STALLS 6.9L/7.3L DIESEL WHEN COMING TO A Article No. STOP OR WHEN CLUTCH IS DISENGAGED

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1 STALLS 6.9L/7.3L DIESEL WHEN COMING TO A Article No. STOP OR WHEN CLUTCH IS DISENGAGED FORD: ECONOLINE, F SUPER DUTY, F-250, F-350 ISSUE The engine may stall when coming to a stop or after clutch disengagement. This may be caused by one or more of the following: System-related conditions identified using the Diesel Engine Performance Chart, Fuel injection pump contamination or Use of low lubricity fuel. ACTION Use the Diesel Engine Performance Chart and the following procedure to diagnose and repair the stall condition. NOTE DO NOT REPLACE THE FUEL INJECTION PUMP UNLESS: INJECTION PUMP TIMING ADVANCE IS NOT AT SPECIFICATION (REFER TO ENGINE PERFORMANCE CHART), OR INJECTION PUMP TRANSFER PRESSURE (MEASURED AT THE RPM DESIGNATED ON THE ENGINE PERFORMANCE CHART) IS NOT AT SPECIFICATION. Perform vehicle road test to verify effectiveness of any corrections made during the diagnostic procedure. DETAILED SERVICE PROCEDURE IF ENGINE STALL CONCERN HAS BEEN RESOLVED, DO NOT PROCEED ANY FURTHER. Completing the Engine Performance Chart assists technicians in identifying and resolving diesel engine 2. Remove the governor assembly cover from the stalling concerns caused by system-related injection pump using the Governor Cover conditions, such as fuel system restrictions. Assembly And Gasket Removal And Installation Procedure Below. Visually inspect the inside of 1. Complete the Engine Performance Chart - the pump: Diesel Engine Diagnostic Guide a. If a red rust color is present, excessive 7.3L base engine - FPS-8512-C; water has run through the pump. Replace 7.3L turbo-charged engine - FPS ; the injection pump, drain the water 6.9L engine - FPS-8433-C separator, replace the fuel filter and clean giving additional attention to the following items: and test the Water In Fuel sensor for proper operation. a. Fuel Quality Check b. If a black sludge is present, the fuel system b. Fuel Supply System Check is contaminated. Flush the fuel system c. Fuel Return Line Pressure Check completely, replace the injection pump, drain the water separator, replace the fuel filter, d. Low Idle (RPM) Check - (make sure that and clean and test the Water In Fuel idle RPM is not set below RPM designated sensor for proper operation. on Emissions Label) c. If the pump is clean inside, the pump is fully e. Injection Pump Timing Check functional. Reinstall the Governor Cover assembly to the injection pump using the Governor Cover Assembly And Gasket Removal And Installation Procedure which follows. PAGE 1

2 Article No Cont d. COVER ASSEMBLY AND GASKET REMOVAL NOTE AND INSTALLATION PROCEDURES THE LOCK WASHER FOR THE GOVERNOR REMOVAL COVER ASSEMBLY MUST BE INSTALLED BETWEEN THE TERMINAL GROUNDING STRAP CAUTION AND THE GOVERNOR COVER BEFORE CLEAN THE TOP OF THE THE PUMP WITH INSTALLING THE SCREW IN THAT CORNER. SOLVENT BEFORE REMOVING THE GOVERNOR REFER TO FIGURE 4. COVER ASSEMBLY. EXTREME CARE MUST BE f. Turn the ignition switch to the RUN TAKEN TO PREVENT DIRT OR FOREIGN position, and touch the red F.S.O. solenoid MATERIAL FROM ENTERING THE INJECTION wire to the solenoid terminal. A clicking PUMP TO PREVENT PUMP DAMAGE. noise should be heard as the wire is 1. Disconnect the battery. connected and disconnected. 2. Disconnect the Fuel Shut-Off (F.S.O.) and CAUTION Housing Pressure Cold Advance (H.P.C.A.) THE IGNITION SWITCH SHOULD NOT BE LEFT solenoid wires from the governor and remove IN THE RUN POSITION WITH THE F.S.O. the fuel return line connector fitting and seal SOLENOID CONNECTED FOR EXTENDED from the top of the governor cover, Figure 1. PERIODS OF TIME. DAMAGE TO THE F.S.O. SOLENOID MAY OCCUR. 3. Remove the seal wire (if applicable). WARNING 4. Remove the three (3) governor cover screws IF F.S.O. CLICKING IS NOT HEARD/OBSERVED, and washers, Figure 2. THE FUEL METERING LINKAGE MAY BE 5. Remove the governor cover and gasket. JAMMED I N THE WIDE OPEN POSITION. THE ENGINE MUST NOT BE STARTED IF CLICKING INSTALLATION IS NOT HEARD, AS A RUNAWAY ENGINE CONDITION MAY OCCUR, RESULTING IN 1. Carefully install the governor cover assembly to SERIOUS ENGINE DAMAGE AND POSSIBLE the pump as follows, Figure 3: BODILY HARM. THE ENGINE CANNOT BE SHUT OFF IF IT IS STARTED WITH JAMMED FUEL a. Make sure the screws are NOT in the METERING LINKAGE. governor cover. b. Position the governor cover about 1/4 2. If F.S.O. clicking is NOT heard/observed: forward of its final alignment (toward the a. DO NOT start the engine. front of the vehicle and about 1/8 above the pump). b. Check for battery voltage (minimum 10 volts) at F.S.O. connector, Figure 5: c. Move the cover rearward and downward into If no voltage, service open circuit in wiring position so that the arm contacts the link, and repeat solenoid click check. being careful not to roll the gasket, Figure 3. If voltage is present, continue to next d. With the cover on the pump and before step. installing the screws, move the governor cover forward and backward until preload of c. Remove the governor cover. Check the internal spring is felt, indicating that the engagement of F.S.O. and internal governor F.S.O. is NOT binding internally. components. Refer to Figure 3. e. Reinstall the three (3) governor cover d. Reinstall the cover carefully, following the screws with one flat washer and one lock previous instructions in step 1, and observe washer with each screw. The flat washer that F.S.O. clicking is heard. must be against the pump cover. Screw with the seal wire hole must be in the rear 3. If F.S.O. clicking is heard/observed: position of the governor cover. Tighten a. Turn off ignition switch. screws to 4.5 N m (40 lb-in), Figure 2. b. Connect the F.S.O. and H.P.C.A wires. PAGE 2

