Diesel Engine Performance Diagnosis. 51 Diesel Engine Performance FCS21133REF. Student Guide FCS REF. Course Code: 51S08T2 VERSION 2

Transcription

1 Diesel Engine Performance Diagnosis 51 Diesel Engine Performance Student Guide FCS21133REF FCS REF Course Code: 51S08T2 VERSION 2

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3 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 WELL VENTILATED 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, THREE WAY 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 2

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5 DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION INTRODUCTION Diesel Engine Performance Diagnosis Intro 1 VERSION 2

6 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 hands on 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 hands on 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 hands on and written evaluations. These will be administered on the afternoon of the fourth day. The hands on 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 hands on exercise AND you must answer at least 80% of the written post test questions correctly. Course Objectives Upon successful completion of this course, you will be able to: Diagnose selected coded, non coded 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, pre turbo exhaust leaks, fuel leaks, high pressure oil leaks and combustion leaks into the fuel system on a PowerStroke diesel engine. Service the high pressure oil system and fuel injectors by disassembly and assembly of the top end of a 6.0L PowerStroke diesel engine. Perform visual inspections and selected tests on various components to verify failures. Diesel Engine Performance Diagnosis Intro 2 VERSION 2

7 DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION Course Agenda LESSON ONE: Prerequisite Review Workstation One: Service Publications And Special Tools Workstation Two: On Vehicle 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 (ON ENGINES) LESSON TWO: Workstation One: 6.4L Diesel Performance Concern Diagnosis Using PID Data Analysis Workstation Two: 6.4L Diesel No Start Concern Diagnosis (ON VEHICLE) Workstation Three: 6.0L Lack Of Power Diagnosis Using PID Data Analysis Workstation Four: 6.0L High Pressure Oil System Service (ON ENGINE) LESSON THREE: Workstation One: 6.0L No Start Diagnosis Workstation Two: 6.4L Diesel Stalls / No Crank Concern Diagnosis (ON VEHICLE) 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 (ON VEHICLE) 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 3 VERSION 2

8 DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION NOTES Diesel Engine Performance Diagnosis Intro 4 VERSION 2

9 LESSON ONE PREREQUISITE REVIEW LESSON ONE Diesel Engine Performance Diagnosis 1 1 VERSION 2

10 LESSON ONE PREREQUISITE REVIEW NOTES Diesel Engine Performance Diagnosis 1 2 VERSION 2

11 LESSON ONE PREREQUISITE REVIEW PREREQUISITE REVIEW Diesel Engine Performance Diagnosis 1 3 VERSION 2

12 LESSON ONE PREREQUISITE REVIEW PREREQUISITE REVIEW DIRECTIONS: Answer the following questions based on what you learned in the Pre Requisite Web programs. The answers will be reviewed in class. 1. How can engine maintenance affect 6.0L engine performance? 2. Why is it extremely important to check fuel pressure, and BOTH fuel filters on 6.0L engines? 3. How is the 6.0L high pressure oil system controlled? 4. How is the fuel pressure controlled on the 6.4L high pressure fuel system? 5. What are some unique cooling system differences between the 6.4L and the 6.0L diesel engines? Diesel Engine Performance Diagnosis 1 4 VERSION 2

13 LESSON ONE PREREQUISITE REVIEW 6. What is the purpose of Coolant Test Strips? 7. What is the result of under 300 ppm nitrites level in engine coolant? 8. How do the exhaust gas temperature (EGT) sensors used on the 6.4L diesel engine operate differently from the ECT, EOT and FRT sensors? 9. How is exhaust backpressure controlled on a 6.0L PowerStroke diesel engine? 10. What is the exception to the answer to Question 9? Diesel Engine Performance Diagnosis 1 5 VERSION 2

14 LESSON ONE PREREQUISITE REVIEW 11. What are some unique features and benefits of the Variable Geometry Turbocharger (VGT) used on 6.0L PowerStroke diesel engines? 12. What type of turbocharger assembly is used on the 6.4L diesel engine? 13. What is the difference between a 6.0L turbo assembly and a 6.4L VGT turbo assembly. 14. What are the components of the 6.0L Exhaust Gas Recirculation (EGR) system? 15. List some components of the 6.4L Exhaust Gas Recirculation (EGR) subsystem. 16. How does a diesel engine react when an EGR cooler is leaking? Diesel Engine Performance Diagnosis 1 6 VERSION 2

15 LESSON ONE PREREQUISITE REVIEW 17. When diagnosing a 6.4L Hard Start/No Start, and you discover high engine oil level, what might be the cause? Select all that apply. A. Injector leaks B. Injector supply tube C. Leaking fuel rail pressure sensor D. EGR cooler 18. What mechanical and electronic components are used in the 6.4L aftertreatment system after the turbocharger down pipe? Diesel Engine Performance Diagnosis 1 7 VERSION 2

16 LESSON ONE PREREQUISITE REVIEW 19. Identify the components of the 6.4L fuel system by placing each illustration number next to its correct component below. No. Component No. Component No. Component 8 Fuel Supply Line (low pressure) 6 HFCM 10 Secondary Fuel Filter 4 High Pressure Fuel Supply Line 2 Fuel Tank 9 Fuel Cooler 7 Fuel Return Lines 1 Fuel Injectors 3 High Pressure Fuel Pump 5 Fuel Rail 11 Primary Fuel Filter 20. What two ECM output components are housed within the 6.4L High Pressure Fuel Injection Pump? 21. What is unique about the 6.4L High Pressure Fuel Injection Pump cover gasket? Diesel Engine Performance Diagnosis 1 8 VERSION 2

17 LESSON ONE PREREQUISITE REVIEW 22. What type of fuel injector is used in the 6.4L engine? 23. Match the numbered Piezo fuel injector components in the illustration below with their names. No. Component 4 High Pressure Chamber 2 Control Piston Chamber 5 Pintle 1 Piezo Crystal Element 3 Mushroom Valve 24. What are some characteristics of this Piezo style injector? Diesel Engine Performance Diagnosis 1 9 VERSION 2

18 LESSON ONE PREREQUISITE REVIEW 25. What special tools are required any time a 6.4L diesel fuel system component is disconnected and the system is open? 26. What two modules work together to control fuel delivery on a 6.0L PowerStroke diesel engine? How do these two modules work together on this engine? Diesel Engine Performance Diagnosis 1 10 VERSION 2

