Diesel Engine Performance Diagnosis 51 Diesel Engine Performance FCS21133REF Student Guide FCS21133REF Course Code: 51S08T2 VERSION IMPORTANT SAFETY NOTICE NOTE: Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring any obligation REPAIR TECHNIQUES Appropriate service methods and 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 performing service with tested, effective techniques Following them will help assure reliability There are numerous variations in procedure, 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 the instructions provided in this manual must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts NOTE, NOTICE, CAUTION AND WARNING As you read through this manual, you may come across a NOTE, NOTICE, CAUTION or WARNING Each one is there for a specific purpose A NOTE calls attention to unique, additional or essential information related to the subject procedure A NOTICE identifies a hazard that could damage the vehicle or property A CAUTION identifies a hazard that could result in minor personal injury to yourself or others A WARNING identifies a hazard that could result in severe personal injury or death to yourself or others Some general WARNINGS that you should follow when you work on a vehicle are listed below • ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION • KEEP SOLVENTS AWAY FROM IGNITION SOURCES SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE OR EXPLODE IF NOT HANDLED CORRECTLY • USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE • MAKE 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 IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION IF YOU HAVE A MANUAL TRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKS AGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING • OPERATE THE ENGINE ONLY IN A WELLVENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE POISONING • KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE DRIVE BELTS • TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD, TAIL PIPE, THREEWAY CATALYTIC CONVERTER AND MUFFLER • DO NOT SMOKE WHILE WORKING ON A VEHICLE • TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON A VEHICLE • WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF THE COOLING FAN BLADES! TOOLS Commercially available hand tools and equipment are used along with Essential Special Service Tools (ESST) and Rotunda equipment Power tools have become the acceptable industry standard and are used for disassembly only where applicable, unless specified otherwise in the Workshop Manual The only exception to this policy is installing wheels in conjunction with the use of torque sticks, when possible Copyright © 2010 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION INTRODUCTION Diesel Engine Performance Diagnosis Intro VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION DIESEL ENGINE PERFORMANCE DIAGNOSIS Course Description This is a four day course facilitated by an instructor This course is designed to provide handson opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previous curriculum courses Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All activities and workstations have an accompanying worksheet designed to complement the handson activities and are identified by number and by name Students will complete the worksheets as they perform each Vehicle, Bench or Computer Workstation Course Requirements Each technician attending this course will be required to pass a combination of handson and written evaluations These will be administered on the afternoon of the fourth day • The handson evaluation is a pass/fail type It will be conducted with exercises in PID review/evaluation and intermittent concern diagnosis and will cover: — diesel performance system diagnosis — service publication navigation — selected special tool usage In order to pass the course, you must demonstrate 100% mastery of the skills covered at the evaluated handson exercise AND you must answer at least 80% of the written posttest questions correctly Course Objectives Upon successful completion of this course, you will be able to: • Diagnose selected coded, noncoded and intermittent PowerStroke® diesel engine performance concerns • Set up a PID list, record PIDs and review/analyze