31S26T0 engine perfomance operation and diagnosis 2009

• Follow a pinpoint test to perform various tests on engine performance related components.. ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION Course AgendaLESSON ONE: • Prerequisi

Engine Performance Operation and

August, 2009

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 in­ dividual 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 in­

structed otherwise for a special service operation If you

have a manual transmission, it should be in REVERSE (en­

gine OFF) or NEUTRAL (engine ON) unless instructed oth­

erwise for a specific service operation.

• Operate the engine only in a well­ventilated 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 hang­ ing 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 do 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 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 © 2009 Ford Motor Company Produced and Coordinated by

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION

INTRODUCTION

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

Course Description

This is a 4–day course facilitated by an instructor This course is designed to provide you a hands­on opportunity

to apply knowledge learned in previous curriculum courses and improve your skills using various tools and

equipment Each day you will have multiple opportunities to practice selected skills The results of your work arerecorded on worksheets

Worksheets

All activities and workstation worksheets are 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 CMTWorkstation

— Using a pinpoint test to diagnose an engine performance concern

In order to pass the course, you must demonstrate mastery of the skills covered at an evaluated hands­on exerciseAND 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:

• Use a scan tool to select PIDs and monitor normal system operation

• Identify faults and monitor changes in system operation using a scan tool

• Use PC/ED, wiring diagrams, and workshop manuals to diagnose an engine performance concern

• Use the SSCC diagnostic process to diagnose an engine performance concern

• Follow a pinpoint test to perform various tests on engine performance related components

• Identify the root cause of an electronic engine performance concern

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION Course Agenda

LESSON ONE:

• Prerequisite Review

• Workstation One: Secondary Ignition Operation and Testing

• Workstation Two: Evaporative Emission (EVAP) Operation and Testing

• Workstation Three: Fuel Delivery System Operation and Testing

• Workstation Four: Electronic PC/ED and VCT

LESSON TWO:

• Workstation One: Exhaust Gas Recirculation (EGR) System Operation

• Workstation Two: Variable Camshaft Timing (VCT) System Operation

• Workstation Three: Fuel Control System Operation

• Workstation Four: Idle Air Systems Operation

LESSON THREE:

• Workstation One: Vehicle: MIL ON, Hesitation

• Workstation Two: MIL ON, Engine Runs Rough

• Workstation Three: Vehicle: MIL ON

• Workstation Four: MIL ON, Hesitation

LESSON FOUR:

• Workstation One: Vehicle: MIL ON

• Workstation Two: MIL ON, Engine Runs Rough

• Workstation Three: Vehicle: MIL ON, Rough Idle

• Workstation Four: MIL ON

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION NOTES

LESSON ONE PREREQUISITE REVIEW

LESSON ONE

LESSON ONE PREREQUISITE REVIEW NOTES

LESSON ONE PREREQUISITE REVIEW

PREREQUISITE

REVIEW

LESSON ONE PREREQUISITE REVIEW

PREREQUISITE REVIEW

DIRECTIONS: Answer the following questions The answers will be reviewed in class.

LESSON ONE PREREQUISITE REVIEW Primary Inputs

1 Describe the function and type of signal (analog, digital etc ) of the primary inputs in the table below

Component

Name/Acronym

Component Function Type of Signal

Ignition Switch Supplies power to the PCM and provides a start and run

A signal that indicates the level of fuel in the fuel tank.

May be either hard wired or networked.

Analog DC or Digital DC

Monitors the power steering and A/C systems to determine

if there is any additional load on the engine.

Analog DC or Digital DC

LESSON ONE PREREQUISITE REVIEW

2 What IDS tests would be helpful in diagnosing these inputs?

1 Describe the function of the components in the ignition system in the table below

Component Name/Acronym Component Function

Coil Pack Provides high voltage to the spark plugs Each coil within

a pack fires two spark plugs in different cylinders at the same time.

Coil on Plug (COP) Provides high voltage to a single spark plug.

Knock Sensor A tuned accelerometer which converts engine vibration to

an electrical signal The PCM uses this signal to detect engine knock and retard ignition timing.