19 LESSON ONE WORKSTATIONS LESSON ONE WORKSTATIONS Diesel Engine Performance Diagnosis 1 11 VERSION 2

20 LESSON ONE WORKSTATIONS NOTES Diesel Engine Performance Diagnosis 1 12 VERSION 2

21 LESSON ONE WORKSTATION ONE WORKSTATION ONE SERVICE PUBLICATIONS AND SPECIAL TOOLS SUMMARY: Use the available service publications to answer questions related to the operation, diagnosis and service of various diesel engine components. DIRECTIONS: Complete Workstation 1 at the PC workstation. Use the 2008 Powertrain Control/Emissions Diagnosis (PC/ED) Manual for 6.4L Diesel Engine, to answer Questions Using the Description and Operation section of the 6.4L PC/ED Manual, what type of sensors are the EGT and the DPF sensors? 2. List all 6.4L Diesel OBD II Monitors shown in the Description and Operation section: 3. Go to the DTC Index in the PC/ED for 6.4L Diesel Engine. List the Malfunction Thresholds for P200E below. 4. What PC/ED Symptom Chart is used for a 6.4L diesel that runs rough at idle? 5. Go to the chart in the answer above. What System/Component check is the easiest to perform? Diesel Engine Performance Diagnosis 1 13 VERSION 2

22 LESSON ONE WORKSTATION ONE 6. Per the same chart, what procedure and steps must be performed for Preliminary Checks? Use the 2008 F Super Duty Workshop Manual to answer Questions Locate the procedures for the High Pressure Fuel Pump Removal and Installation in Section C of the Workshop Manual. What does the Workshop Manual note about the installation of the pump gear retaining bolt? 8. Locate the procedures for both Front Cover and Rear Cover Removal and Installation in Section C of the Workshop Manual. What special tools are required to service the front and rear oil seals? 9. Locate the procedures for the Turbocharger Actuator Removal and Installation in Section B of the Workshop Manual. Can the Turbocharger Actuator be serviced separately from the turbocharger? 10. Locate the procedures for Glow Plug Removal and Installation in Section B of the Workshop Manual. What special tool(s) is required to service the glow plugs? Diesel Engine Performance Diagnosis 1 14 VERSION 2

23 LESSON ONE WORKSTATION ONE 11. After servicing the Fuel and Turbocharger Coolant Pump (in Section E) on a vehicle with a 6.4L diesel engine and refilling the coolant to the proper level, what additional procedure is required? 12. Locate the Workshop Manual Section , for the EGR Coolers. List the tool numbers for the EGR Cooler Test Plates and describe their purpose. 13. Go to No DTCs Symptom Chart in the L F Super Duty PC/ED manual. With a symptom of Cooling Fan Does Not Operate, what is the Pinpoint Test and what are the first two steps? Use the 2008 F Super Duty Wiring Diagrams Manual to answer Questions 14 through Locate the group of wiring diagrams for 6.4L Electronic Engine Controls Cell Where is the high voltage driver for the fuel injectors located? 15. How does the ECM communicate with the Turbocharger Actuator? 16. Locate the group of wiring diagrams for Electronic Engine Controls Cell Find a view of the Fuel Pressure Control Valve and Fuel Volume Control Valve. How many pins are on each connector for these components? 17. Is there another connector between the Fuel Pressure/Volume Control Valves and the ECM? If yes, how many pins are on this connector? Where is it located? Diesel Engine Performance Diagnosis 1 15 VERSION 2

24 LESSON ONE WORKSTATION ONE Use the Powertrain Control/Emissions Diagnosis (PC/ED) Manual for L Diesel Engine, to answer Questions Go to Pinpoint Test AB. What step is the Inverse Injector test? 19. Go to Pinpoint Test ME. What wiring and components does this test diagnose? Use the L F Super Duty PC/ED Manual to answer the following Questions. 20. What pinpoint test is used for DTC P0336? 21. What is the description of the circuits/components being checked in this test? 22. Go to Hard Start/No Start Test 5. What is the tool number for the 6.0L fuel pressure tester? Diesel Engine Performance Diagnosis 1 16 VERSION 2

25 LESSON ONE WORKSTATION TWO WORKSTATION TWO ON VEHICLE PID SELECTION, RECORDING AND ANALYSIS SUMMARY: This activity allows you to select and view various 6.4L PowerStroke diesel performance parameters under normal conditions. You are to create and be able to review KOEO and KOER recordings by saving them to the IDS. You are not diagnosing a customer concern in this activity. DIRECTIONS: Complete Workstation 2 at the VEHICLE workstation, following the steps on this worksheet. Perform all preliminary set up tasks for vehicle safety. (Block wheels, transmission in Park, set park brake.) Connect the scan tool and establish a scan tool session. Perform KOEO Self Test and record any DTCs. Exit Self Test when finished. Select Datalogger function. Select Powertrain, then select Engine. Press Erasure button. This de selects all PIDs. Select the upper half the PIDs listed on the next page and press Save Parameter and Display Settings. Arrow left and save file. Name the file (Your name). Name the description (For example: Normal_1, LowPower_2) View the PID list and click on the clock. Perform the Capture Buffer Setup. Select 30 for duration. Pre = 0 and Post = 30. Press the Movie button. Wait until Capture Event 1 is blue all the way across. Repeat the above steps for your lower half of the PID list. View the PID lists and fill in KOEO values on the next page. Repeat the above steps for your KOER PID values as well. It is not necessary to warm up the engine before making your recordings. Shut off the engine. Diesel Engine Performance Diagnosis 1 17 VERSION 2

26 LESSON ONE WORKSTATION TWO View PID list recording and fill in KOER values. PID KOEO KOER PID KOEO KOER APP % 0% 0% EBP_DSD (psi) 8.7 psi 3.8 psi APP _MODE CT CT ECT (deg. F) 77 ºF ºF APP 1(volt) 4.09 V 4.09V EGRT_A (deg. F) APP 2(volt) 1.44V 1.44V EGRT_B (deg. F) 140 ºF ºF 73.4 ºF ºF BARO (psi) 14.5 psi 14.5 psi EGRTP#(%) 95% 95% DPF (volt).45v.57v EGRVP (volt) 1.1V 1.61V DPF (psi) 0 psi 0.21 psi EGT11 ºF 82.4 ºF ºF DPF_REGEN INACTIVE INACTIVE EGT12 ºF 86 ºF 356 ºF EBP_A (psi) 14.5 psi 16.0 psi EGT13 ºF 86 ºF ºF EBP_V (volt).72v.81v EOT ºF 78.8 ºF ºF MAF (Hz) khz 5.1 khz F_PCV% 0% 14% MAP (psi) 14.5 psi psi F_VCV% 0% 24% MFDES FANDC% 0% 0% MGP (psi) 0 psi 0.32 psi FANSS 0 RPM 313 RPM RPM# 0 RPM 750 RPM FLI% 100% 100% SYNC NO YES FRP (psi) 0 psi psi VGTDC# 10% 95% FRP (volts).49v 1.2V VGT_MES 10% 95% FRP_DSD 0 psi psi VPWR 12.5V 13.44V FUELPW (ms) 0 us 3.4 us VREF (volt) 4.98V 4.98V IAT (deg. F) 86 ºF 68 ºF VSS (volt) 0V 0V IAT2 (deg. F) 77 ºF 96.8 ºF VSS (mph) 0 0 LOAD 0% 5.09% Start engine and select Live Display. 1. Disconnect the EBP sensor. What happens to EBP PID values (EBP_A, EBP_V, EBP _DSD)? Diesel Engine Performance Diagnosis 1 18 VERSION 2