PID data related to PowerStroke® diesel engine performance concerns • Perform tests to verify and pinpoint air leaks, preturbo exhaust leaks, fuel leaks, highpressure oil leaks and combustion leaks into the fuel system on a PowerStroke® diesel engine • Service the highpressure oil system and fuel injectors by disassembly and assembly of the topend of a 6.0L PowerStroke® diesel engine • Perform visual inspections and selected tests on various components to verify failures Diesel Engine Performance Diagnosis Intro VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION Course Agenda LESSON ONE: • Prerequisite Review • Workstation One: Service Publications And Special Tools • Workstation Two: OnVehicle PID Selection, Recording And Analysis • Workstation Three: 6.4L Diesel Temperature And Pressure Rationality PID Graph Analysis • Workstation Four: 6.4L/6.0L Component Identification (ONENGINES) LESSON TWO: • Workstation One: 6.4L Diesel Performance Concern Diagnosis Using PID Data Analysis • Workstation Two: 6.4L Diesel No Start Concern Diagnosis (ONVEHICLE) • Workstation Three: 6.0L Lack Of Power Diagnosis Using PID Data Analysis • Workstation Four: 6.0L HighPressure Oil System Service (ONENGINE) LESSON THREE: • Workstation One: 6.0L No Start Diagnosis • Workstation Two: 6.4L Diesel Stalls / No Crank Concern Diagnosis (ONVEHICLE) • Workstation Three: 6.0L Poor Performance / Lack Of Power Using PID Data Analysis • Workstation Four: Fuel Injector Service And Inspection LESSON FOUR: • Workstation One: VGT Turbocharger System • Workstation Two: 6.4L Diesel Performance Concern Diagnosis (ONVEHICLE) • Workstation Three: 6.4L Stalls/No Start Diagnosis Using PID Data Analysis • Workstation Four: 6.4L EGR Valve Service And 6.0L Component Leak Testing Diesel Engine Performance Diagnosis Intro VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION NOTES Diesel Engine Performance Diagnosis Intro VERSION LESSON ONE PREREQUISITE REVIEW LESSON ONE Diesel Engine Performance Diagnosis 11 VERSION LESSON ONE PREREQUISITE REVIEW NOTES Diesel Engine Performance Diagnosis 12 VERSION LESSON FOUR WORKSTATIONS NOTES Diesel Engine Performance Diagnosis 44 VERSION LESSON FOUR WORKSTATION ONE WORKSTATION ONE 6.0L VGT TURBOCHARGER SERVICE SUMMARY: In this PC and bench workstation, you will disassemble, inspect and reassemble a 2007 6.0L turbocharger using Service Information DIRECTIONS: Use the following symptoms: Lack of power, white or black smoke, and or surging Follow the instructions on the work sheet What IDS test or tests need to be performed before turbo service can be performed Diesel Engine Performance Diagnosis 45 VERSION LESSON FOUR WORKSTATION ONE In the above graph, looking at the similarity between the top (Command) and the bottom (Response) graph, would the turbo need service? Go to the Turbo Center Housing Rotating Assembly Replacement procedure This is located in the Student Content Area of CMI When servicing a turbo center section, if corrosion is present on the center housing flange or hub, would the whole center section need to be replaced? Diesel Engine Performance Diagnosis 46 VERSION LESSON FOUR WORKSTATION ONE When is the drain tube replaced? • Disassemble the turbo as described in the Service Information What if upon inspection the unison ring is cracked or broken? Why would you not try and clean the precision turbine wheel? • Reassemble the turbo for the next group Diesel Engine Performance Diagnosis 47 VERSION LESSON FOUR WORKSTATION ONE NOTES Diesel Engine Performance Diagnosis 48 VERSION LESSON FOUR WORKSTATION TWO WORKSTATION TWO 6.4L DIESEL TURBOCHARGER DIAGNOSIS (ONVEHICLE) SUMMARY: In this activity, the purpose is to become familiar with Pinpoint Test KA There is no fault with the vehicle DIRECTIONS: Complete Workstation at the classroom vehicle, using any available special tools and service publications provided • Using 2010 F250 6.4L PC/ED, in DTC Charts and Descriptions, locate DTC P2263– Turbocharger Boost System Performance List Possible Causes and Diagnostic Aids below What Pinpoint Test is required? Go to the above Pinpoint Test Start at KA2 and using the classroom vehicle, perform and record your Test Steps and Results in the table below Stop after Step