2 What IDS tests would be helpful in diagnosing the ignition system?

LESSON ONE PREREQUISITE REVIEW Fuel Delivery System

1 Describe the function of the components in the fuel delivery system in the table below

Component Name/Acronym Component Function

Fuel Pump Relay Controlled by the PCM Sends power to the fuel pump or

fuel pump driver module.

Inertia Switch Used to disable the fuel pump in the event of a collision.

Fuel Filter Filters the fuel May be in the tank or connected to the

external fuel lines.

Fuel Pump Module Contains the fuel pump which provides pressurized fuel to

the fuel rail, and the sender assembly which provides a fuel level signal.

Fuel Pump Driver Module (FPDM) Varies the fuel pump duty cycle to control its speed

in order to regulate fuel pressure on vehicles with an electronic returnless fuel system (ERFS).

Fuel Rail Pressure Temperature

(FRPT) Sensor

Provides a fuel rail pressure and temperature signal to the PCM on vehicles with an electronic returnless fuel system (ERFS).

2 How is fuel pressure controlled in electronic returnless fuel systems?

LESSON ONE PREREQUISITE REVIEW Fuel Control System

1 Describe the function of the components in the fuel control system in the table below

Component Name/Acronym Component Function

Fuel Injector Electrical solenoid that meters and atomizes fuel that is

delivered to the combustion chamber.

Heated Oxygen Sensor (HO2S) Sensor that measures the amount of oxygen in the

LESSON ONE PREREQUISITE REVIEW Evaporative Emission (EVAP) System

1 Describe the function of the components in the EVAP system in the table below

Component Name/Acronym Component Function

Rollover Vent Valve (RVV) Located on top of the fuel tank Allows vapors from the

tank to enter the EVAP system but prevents liquid fuel from doing so.

EVAP Canister Uses charcoal to collect and store fuel vapors to be burned

later by the engine.

Canister Vent Valve/Solenoid (CVV

or CVS)

A normally open solenoid connected to the canister vent,

it is used to seal the EVAP system from the atmosphere during EVAP leak check monitoring.

Canister Purge Valve (CPV)/Vapor

Management Valve (VMV)

Meters the amount of fuel vapor sent to the engine from the fuel tank and canister.

Fuel Tank Pressure (FTP) A pressure sensor which sends an analog signal to the PCM

indicating the amount of vapor pressure or vacuum in the EVAP system.

2 Explain the operation of the EVAP system

LESSON ONE PREREQUISITE REVIEW NOTES

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS NOTES

LESSON ONE WORKSTATION ONE

WORKSTATION ONE Secondary Ignition Operation and Testing

SUMMARY: In this vehicle workstation, you will investigate the operation of the secondary ignition system You

will determine the effects of faults on both a coil pack system and a coil­on­plug system

DIRECTIONS: Complete this VEHICLE workstation following the steps in this worksheet.

Part A: Ignition Workstation – Coil Pack Ignition System

Normal Test ­ Follow the steps below to perform a test on a properly operating ignition system.

• Use the IDS to start a new session If the IDS detects a previous session, select the “Cancel” button and continue

• Select “Toolbox”, “Powertrain”, “Ignition Tools”, and “Ignition Test”

• Follow the IDS instructions and connect the Secondary Ignition Transducers to cylinders# 3 and #6 The

instructor has connected the others for you Be sure to route all IDS cables away from the coil and sparkplug wires

• Start the vehicle and idle until the engine reaches operating temperature View the Ignition System live displayand press the “Capture” button

• When recording is finished (approximately 15 seconds), shut off the engine

30 kV Test ­ Follow the steps below to simulate an open secondary wire or very wide spark plug gap.

• Set the Spark Tester to 30 kV

• Remove the secondary wire from cylinder #5 spark plug, install the spark tester in the secondary wire, and attachthe spark tester to a ground (DO NOT USE BATTERY NEGATIVE AS THE GROUND)

• Start engine, restart ignition test, and capture ignition system values

• When recording is finished (approximately 15 seconds), shut off the engine

3 kV Test ­ Follow the steps below to simulate a shorted secondary wire or a closed spark plug gap.

• Set the Spark Tester to 0, then back the adjustment off one half of a turn Start engine, restart ignition test, andcapture ignition system values

• When recording is finished (approximately 15 seconds), shut off the engine.Select “Playback Viewer” to view

the recordings you made Play each recording from beginning to end (To switch between recordings, use the

forward and back buttons below the menu button.)