27 LESSON ONE WORKSTATION TWO 2. Does the EBP_A remain at an almost normal level? Reconnect the EBP sensor. 3. Command RPM to approximately 1200, then monitor and record the following PID values: VGTDC# 48.5% TORQUE 25.78% MGP near 0 EGRDC# 35.05% EGRVP 1.29V EBP_A psi LOAD 15% warm, Up to 30% cold MAF 3.78 khz IAT2 86 deg F 4. Command VGT duty cycle to 0% and then up to 80% at 1200 RPM. What happens to the EBP_A PID at 0% and at 80% VGT? 5. Command EGR open, then closed with VGT at 85% at 1200 RPM. What happens to the EBP_A PID? 6. When the EGR is commanded open, how do the MAF and IAT2 PIDs react? Describe why. Release all active commands. 7. Why do the two events in Questions 4 and 5 occur? Go to PID screen, select Load Parameters icon and highlight your file(s). Select Delete File icon, confirm and exit Datalogger. Perform a Power Balance Test, then exit. Perform a Relative Compression Test, then exit. Diesel Engine Performance Diagnosis 1 19 VERSION 2

28 LESSON ONE WORKSTATION TWO 8. What would cause a good Relative Compression reading, but have one weak cylinder on the Power Balance Test? Select Datalogger function. Select Powertrain, then select Fuel System. 9. What would be the benefit of having the PIDs grouped in this way? Select Datalogger function. Select Powertrain, then select Air Management. 10. What are the EGRPCT and EGRTP# PID descriptions and values? Clear DTCs and delete the session. Diesel Engine Performance Diagnosis 1 20 VERSION 2

29 LESSON ONE WORKSTATION THREE WORKSTATION THREE 6.4L DIESEL TEMPERATURE AND PRESSURE RATIONALITY PID GRAPH ANALYSIS SUMMARY: In this activity, you will Complete Workstation 3 at the PC workstation, using the IDS recording provided by your instructor as reference to perform tasks and to answer questions. This activity requires you to open and view two separate recording files. DIRECTIONS: Open IDS and Select Previous Sessions. Open the recording file named L1W3A. Select Datalogger and click the check mark. Then select Playback Display at the bottom of the screen. KOEO is Recording 1 and KOER is Recording 2. Observe the specific readings for all PIDs shown below at the 0 second mark of the KOEO and KOER recording, and write the readings in the appropriate spaces in the worksheets. After recording the readings in the pages below, answer the remaining questions on these worksheets. 1. Look at the readings for ECT, EGRT_B, EOT, FRT, IAT and IAT2. Are the temperature readings within 5 degrees F of each other at KOEO (Cold)? PID: KOEO (Cold): KOER (Hot): ECT 77 F F EGRT_B 73.4 F F EOT 78.8 F F FRT 2.94v 2.54v IAT 86 F 68 F IAT2 77 F 96.8 F 2. Which PID is higher than the others at KOEO (Cold)? 3. At KOER (Hot), what other temperature PID(s) is close to Engine Coolant Temperature (ECT)? Is this normal? Diesel Engine Performance Diagnosis 1 21 VERSION 2

30 LESSON ONE WORKSTATION THREE 4. At KOER (Hot), why is the IAT2 PID showing a higher temperature than IAT? 5. Look at the PID data for the following temperature sensors at KOER (Hot): EGRT_A, EGRT_B, EGT11, EGT12 and EGT13. What do these five sensors have in common? PID: KOEO (Cold): KOER (Hot): EGRT_A 140 F F EGRT_B 73.4 F F EGT F F EGT12 86 F 356 F EGT13 86 F F 6. At KOER (Hot), how much temperature difference is there between EGRT_A and EGRT_B? Why would one be lower than the other? 7. Where are the three exhaust gas temperature sensors located? Why might the temperature readings increase from EGT11 to EGT 13 as shown in the PIDs? Diesel Engine Performance Diagnosis 1 22 VERSION 2

31 LESSON ONE WORKSTATION THREE 8. Examine the pressure readings for BARO, EBP_A and MAP at KOEO (Cold). Are they all reading within 1.5 psi of each other? What does this tell you about what the three sensors for these PIDs are reading? PID: KOEO (Cold): KOER (Hot): BARO 14.5 psi 14.5 psi EBP_A 14.5 psi 16.0 psi MAP 14.5 psi psi 9. What do the KOER (Hot) values for FRP and FRP_DSD# tell you about the current fuel control on this engine? PID: KOEO (Cold): KOER (Hot): FRP 0 psi psi FRP_DSD# 0 psi psi MAF_HZ khz 5.1 khz 10. What would you think is occurring if FRP and FRP_DSD# are exactly the same at all times? 11. What do the KOEO (Cold) and KOER (Hot) readings for MAF_HZ tell you about how this sensor works? Exit the current session on IDS (select Hold Session), and open the session called L1W3B The vehicle has an audible knock that is RPM dependent. Power Balance and Relative Compression Tests have been performed and do not indicate a concern at this time. View the recording and answer the questions below. 12. Go to the 1 second mark on the new recording and record the values for Short Fuel Trim (SFT): Cylinder % Cylinder 2 25% Cylinder 3 0% Cylinder % Cylinder % Cylinder 6 22% Cylinder % Cylinder % Diesel Engine Performance Diagnosis 1 23 VERSION 2

32 LESSON ONE WORKSTATION THREE 13. What did you observe of the SFT values from cylinder to cylinder in the above reading? 14. What do you think could be causing the large variation in the recorded values? 15. After viewing the recording, what component is at fault? 16. What active command could help diagnose this concern? Diesel Engine Performance Diagnosis 1 24 VERSION 2