Test Steps Results KA2-VTG Actuator Visual Inspection Are there any concerns found during the visual inspection? No-Go to AK3 Yes-Go to KA4 KA3-Ck.the mechanical operation of the VTG Actuator Does the actuator linkage move and quickly return to the start position when released? KA4-Ck.the Input Sensors for Bias Are the BARO, EBP_A and MAP PIDs within specifications and is the EBP_A PID within 10.35 kPa (1.5 psi) of the MAP and BARO PID values? Yes-Go to KA5 KA5-Ck.the electrical operation of the VTG Actuator Does the turbocharger actuator operate as commanded? Yes-Go to KA6 KA6-Check the EGR valve operation No concern present.Go to KA7 KA7–Ck the Turbo Operation Is the MGP PID below kPa (0.15 psi) at 0% VGTDC duty cycle and above 30 kPa (4.35 psi) at 90% VGTDC duty cycle? Yes-Go to KA8 KA8–Ck The CAC , AIR INT AND EXH Systems for Leaks and Restrictions No Leaks or restrictions found The turbocharger system is operating correctly Diesel Engine Performance Diagnosis 49 VERSION LESSON FOUR • WORKSTATION TWO Return the vehicle to as you found it at the beginning of the workstation Diesel Engine Performance Diagnosis 10 VERSION LESSON FOUR WORKSTATION THREE WORKSTATION THREE 6.4L STALLS/NO START DIAGNOSIS USING PID DATA ANALYSIS SUMMARY: In this activity, on a 2010 6.4L F250, you are diagnosing a Stalls/No Start concern and identifying the root cause and required repair DIRECTIONS: Complete Workstation at the PC using service publications provided • You have performed all the listed preliminary inspections and no concerns were identified Continue with your diagnosis as directed in the PC/ED manual • Checked TSBs and OASIS • Checked for aftermarket addon accessories • Checked for sufficient clean fuel • Checked intake system for leaks and blockages • Checked air filter minder You have performed the KOEO Quick Test using IDS DTC P0087 is shown What is the description of this test? What is the Pinpoint Test for this DTC? • Record the necessary steps to diagnose this concern in the table below All steps check OK up to step M13 At Step M13, the fuel is aerated Stop at M13 and continue to answer questions Test Steps Results M1–Retrieve DTCs P0087 M2– Check engine oil level OK- Go to M3 M3–Sufficient Clean Fuel test OK-Go to M4 M4–Electric Fuel Pump Pressure Test OK-Go to M13 M13– Bleed the High Pressure Fuel System Test-Low Pressure Fuel System Validated Fuel Aerated- Go to Combustion Gas in the Fuel Rail Test What special tools are used for bleeding the air from the Low and High Pressure Fuel System in Step M13? Diesel Engine Performance Diagnosis 11 VERSION LESSON FOUR WORKSTATION THREE What are the possible causes for the fuel to be still aerated? Where is the check valve located that is described in the Combustion Gas in the Fuel Rail test? For the above test, why are the glow plugs all removed except one? After identifying the injector with the concern, you find a loose hold down bolt What would the repair be? While torquing the new injector hold down for the final time, would it be wise to check the other hold downs for proper torque, even if they show no sign of leaking? Would the fuel supply tube from the rail to the injector need to be replaced also? 10 How you check the repair? Diesel Engine Performance Diagnosis 12 VERSION LESSON FOUR WORKSTATION FOUR WORKSTATION FOUR 6.4L EGR VALVE SERVICE and 6.4L COMPONENT LEAK TESTING SUMMARY: In this activity, first you are performing removal and installation of the EGR valve on the 6.4L diesel engine This procedure requires assembly of the EGR Valve Puller 3031267 on the engine’s EGR valve Second, a leak test will be performed, on a 6.4L EGR cooler Follow the procedures in the appropriate model year FSuper Duty Workshop Manual, Section 30308 to remove and install the EGR valve and to leak test the EGR cooler from the 6.4L diesel engine Answer the questions in this worksheet as you perform the steps in this procedure DIRECTIONS: Complete Workstation at the engine on stand and bench, using the available Service Information and special tools provided Why is EGR Valve Puller 3031267 required for the removal procedure? Can the sliding Uhooks be installed to any two of the three long bolts of EGR Valve Puller 3031267? • The EGR cooler leak test