor Lecture – The instructor presents new information as it relates to guided diagnosis and testing • Student Activities – The student activities are designed to reinforce concepts presented during the instructor lecture • Workstations – The instructor presents the concepts that are critical to successfully completing the workstations You participate in four on-vehicle hands-on exercises, two classroom media training (CMT) activities delivered on CD-ROM, and two PC-assisted activities during the workstation portion of the course • Worksheets – All activities and workstations have an accompanying worksheet designed to complement the hands-on activities Day One and Day Two student activity worksheets are identified by name Day Three and Day Four worksheets are identified by number • Evaluation – At the end of the four-day course, the instructor asks you to complete a final written test, a final hands-on workstation, and a course evaluation Diagnosis and Testing January, 2006 Intro INTRODUCTION Course Objectives Upon completion of the Engine Performance Diagnosis and Testing classroom course, you will be able to: • Use the SSCC diagnostic process to diagnose engine performance concerns • Explain how to perform diagnostic tests − Quick Tests KOEO on-demand self-tests, KOER on-demand self tests, Continuous memory self-tests − PID Monitor • Explain PCM circuits and wiring • Use critical thinking skills and available resources to diagnose and test specific engine performance systems, including: − Ignition system Identify the types of misfires Explain the relationship of ignition patterns to diagnosis Explain how to diagnose misfire concerns Explain how to diagnose no start concerns − Fuel System Fuel delivery ⇒ Identify the types of fuel delivery systems ⇒ Describe conditions related to fuel delivery concerns ⇒ Describe the testing related to fuel delivery concerns Fuel control ⇒ Describe how to diagnose a contaminated MAF sensor ⇒ Identify open/closed loop conditions ⇒ Explain conditions related to abnormal fuel trims ⇒ Describe the testing related to fuel control concerns − Air Inlet System Explain the conditions and tests related to diagnosing and testing the IAC valve Explain the conditions and tests related to diagnosing and testing Controlled Air Inlet Systems − Exhaust/Emissions System Explain the conditions and tests related to diagnosing specific emission systems, including PCV, EGR, CAT, and EVAP • Explain the basic operation of the Passive Anti-Theft System (PATS) • Using available resources, perform hands-on diagnosis and testing of specific engine performance systems including, Ignition, Fuel, Air Inlet, and Emissions Intro April, 2002 Diagnosis and Testing WORKSHEETS DAY THREE WORKSHEET Runs Very Rough at Idle Vehicle: DIRECTIONS: Your instructor has provided you with a repair order that states the concern of the vehicle at this workstation Verify the concern, perform tests and diagnose the concern What is the symptom? Based on the symptom, what system(s) could be at fault? Based on the symptom, what component (s) could be at fault? Diagnose the vehicle concern and fill in the table below Include all critical information such as: wire color circuit numbers, and measurements that you have obtained DIAGNOSTIC STEP RESULT Continued on next page WS3-6 January, 2006 Diagnosis and Testing DAY THREE WORKSHEETS WORKSHEET Runs Very Rough at Idle Diagnostic table- continued DIAGNOSTIC STEP RESULT What was the cause of the customer concern? Diagnosis and Testing January, 2006 WS3-7 WORKSHEETS DAY THREE WORKSHEET Crank / No Start Customer’s Concern: The customer brings in a 2001 Town Car with an engine that cranks but does not start Directions: Based on the customer’s concern, perform the diagnostic steps directed by the PC/ED until you locate the failed component or circuit Identify the diagnostic steps you took and the results of those steps in the table below (i.e QT1=Yes or Performed test XX and the test results were XX Volts) DIAGNOSTIC STEP WS3-8 RESULT April, 2002 Diagnosis and Testing DAY THREE WORKSHEETS WORKSHEET Crank / No Start What component(s) or circuit(s) failed? What pinpoint test step checks the Flash EPROM power supply? Why is the Flash EPROM power supply checked? After the repair is made, how would you verify the repair? What is the final step to complete the diagnostic process? Diagnosis and Testing April, 2002 WS3-9 WORKSHEETS DAY THREE NOTES WS3-10 April, 2002 Diagnosis and Testing DAY FOUR WORKSHEETS Worksheet – NO CRANK / NO START or CRANK / NO START This workstation is a hands-on activity that requires you to diagnose a “No Crank/No Start” or a “Crank/No Start” condition You are asked to locate the cause of the fault and identify all of the diagnostic steps taken to resolve the concern