33 LESSON ONE WORKSTATION FOUR WORKSTATION FOUR 6.4L/6.0L COMPONENT IDENTIFICATION (ON ENGINES) SUMMARY: In this activity, you are identifying components and tools and related pinpoint tests on the 6.4L engine and identifying tools and components and functions on the 6.0L engine. Two components can have the same pinpoint test. DIRECTIONS: Complete Workstation 4 at the engines on stands, using the Coffee Table Books for component locations, and Service Information DTC Charts, Description and Operation for the other columns and for the tool identification. An engine tag may have a connector number along with a component number. If so, search the Wiring Diagrams for the specific component associated with the connector. 1. Fill in this 6.4L worksheet as you identify each component and it s pinpoint test. No. Component Pinpoint Test 1 Engine Oil temperature (EOT) sensor L 2 Engine Coolant Temperature (ECT) Sensor K 3 Exhaust Gas Recirculation (EGR) valve W 4 Manifold Absolute Pressure (MAP) sensor E 5 EGR Cooler Inlet Temperature sensor AZ, WA 6 Fuel Rail Temperature (FRT) sensor MC 7 Fuel Rail Pressure (FRP) sensor MB 8 Camshaft Position Sensor V 9 Crankshaft Position Sensor D 10 Exhaust Pressure (EP) sensor X Diesel Engine Performance Diagnosis 1 25 VERSION 2

34 LESSON ONE WORKSTATION FOUR 2. Fill in this 6.0L worksheet as you identify each component s function. No. Component Function 1 Secondary fuel filter filters fuel a second time down to 4 microns 2 Fuel check valves prevents fuel spikes 3 ICP sensor measures HP oil pressure in the rail 4 IPR valve controls HP oil pressure in the rail 5 IAT2 measures manifold air temp 6 Crankshaft trigger wheel signals crank speed and position 7 Engine oil cooler cools engine oil 8 HP oil rail acts as a reservoir for high pressure oil and connects the injectors to the stand pipes Diesel Engine Performance Diagnosis 1 26 VERSION 2

35 LESSON ONE WORKSTATION FOUR Using the Service Information, fill in the blanks below. 3. What essential tool(s) are required to service the 6.4L turbo seals? 4. What essential tool(s) are required to remove the 6.4L turbo from the engine? 5. What essential tool(s) are required to clean the 6.4L injector cup bore in the cylinder head? 6. What essential tool(s) are required to remove the 6.4L EGR valve out of the intake manifold? 7. What essential tool(s) are required to align the cam to the crank upon installation? 8. What essential tool(s) are required for cylinder head removal from the engine? 9. What essential tool(s) are required to accurately measure crankcase pressure? Diesel Engine Performance Diagnosis 1 27 VERSION 2

36 LESSON ONE WORKSTATION FOUR NOTES Diesel Engine Performance Diagnosis 1 28 VERSION 2

37 LESSON TWO LESSON TWO Diesel Engine Performance Diagnosis 2 1 VERSION 2

38 LESSON TWO NOTES Diesel Engine Performance Diagnosis 2 2 VERSION 2

39 LESSON TWO WORKSTATIONS LESSON TWO WORKSTATIONS Diesel Engine Performance Diagnosis 2 3 VERSION 2

40 LESSON TWO WORKSTATIONS NOTES Diesel Engine Performance Diagnosis 2 4 VERSION 2

41 LESSON TWO WORKSTATION ONE WORKSTATION ONE 6.4L DIESEL PERFORMANCE CONCERN DIAGNOSIS USING PID DATA ANALYSIS SUMMARY: In this activity, you are reviewing recorded PID data to determine possible causes of a 6.4L diesel Low Power concern. After you have recorded the necessary data on this worksheet, you must compare it to the data already provided in the Normal column to determine problem areas. DIRECTIONS: Complete Workstation 1 at the PC workstation, using the appropriate IDS recording files on the computer. Open IDS and select Previous Sessions. Open session L2W1. Open Toolbox, select Datalogger, and select Recording 2. Move the scroll bar to the 2.0 second mark on the recording. Record any PID data that looks significantly different from Normal in the appropriate spaces of the table on the next page. Move the scroll bar to the 12 second mark on the recording. Record any PID data that looks significantly different from Normal in the appropriate spaces of the table on the next page. Move the scroll bar to the 24 second mark on the recording. Record any PID data that looks significantly different from Normal in the appropriate spaces of the table on the next page. Continued on next page. Diesel Engine Performance Diagnosis 2 5 VERSION 2

42 LESSON TWO WORKSTATION ONE Record PID values with large variations in the table below. Use the data to answer the questions on the following pages of this worksheet. PID IDLE(2.0s) CONCERN PRESENT PART THROTTLE ACCEL(12s) HARD ACCEL (24s) IDLE NORMAL PART THROTTLE ACCEL APP 0% 19% 99% 0% 29% 99% HARD ACCEL DPF.12 psi 1.04 psi 1.36 psi 0.04 psi 1.61 psi 4.9 psi EBP_A psi psi psi psi psi 52.2 psi ECT (temp) F F F 194 F 194 F 196 F EGRVPA# % % % % % % EGRVPDES % % % % 14.8 % % EGT F F 387 F 401ºF 429.8ºF 530.6ºF EGT F F F 438.8ºF 429.8ºF 462.2ºF EGT F F F 395.6ºF 404.6ºF 429.8ºF EOT F F F 196 F 196 F 198 F FANDC# % 51.9 % % 0 % 0% 0 % FRP psi psi psi FRP_DSD# psi psi psi psi psi psi psi psi psi FRT 2.74 V 2.70 V 2.67 V 2.62 V 2.62 V 2.62 V IAT 59.0 F 57.2 F 57.2 F 69.8ºF 69.8ºF 66.2ºF IAT F 68.0 F 86.0 F 91.4ºF 87.8ºF 105.8ºF LOAD % % 100 % 20.39% 52.16% 99.61% MAF_HZ 4.83 khz 2.84 khz 2.80 khz 5.81 khz 2.95 khz 2.36 khz MAP psi psi psi psi psi psi MFDES.23 gr.63 gr.63 gr 0.21 gr 0.7 gr 1.36 gr MGP.25 psi psi psi 0.61 psi psi psi RPM# VGTDC# 94.9 % 73.9 % % 95% 85.18% 32.72% VSS 0 mph mph mph 0 mph 32.3 mph mph Diesel Engine Performance Diagnosis 2 6 VERSION 2