3 Article No Cont d. c. Reinstall original return line connector fitting Please contact the distributor nearest you. with a new connector fitting seal (if appropriate). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To d. Reinstall the fuel return line. Bumper Warranty Coverage e. Start engine and check for leaks. For Model Years. Eligible Under Basic f. If no leaks are evident, install new seal Warraty Coverage And wires (if appropriate) and crimp the seal, Powertrain For Figure 2. Model Years. Eligible Under Emission Coverage For All Perform vehicle road test to verify effectiveness of Model Years. any service procedures performed. OPERATION DESCRIPTION TIME A Remove Governor Cover, 0.7 Hr. IF ENGINE STALL CONCERN HAS BEEN Check For Presence Of RESOLVED, DO NOT PROCEED ANY FURTHER. Rust Or Sludge, Re-install 4. Try different blends / suppliers of #2D diesel Cover - F-Series fuel (winter blend #2D fuel for temperatures B Remove Governor Cover, 0.8 Hr. below 20 F) or add Stanadyne All Season Check For Presence Of Diesel Fuel Conditioner to fuel per directions Rust Or Sludge, Re-install on the container. Conditioner may require using Cover - E-Series one full tank of fuel to take full effect, but often C Additional Time To 2.6 Hrs. begins working after driving 2-5 miles. Other Replace Fuel Injection brands of conditioners or additives are not Pump, Clean, Test (and recommended. The Stanadyne conditioner was replace if necessary) The tested and found to be the best available Water In Fuel Sensor, product for resolving the low lubricity Replace Fuel Filter - fuel-related engine stalling concern without F-Series adverse side effects. Case lots of the D Additional Time To 3.1 Hrs. conditioner can be purchased through Replace Fuel Injection Stanadyne Regional Distributors, Figure 6. Pump, Clean, Test (and Individual bottles of the conditioner can be replace if necessary) The purchased through many stanadyne and John Water In Fuel Sensor, Deere dealers: Replace Fuel Filter - E-Series STANADYNE DIESEL FUEL CONDITIONER E Additional Time To Flush 0.5 Hr. STANADYNE Fuel Lines - All Vehicles CASE PART SIZE OF GALLONS OF DEALER CODING # CONTAINER FUEL TREATED CONDITION Pint 60 BASIC PART NO. CODE Gallon 2,500 9A Gallon 27,500 OASIS CODES: Refer to Figure 6 for a list of Stanadyne Regional Distributors. PAGE 3

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5 Figure 2 - Article Figure 3 - Article PAGE 5

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HEATER LOW/NO HEAT WHEN TEMPERATURE Article No. KNOB IS SET AT FULL HEAT

HEATER LOW/NO HEAT WHEN TEMPERATURE Article No. KNOB IS SET AT FULL HEAT 94-20-16 FORD: 1992-1994 BRONCO, F-150-350 SERIES ISSUE Some vehicles may exhibit a low or no heat condition when the temperature