is performed using special tools and an air supply regulated to 30 psi What are the special tool numbers? When tightening the fasteners that hold the tools in place, how tight should you torque the fasteners? When submerged, where would you look for bubbles if a leak was present? Diesel Engine Performance Diagnosis 13 VERSION LESSON FOUR WORKSTATION FOUR NOTES Diesel Engine Performance Diagnosis 14 VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS APPENDIX STUDENT GUIDE APPENDIX Diesel Engine Performance Diagnosis Appendix VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS APPENDIX NOTES Diesel Engine Performance Diagnosis Appendix VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS APPENDIX ENGINE OIL TEMPERATURE (EOT) AND ENGINE COOLANT TEMPERATURE PERFORMANCE TEST OASIS SPECIAL SERVICE MESSAGE NUMBER: 20794 MESSAGE TITLE: 20082009 FSUPER DUTY RADIATOR COOLANT LEAKS APPLICABLE VEHICLES : 2008 2009 TRUCK : 00028 FSERIES OASIS MESSAGE : Engineering is currently investigating some 6.4L diesel equipped vehicles that exhibit a radiator coolant leak due to malfunctioning thermostats Use an IDS and monitor engine oil temperature (EOT) and engine coolant temperature (ECT) PIDs With EOT at 195 deg F (90 deg C) drive on the highway unloaded at 5570 mph (88112 kph) constant speed to observe EOT and ECT temp If EOT is less than deg F (4.4 deg C) higher than ECT, and the coolant temp fluctuates roughly deg F (2.7 deg C), the thermostat is OK Only replace thermostats if EOT exceeds ECT by greater than deg F (4.4 deg C) or if the ECT readings fluctuate 10 to 12 deg F (5.556.66 deg C) roughly every 30 seconds Reference workshop manual engine cooling section 30303 for thermostat removal and installation procedures APPLICABLE SYMPTOM CODES : 200000 ELECTRICAL 204000 ELECTRICAL INSTRUMENTATION 206000 ELECTRICAL WARNING INDICATORS 400000 ENGINE 402000 ENGINE COOLING SYSTEM CONCERNS 499000 ENGINE BASIC ENGINE Diesel Engine Performance Diagnosis Appendix VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS APPENDIX OSCILLOSCOPE HOOK UP WITH IDS TO MONITOR CMPtoCKP OFFSET Fully charge the vehicle batteries Connect the power supply cable (A401) of the VMM to the isolated battery described in step 2 Provide an isolated battery for the VMM by method A or B A Isolate one of the vehicle’s batteries by disconnecting the cables from its terminals B Use a separate battery (booster battery or jump box) If one of the vehicle’s batteries is to be used, insulate the disconnected positive battery cable end with a shop towel or other means to prevent a short to ground Use the two universal probes (T015) of the VMM kit to probe the CKP and CMP terminals of the engine harness connector Connect these circuits to the same battery negative terminal as the VMM black alligator lead Use fused jumper wires and the black alligator clip (T019) Fused jumper wires with stackable banana plugs may be fabricated or obtained locally Disconnect only the engine harness connector (middle connector) of the PCM This connector will remain unplugged during this procedure This procedure will be performed while cranking the engine for approximately seconds Make sure all cables and tools are clear of moving engine components prior to cranking the engine Connect the red roving probe (C403) to the CKP+ signal and the black roving probe (C402) to the CMP+ signal using the purple colored flex probes (T013) When ready, select the tick, wait for seconds, and then crank the engine until the oscilloscope displays a consistent waveform Do not crank the engine for more than 15 seconds Diesel Engine Performance Diagnosis Appendix VERSION ... And 6.0L Component Leak Testing Diesel Engine Performance Diagnosis Intro VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION NOTES Diesel Engine Performance Diagnosis Intro VERSION LESSON... DIAGNOSIS INTRODUCTION INTRODUCTION Diesel Engine Performance Diagnosis Intro VERSION DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION DIESEL ENGINE PERFORMANCE DIAGNOSIS Course Description This is... ONE Diesel Engine Performance Diagnosis 11 VERSION LESSON ONE PREREQUISITE REVIEW NOTES Diesel Engine Performance Diagnosis 12 VERSION LESSON ONE PREREQUISITE REVIEW PREREQUISITE REVIEW Diesel