43 LESSON TWO WORKSTATION ONE 1. List any PIDs for which the Concern Present data is noticeably different than the Normal data: 2. Which of the PIDs you listed in Question #1 appears to be most significantly different than Normal? 3. Referring to Question #2, is there a cause and effect relationship? If so, what is the cause and what is the effect? Go the Appendix and look up SSM and review. 4. Based on the data you ve analyzed, what component(s) require further diagnosis? 5. How would the above system/component(s) concern cause a Low Power symptom? 6. What diagnostic path would you take to better determine the failed component? Diesel Engine Performance Diagnosis 2 7 VERSION 2

44 LESSON TWO WORKSTATION ONE NOTES Diesel Engine Performance Diagnosis 2 8 VERSION 2

45 LESSON TWO WORKSTATION TWO WORKSTATION TWO 6.4L DIESEL NO START CONCERN DIAGNOSIS (ON VEHICLE) SUMMARY: In this activity, you are diagnosing a No Start concern on the classroom vehicle, and identifying the root cause and required repair. DIRECTIONS: Complete Workstation 2 at the classroom vehicle, using any available special tools and service publications provided. You have preformed all the listed preliminary inspections and no concerns were identified. Continue with your diagnosis as directed in the 2010 Super Duty 6.4L PC/ED manual. Checked TSBs and OASIS and Checked for aftermarket add on accessories. Checked for sufficient clean fuel. Checked the intake system for leaks and blockages. Checked air filter minder. 1. Perform the KOEO Quick Test using IDS. What DTC(s) are shown? Record the pinpoint test steps in the table below. Stop at your first out of spec. result. This vehicle does NOT have aerated fuel. M1 Retrieve DTCs Test Steps P Go to M2 M2 Check engine oil level OK- Go to M3 M3 Sufficient Clean Fuel Test M4 Electric Fuel Pump Pressure Test M13 Bleed the High Pressure Fuel System Test-Low Pressure Fuel System Validated. M14 Perform PCV/VCV Adaptive Learning Reset OK-Go to M4 OK-Go to M13 Results Fuel not aerated-go to M14 M15 Ck for a Biased FRP sensor. OK-Go to M16 M16 Ck FRP Sensor Functionality OK-Go to ME1 ME1- Checked for DTCs Test ME2 Ck PCV/VCV Resistance Concern still present-go to M15 P Go to ME2 100 ohms in PCV ckt. 2. What is the cause of the No Start concern? Diesel Engine Performance Diagnosis 2 9 VERSION 2

46 LESSON TWO WORKSTATION TWO 3. What would be the next step in the diagnostic process? Return this workstation to the way you found it, and DO NOT REPAIR the concern. Diesel Engine Performance Diagnosis 2 10 VERSION 2

47 LESSON TWO WORKSTATION THREE WORKSTATION THREE 6.0L LACK OF POWER DIAGNOSIS USING PID DATA ANALYSIS SUMMARY: In this activity, you will review a scan tool recording for a Lack of Power concern, compare CONCERN PRESENT PID data to Normal PID data under various conditions, note any major differences in PID values, and determine possible causes for the difference(s) in PID values. DIRECTIONS: Complete Workstation 3 at the PC workstation, using the IDS recording file provided. 1. You are diagnosing a lack of power condition on a Excursion equipped with a 6.0L PowerStroke diesel engine. Open IDS and open Session L2W3_L3W3. Open Toolbox, select DataLogger. Select the recording marked DRV_4. This is a recording made with a concern present. Move the scroll bar to the light acceleration portion (3s) of the recording and record any large variations PID values in the LIGHT ACCEL column versus NORMAL values. Move the scroll bar through the recording and record any large variations in PID values in the CRUISE (20s) column versus NORMAL values. Move the scroll bar to the peak of hard acceleration and record any large variations in PID values in the HARD ACCEL (37s) column versus NORMAL values. Move the scroll bar and record any large variations in PID values in the COAST (50s) column versus NORMAL values. Use the data to answer the questions on the following page of this worksheet. Diesel Engine Performance Diagnosis 2 11 VERSION 2

48 LESSON TWO WORKSTATION THREE CONCERN PRESENT NORMAL PID LIGHT ACCEL (3s) CRUISE (20s) HARD ACCEL (37s) COAST (50s) LIGHT ACCEL (3s) CRUISE (20s) HARD ACCEL (37s) APP 17% 20% 70% 0% 18% 19.5% 74% 0% COAST (50s) BARO 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi ECT ºF ºF ºF 192 ºF ºF ºF ºF 194 ºF LOAD 40.78% 35.69% 99.61% 5.09% 42.75% 38.43% 99.61% 7.05% EOT ºF ºF ºF 194 ºF 185 ºF ºF ºF ºF RPM# EBP 1.51V 1.23V 3.22V 0.98V 1.6V 1.35V 3.6V 1.06V EGRDC# 23.56% 29.93% 48.25% 12.03% 7.2% 29.28% 43.31% 26.35% EGRVP 0.76V 1.18V 1.29V 0.74V 0.74V 1.04V 2.37V 0.88V ICP psi psi psi psi psi psi psi psi IPR# 31.25% 35.55% 76.17% 23.05% 32.42% 33.98% 77.34% 23.44% IAT 55.4 ºF 51.8 ºF 51.8 ºF 50 ºF 66.2ºF 60.8ºF 55.4ºF 55.4ºF IAT2 131 ºF ºF ºF ºF ºF 104 ºF 95 ºF 93.2 ºF MAP psi psi psi psi psi psi psi 14.9 psi MGP 0.32 psi 2.32 psi 4.38 psi 0.32 psi 0.83 psi 2.46 psi psi 0.43 psi MAF 1.57V 2.15V 2.55V 1.61V 1.98V 2.2V 4.23V 1.68V MFDES.33 gr.35 gr.68 gr.03 gr.23 gr.23 gr.72 gr.03 gr VGTDC# 77.45% 52.93% 59.61% 54.46% 67.01% 54.89% 37.89% 57.41% VSS 2.9 mph mph mph 45.4 mph 2.82 mph 34.3 mph 49.9mph 42.6mph 2. When comparing the two recordings, which PIDs are most affected by the concern? Diesel Engine Performance Diagnosis 2 12 VERSION 2

49 LESSON TWO WORKSTATION THREE 3. Based on the MGP, IAT2 and MAF PID values, which subsystems are most affected by the concern? 4. Based on the MGP, IAT2 and MAF PID values, which component would you check first for a concern? 5. What information leads you to believe that this component is the cause of the concern? Diesel Engine Performance Diagnosis 2 13 VERSION 2