Worksheet – ENGINE RUNS ROUGH This workstation is a PC-assisted activity that requires you to diagnose a rough running engine on a 2001 Town Car You are required to toggle between the computer images and the Ford electronic PC/ED and asked to identify all of the diagnostic steps taken to resolve the concern Worksheet – HESITATION ON ACCELERATION This workstation is a hands-on activity that requires you to diagnose the cause of a slight hesitation on acceleration and identify all of the diagnostic steps taken to resolve the concern Worksheet – ENGINE RUNS ROUGH This workstation is a computer-simulated activity that requires you to diagnose a rough running engine on a 2001 Ranger and identify all of the diagnostic steps taken to resolve the concern Diagnosis and Testing January, 2006 WS4-1 WORKSHEETS DAY FOUR WORKSHEET No Crank / No Start Vehicle: DIRECTIONS: Your instructor has provided you with a repair order that states the concern of the vehicle at this workstation Verify the concern, perform tests and diagnose the concern What is the symptom? Based on the symptom, what system(s) could be at fault? Based on the symptom, what component (s) could be at fault? Diagnose the vehicle concern and fill in the table below Include all critical information such as: wire color circuit numbers, and measurements that you have obtained DIAGNOSTIC STEP RESULT Continued on next page WS4-2 January, 2006 Diagnosis and Testing DAY FOUR WORKSHEETS WORKSHEET No Crank / No Start Diagnostic table- continued DIAGNOSTIC STEP RESULT What was the cause of the customer concern? Diagnosis and Testing January, 2006 WS4-3 WORKSHEETS DAY FOUR WORKSHEET Engine Runs Rough Customer’s Concern: The customer brings in a 2001 Town Car with the MIL ON and a rough running engine Directions: Based on the customer’s concern, perform the diagnostic steps directed by the PC/ED until you locate the failed component or circuit Identify the diagnostic steps you took and the results of those steps in the table below (i.e QT1=Yes or Performed test XX and the test results were XX Volts) DIAGNOSTIC STEP WS4-4 RESULT September, 2003 Diagnosis and Testing DAY FOUR WORKSHEETS WORKSHEET Engine Runs Rough What component(s) or circuit(s) failed? Why did the pinpoint test have you check the DPFEGR PID at KOER and at KOEO? Why didn’t the INJx_F PID detect the fault? After the repair is made, how would you verify the repair? What is the final step to complete the diagnostic process? Diagnosis and Testing September, 2003 WS4-5 WORKSHEETS DAY FOUR WORKSHEET Hesitation on Acceleration Vehicle: DIRECTIONS: Your instructor has provided you with a repair order that states the concern of the vehicle at this workstation Verify the concern, perform tests and diagnose the concern What is the symptom? Based on the symptom, what system(s) could be at fault? Based on the symptom, what component (s) could be at fault? Diagnose the vehicle concern and fill in the table below Include all critical information such as: wire color circuit numbers, and measurements that you have obtained DIAGNOSTIC STEP RESULT Continued on next page WS4-6 January, 2006 Diagnosis and Testing DAY FOUR WORKSHEETS WORKSHEET Hesitation on Acceleration Diagnostic table- continued DIAGNOSTIC STEP RESULT What was the cause of the customer concern? Diagnosis and Testing January, 2006 WS4-7 WORKSHEETS DAY FOUR WORKSHEET Engine Runs Rough Customer’s Concern: The customer brings in a 2001 Ranger (4.0L) with the MIL ON and the engine running rough Directions: Based on the customer’s concern, perform the diagnostic steps directed by the PC/ED until you locate the failed component or circuit Identify the diagnostic steps you took and the results of those steps in the table below (i.e QT1=Yes or Performed test XX and the test results were XX Volts) DIAGNOSTIC STEP WS4-8 RESULT September, 2003 Diagnosis and Testing DAY FOUR WORKSHEETS WORKSHEET Engine Runs Rough What component(s) or circuit(s) failed? After the repair is made, how would you verify the repair? What is the final step to complete the diagnostic process? Diagnosis and Testing September, 2003 WS4-9 WORKSHEETS DAY FOUR NOTES WS4-10 September, 2003 Diagnosis and Testing ... courses: Ignition Theory and Operation – Code Ignition SystemCourse Theory and3 1S01W0 Operation Fuel and Air Theory and Operation – Course Code 31S02W0 Exhaust/Emission Theory and Operation – Course... Code 31S08W0 Engine Performance Diagnosis and Testing – Course Code 31S10T0 Diagnosis and Testing of OBD II Vehicles – Course Code 31S12W0 Advanced Engine Performance Diagnosis and Testing –... test, a final hands-on workstation, and a course evaluation Diagnosis and Testing January, 2006 Intro INTRODUCTION Course Objectives Upon completion of the Engine Performance Diagnosis and Testing