50 LESSON TWO WORKSTATION THREE NOTES Diesel Engine Performance Diagnosis 2 14 VERSION 2

51 LESSON TWO WORKSTATION FOUR WORKSTATION FOUR 6.0L HIGH PRESSURE OIL SYSTEM SERVICE (ON ENGINE) SUMMARY: In this activity you will use the correct block off tool, adapters and a stethoscope to diagnose leaks and other concerns in the high pressure oil system. DIRECTIONS: Complete Workstation 4 at the engine on a stand, using the special tools provided. For this activity, with the engine on the stand, you will use shop air to check for HP oil leaks as if you had a vehicle with a hot no start or stall no restart hot condition. When performing high pressure oil leak testing on vehicle with the engine OFF, the IPR is open (bypassing oil) until commanded ON with the IDS. Disconnect the crank sensor when on vehicle as default ICP values will occur otherwise. Use the 12V power supply and wire leads to command the IPR valve ON (closed) for this activity, no longer than one minute at a time. Make sure to use proper safety equipment. Diesel Engine Performance Diagnosis 2 15 VERSION 2

52 LESSON TWO WORKSTATION FOUR High Pressure Oil System Components Item Description Possible Leak Area 1 ICP Sensor 8 High Pressure Manifold 2 Access Plug for Air Adapter Item Description Possible Leak Area 9 Left Check Valve 3 Right Check Valve 10 Left Stand Tube 4 Right Stand Tube 11 HP Oil pump plug 5 Branch Tube 12 Dummy plug (2) 6 High Pressure Oil Pump 13 STC fitting 7 IPR Solenoid 14 Injector D ring (8) This workstation will be a process of elimination, and at this point, all of the components listed in the chart could be a possible HP oil leak. Remove the ICP sensor and install an air line adapter to the high pressure manifold with the proper adapter ( ). Hook up a regulated air supply set at 100 psi. Apply the air slowly. Listen with the stethoscope as you connect power to the IPR solenoid. A difference in sound should be heard as the IPR closes. Listen with the stethoscope to the rest of the HP oil system. Disconnect the IPR power and air pressure after each test as the IPR will be damaged at 100% duty cycle for over a minute. Diesel Engine Performance Diagnosis 2 16 VERSION 2

53 LESSON TWO WORKSTATION FOUR 1. If you found any leaks, record them below. 2. If no difference in sound was heard when the IPR was energized, what would this indicate? 3. A leak may be apparent on either side of the engine. If air is heard on the right or left side only, what can you determine? 4. If air is heard on both sides, what could this mean? Remove air pressure from the High Pressure Oil system. Remove the check valve from the right HP manifold. Install the solid block off tool in its place. Charge the isolated manifold with air and check for leaks. Diesel Engine Performance Diagnosis 2 17 VERSION 2

54 LESSON TWO WORKSTATION FOUR 5. If you found any leaks, record them below. 6. What components are we testing with this setup? Place an X in the Possible Leak Area box for each component. Use a L or R to indicate left or right bank or a B for both if necessary. High Pressure Oil System Components Item Description Possible Leak Area Item Description 1 ICP Sensor 8 High Pressure Manifold RX 2 Access Plug for Air Adapter RX 9 Left Check Valve 3 Right Check Valve 10 Left Stand Tube 4 Right Stand Tube 11 HP Oil pump plug 5 Branch Tube 12 Dummy plug (2) RX 6 High Pressure Oil Pump 13 STC fitting 7 IPR Solenoid 14 Injector D ring (8) RX Possible Leak Area Remove the check valve from the left HP manifold and install the other block off tool in its place. The hole in the block off tool is for the ICP sensor for on vehicle testing. Remove the Access Plug for the Air adapter and install the special tool in the left HP manifold and charge it with air. Check for leaks. 7. If you found any leaks, record them below. 8. What components are we testing with this setup? Place an X in the Possible Leak Area box for each component. Use a L or R to indicate left or right bank or a B for both if necessary. High Pressure Oil System Components Item Description Possible Leak Area Item Description 1 ICP Sensor 8 High Pressure Manifold LX 2 Access Plug for Air Adapter 9 Left Check Valve 3 Right Check Valve 10 Left Stand Tube 4 Right Stand Tube 11 HP Oil pump plug 5 Branch Tube 12 Dummy plug (2) LX 6 High Pressure Oil Pump 13 STC fitting 7 IPR Solenoid 14 Injector D ring (8) LX Possible Leak Area Diesel Engine Performance Diagnosis 2 18 VERSION 2

55 LESSON TWO WORKSTATION FOUR Remove air pressure from the High Pressure Oil system. Remove the special tool from the right manifold and install it into the block off tool with the threaded hole and charge it with air. Check for leaks. 9. If you found any leaks, record them below. 10. What components are we testing with this setup? Place an X in the Possible Leak Area box for each component. Use a L or R to indicate left or right bank or a B for both if necessary. High Pressure Oil System Components Item Description Possible Leak Area Item Description 1 ICP Sensor 8 High Pressure Manifold 2 Access Plug for Air Adapter 9 Left Check Valve 3 Right Check Valve 10 Left Stand Tube X 4 Right Stand Tube X 11 HP Oil pump plug X 5 Branch Tube X 12 Dummy plug (2) 6 High Pressure Oil Pump X 13 STC fitting X 7 IPR Solenoid X 14 Injector D ring (8) Possible Leak Area As it is possible that a high pressure pump could have no output, verify base oil pressure, if no leaks were found and the STC fitting has been updated, a pump replacement may be required. Return the workstation to its original condition. Diesel Engine Performance Diagnosis 2 19 VERSION 2

56 LESSON TWO WORKSTATION FOUR NOTES Diesel Engine Performance Diagnosis 2 20 VERSION 2

57 LESSON THREE LESSON THREE Diesel Engine Performance Diagnosis 3 1 VERSION 2

58 LESSON THREE NOTES Diesel Engine Performance Diagnosis 3 2 VERSION 2

59 LESSON THREE WORKSTATIONS LESSON THREE WORKSTATIONS Diesel Engine Performance Diagnosis 3 3 VERSION 2

60 LESSON THREE WORKSTATIONS NOTES Diesel Engine Performance Diagnosis 3 4 VERSION 2

61 LESSON THREE WORKSTATION ONE WORKSTATION ONE 6.0L NORMAL CRANK NO START DIAGNOSIS SUMMARY: In this workstation, you will diagnose a No Start concern using available service information for a L F 250. Use the steps in this worksheet to determine possible causes. This particular concern does not act the same all the time, may or may not set DTCs and the vehicle may or may not run. Do not diagnose as an intermittent concern. The purpose of this workstation is to teach you when to check for the concern. DIRECTIONS: Diagnose the concern and complete the necessary information on the pages that follow. The Symptom Chart Index sends you to QT. You found no DTCs. You Performed Preliminary Checks. The engine oil level and condition, sufficient clean fuel, intake restriction, fuel pump pressure are all OK. 1. Based on the above result, where in the PC/ED manual do you continue your diagnosis? 2. Look up the customer concern in the table indicated above. What chart is indicated for the concern? All steps up to this point check OK. Hard Start/No Start Chart has you check Parameter Identification (PIDs) while cranking the engine. Use the results below. PID RPM ICP VALUE 156 RPM 1525 PSI IPR 45% FICMLPWR FICMVPWR 11V 11V 3. What can you determine from the above PIDs about the CKP sensor? 4. Refer to Test Steps 10e and 10f. If there was not an RPM reading, what would the PCM do with the IPR PID? 5. For this concern SYNC and FICM SYNC is NO. What does step 10d say about FICM SYNC? Diesel Engine Performance Diagnosis 3 5 VERSION 2

62 LESSON THREE WORKSTATION ONE 6. What do you think FICM SYNC value would be if the FICMLPWR was zero? 7. If you have a RPM signal between 150 and 190 RPM, a steady CKP signal and SYNC and FICM SYNC is NO, would you check CKP or CMP first? You have the key ON, and disconnected the CMP sensor, the CMP fault PID switches to YES while the engine is cranking. You reconnect the sensor, the CMP fault PID remains NO while cranking. You retested for DTCs and there were none. 8. What does this tell us? 9. What mechanical issue could cause NO FICM SYNC? 10. What IDS function could be used to compare CMP and CKP signals? Note in the graphic below that the cam sensor signal is at the correct trigger point, as shown by the pins relationship to the sensor, and the correct crank sensor relationship to the cam signal to the 60 minus 2 gap in the wheel is also shown. Diesel Engine Performance Diagnosis 3 6 VERSION 2

63 LESSON THREE WORKSTATION ONE 11. How many teeth (negative pulses) are there between the minus two teeth and the middle of the crank sensor? Count clockwise from the minus 2 teeth gap. View the scope pattern below. This is the CKP and CMP signals overlapped using the IDS in Oscilloscope mode, of our vehicle with the concern. Diesel Engine Performance Diagnosis 3 7 VERSION 2

64 LESSON THREE WORKSTATION ONE 12. Notice the intersection at the circle and the square. How many negative pulses to the intersection? 13. Could this be the reason that our engine does not start? Why? 14. What would be our next step? Diesel Engine Performance Diagnosis 3 8 VERSION 2

65 LESSON THREE WORKSTATION TWO WORKSTATION TWO 6.4L DIESEL STALLS / NO CRANK CONCERN DIAGNOSIS (ON VEHICLE) SUMMARY: In this activity, you are diagnosing a Stalls No Crank concern on the classroom vehicle, and identifying the root cause and required repair. DIRECTIONS: Complete Workstation 2 at the classroom vehicle, using any available special tools and service publications provided. Start up the vehicle and let it idle. Select drive and let the rear wheels rotate. Change the fault box switch position from A to B. Observe the Message center. 1. What did the engine do? What message is displayed in the message center? Try to re start the engine. 2. What happened when you turned the key? You have preformed 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 and Checked for aftermarket add on accessories. Checked for sufficient clean fuel. Checked the intake system for leaks and blockages. Checked air filter minder. 3. Perform the KOEO Quick Test using IDS. What DTC(s) are shown? 4. Go to the Pinpoint Test for this DTC / concern. What is the Pinpoint test? Record the pinpoint test steps in the table below. Stop at Step 10. Diesel Engine Performance Diagnosis 3 9 VERSION 2

66 LESSON THREE WORKSTATION TWO RC1 Check for DTCs TEST STEPS RC2- Check for correct oil level RC3 Check the engine coolant level RC5 Visually inspect the exhaust system for the following: exhaust leaks at flanges and gaskets punctures or cracks in the catalyst punctures or cracks in the diesel particulate filter engine coolant or oil contamination RC7- Inspect the turbocharger compressor inlet and outlet for excessive oil contamination. RC9 Are both EGT PID readings within 20ºC (36ºF) of ambient temperature? RC-10 CHECK THE EGT SENSOR FOR CORRECT RESISTANCE-Is the resistance between 165 Ohm Ohms? RESULTS P200E - Go to RC2 OK Go to RC3 OK Go to RC5 OK Go to RC7 OK Go to RC9 NO EGT13 = 1288ºC (2350ºF) NO- Replace EGT13 sensor 5. In the first page of diagnosis, it says to attempt to re create the concern. Freeze Frame data would help you to duplicate the condition. What PIDs would you look at for this concern for a road test? 6. What is the cause of the No Crank/ NoStart concern? 7. What would be the next step in the repair process? 8. Did the DTC clear? Why or why not? Change the fault box switch position from B to A with the key in the ON position. Cycle the key 3 times. Run the self test. Under the hood, rear of the passenger battery, disconnect the heavy wire brown with the green tracer, CDC25 at C139. With the key ON, using a jumper wire, touch the battery positive terminal twice momentarily with CDC25 to activate the starter until the engine starts. Repeat the self test. Diesel Engine Performance Diagnosis 3 10 VERSION 2

67 LESSON THREE WORKSTATION TWO 9. Will the starter crank the engine with the key? 10. Have the DTCs been cleared? Diesel Engine Performance Diagnosis 3 11 VERSION 2

68 LESSON THREE WORKSTATION TWO NOTES Diesel Engine Performance Diagnosis 3 12 VERSION 2

69 LESSON THREE WORKSTATION THREE WORKSTATION THREE 6.0L POOR PERFORMANCE / LACK OF POWER DIAGNOSIS USING PID DATA ANALYSIS SUMMARY: In this activity, you will review a 6.0L Excursion scan tool recording for a Lack of Power concern, compare CONCERN PRESENT PID data to Normal PID data under various conditions, note any major differences in PID values, and determine possible causes for the difference(s) in PID values. DIRECTIONS: Complete Workstation 3 at the PC workstation, using the recording file on the Classroom PC. Open IDS and Previous Session L2W3_L3W3. Open Toolbox, select DataLogger, and select the recording marked DRV4B. This is a recording made with a concern present. Move the scroll bar to the light acceleration portion of the recording and record any large variations PID values in the LIGHT ACCEL column versus NORMAL values. Move the scroll bar through the recording and record any large variations in PID values in the CRUISE (20s) column versus NORMAL values. Move the scroll bar to the peak of hard acceleration and record any large variations in PID values in the HARD ACCEL (44s) column versus NORMAL values. Record PID values with large variations in the table below. Use the data to answer the questions on the following pages of this worksheet. Diesel Engine Performance Diagnosis 3 13 VERSION 2

70 LESSON THREE WORKSTATION THREE PID LIGHT ACCEL (2s) CONCERN PRESENT CRUISE (20s) HARD ACCEL (44s) LIGHT ACCEL (2s) NORMAL CRUISE (20s) APP 17.5% 23.5% 72.5% 18% 19.5% 74% HARD ACCEL (44s) BARO 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi 14.3 psi ECT ºF ºF ºF ºF ºF ºF LOAD 42.75% 44.71% 79.22% 42.75% 38.43% 99.61% EOT 194 ºF 194 ºF 194 ºF F F F RPM# EBP 0.89V 0.89V 0.89V 1.6V 1.35V 3.6V EGRDC# 40.56% 57.61% 65.67% 7.2% 29.28% 43.31% EGRVP 2.14V 3.77V 2.05V 0.74V 1.04V 2.37V ICP psi psi 2220 psi psi psi psi IPR# 32.81% 37.89% 64.06% 32.42% 33.98% 77.34% IAT 66.2 ºF 62.6 ºF 60.8 ºF 66.2 ºF 60.8 ºF 55.4 ºF IAT2 203 ºF ºF ºF ºF 104 ºF 95 ºF MAP psi 15.7 psi psi psi psi psi MGP 0.14 psi 1.3 psi 7.17 psi 0.83 psi 2.46 psi psi MAF 1.07 V 1.34 V 2.13 V 1.98V 2.2V 4.23V MFDES.34 gr.42 gr.81 gr.23 gr.23 gr.72 gr VGTDC# 85% 85% 85% 67.01% 54.89% 37.89% VSS 3.71 mph mph mph 2.82 mph 34.3 mph 49.9mph 1. What does the MGP PID value from CONCERN PRESENT recording tell you about the performance of the engine? 2. Which PIDs were most affected by the concern? Diesel Engine Performance Diagnosis 3 14 VERSION 2

71 LESSON THREE WORKSTATION THREE 3. Is the BARO PID value affected by the fault? Why or why not? 4. Is the EGRDC # PID value affected by the fault? Why or why not? 5. What conditions could cause the MGP PID value that you observed? 6. Is the VGTDC # PID value affected by the fault? Why or why not? Diesel Engine Performance Diagnosis 3 15 VERSION 2

72 LESSON THREE WORKSTATION THREE 7. How does the VGT solenoid increase or decrease the exhaust pressure? 8. What does the EBP PID value from CONCERN PRESENT recording tell you about the operating condition of this EP sensor? 9. Which sensor is used by the PCM as an input to adjust the VGT solenoid duty cycle? 10. What component or system would you check further to locate the root cause of this concern? Diesel Engine Performance Diagnosis 3 16 VERSION 2

73 LESSON THREE WORKSTATION FOUR WORKSTATION FOUR FUEL INJECTOR SERVICE AND INSPECTION SUMMARY: Record the removal torque of each injector hold down as you remove each injector from the designated bank of the classroom 6.0L PowerStroke diesel engine. Evaluate the four injectors for installation and physical condition. Use the data from the inspections and Workshop Manual to fill in the chart and answer the questions below. Then remove an injector from the 6.4L engine and answer the questions on the worksheet. DIRECTIONS: Complete Workstation 4 at the ENGINES ON STANDS workstation, following the steps on these worksheets. 6.0L Injector Condition Chart INJECTOR INSPECTION RESULTS LIKELY SYMPTOM REQUIRED REPAIR Removal torque:ok Upper O-ring is damaged Diluted engine oil Replace O-rings and copper washer, install and properly torque bolt. Change oil. Removal torque:ok Copper washer missing Compression loss, combustion gas in fuel, runs rough, hydrolocked engine Replace injector; install and properly torque bolt. Replace injector; install and properly torque bolt. Removal torque: Loose Improper hold down bolt torque Compression loss, combustion gas in fuel, copper washer burned Replace injector; install and properly torque bolt. Removal torque:ok No problem found N/A Replace O-rings and copper washer; reinstall and properly torque bolt. 1. What service can be performed on the high pressure oil D ring in the top of the injector? 2. What is the injector hold down bolt torque? When you have completed all the questions on this worksheet see the instructor and then reinstall the injectors on the engine for the next group. Install the injectors in their original positions, with the concerns still present. Have the instructor check for proper installation before finishing the worksheet. Follow the procedures in the appropriate model year F Super Duty Workshop Manual, Section C to remove an injector from the 6.4L engine. Answer the following questions concerning the 6.4L diesel engine. Diesel Engine Performance Diagnosis 3 17 VERSION 2

74 LESSON THREE WORKSTATION FOUR 3. What special tool is required to disconnect the electrical connector from a fuel injector? 4. Can the fuel supply tubes at the injectors be reused after loosening or removing? Why or why not? 5. What must be done with the steel gasket and O ring on a fuel injector that is being re installed? For this workstation use the existing supply tube, o ring and sealing washer for re assembly. 6. After loosely installing a fuel injector, the next steps are to tighten injector hold down bolt and fuel supply tube nuts to what torque specification? 7. What is the final fuel injector hold down bolt torque? 8. What is the final torque on the fuel supply tube nuts? 9. Why do you think the fuel injector hold down bolt is tightened only AFTER installation and initial torque on the corresponding fuel supply tube? 10. What are the differences between 6.0L and 6.4L injector service? Diesel Engine Performance Diagnosis 3 18 VERSION 2

75 LESSON FOUR LESSON FOUR Diesel Engine Performance Diagnosis 4 1 VERSION 2

76 LESSON FOUR NOTES Diesel Engine Performance Diagnosis 4 2 VERSION 2

77 LESSON FOUR WORKSTATIONS LESSON FOUR WORKSTATIONS Diesel Engine Performance Diagnosis 4 3 VERSION 2

78 LESSON FOUR WORKSTATIONS NOTES Diesel Engine Performance Diagnosis 4 4 VERSION 2

79 LESSON FOUR WORKSTATION ONE WORKSTATION ONE 6.0L VGT TURBOCHARGER SERVICE SUMMARY: In this PC and bench workstation, you will disassemble, inspect and re assemble a L 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. 1. What IDS test or tests need to be performed before turbo service can be performed. Diesel Engine Performance Diagnosis 4 5 VERSION 2

80 LESSON FOUR WORKSTATION ONE 2. In the above graph, looking at the similarity between the top (Command) and the bottom (Response) graph, would the turbo need service? 3. 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 4 6 VERSION 2