LESSON ONE WORKSTATION ONE

For each cylinder, draw a line showing the min and max of each recording in the appropriate IDS screen.

LESSON ONE WORKSTATION ONE

1 In the normal recording, what is the average firing voltage of all cylinders?

4 Which cylinder is paired to the cylinder with the Spark Tester installed? Cylinder #1

5 With the Spark Tester set to 30 kV, why is the duration so short on that cylinder?

6 With the Spark Tester set close to 0, why is the duration so long on that cylinder?

7 What type of fault might cause low peak kV?

8 What type of fault might cause high peak kV?

9 If the firing voltage for a cylinder remains constant, what type of concern may be present?

• Disconnect the Secondary Ignition Transducers from cylinders #3 and #6 Reconnect the spark plug forcylinder #5

LESSON ONE WORKSTATION ONE

10 What happens when KAM is reset?

• Delete the IDS vehicle session Return vehicle to normal operating condition

Part B: Ignition Workstation – COP Ignition System

Review the results of power balance and ignition tests on a COP vehicle

• Prior to using the Ignition Test, the suspect cylinder must be identified using the Power Balance test Performthe following steps to view the results of this test

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Grand Marquis 4.6L IGNITION)

• Access the Power Balance test (“Toolbox” > “Powertrain” > “Power Balance”)

• Select playback display (Recordings Group COP_ALL_PIDS, Recording 1) Play the recording frombeginning to end

1 Which cylinder indicates a concern? Cylinder #4

• After the suspect cylinder was identified, the Ignition Test was performed The red clip was placed on thesuspect cylinder’s coil The blue clip was placed on the coil from a good cylinder Perform the following steps

to view the results of this test

• Access the Ignition Test (“Toolbox” > “Powertrain” > “Ignition Tools” > “Ignition Test”)

• Select playback display (Recordings Group COP, Recording 1)

LESSON ONE WORKSTATION ONE

• Draw a copy of the recording on the IDS screen.

2 What is the average spark duration of the two cylinders? DUR1 1.2 ms DUR2 1.6 ms

3 What is the average firing voltage of the two cylinders? PKV1 15 KV PKV2 12 KV

4 What type of fault might cause the concern in this recording?

LESSON ONE WORKSTATION ONE NOTES

LESSON ONE WORKSTATION TWO

WORKSTATION TWO Evaporative Emission System (EVAP) Operation and Testing

SUMMARY: In this activity you will learn how to use the IDS and a smoke machine to test the evaporative

system for leaks

DIRECTIONS: Complete Workstation 2 at the BENCH workstation, following the steps in this worksheet.

Part A: Normal EVAP System

• Open a new IDS session

• View the scan tool recording and answer the following questions

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Ranger 4.0L EVAP)

• Access the recording (“Toolbox” > “Datalogger” > “Playback Viewer”)

• Select playback display (Recordings Group EVAP, Recording 1) Play the recording from beginning to end

1 During the recording, was the canister vent solenoid open or closed? Open.

2 Explain what is happening to the canister purge valve (EVMV) during the recording

LESSON ONE WORKSTATION TWO

• View Recording 2 and answer the following questions Play the recording from beginning to end (To switchbetween recordings, use the forward and back buttons below the menu button.)

6 When did the canister vent solenoid (EVAPCV) first close?

7 Why does the FTP voltage decrease during this recording?

8 What happened in the recording to the following PIDs between –20 seconds and the trigger point (0 seconds)?

PID Action

Leak size (diameter in inches) Definition Associated DTCs

Gross leak – much larger than

0.040

Unable to pull a vacuum on thetank

P0455

Small leak – <0.040 Significant vacuum bleed up once

the vacuum is pulled on the tank

P0442

Very small leak – < 0.020 Vacuum bleed up once the vacuum

is pulled on the tank

View the scan tool recording and answer the following questions

• Access the recording (Load Saved Recording button)

LESSON ONE WORKSTATION TWO

• Select playback display (Recordings Group EVAP FAULT, Recording 1) Play the recording from beginning

to end

1 This is a recording in which the canister vent valve (EVAPCV) was closed and the canister purge valve (EVMV)was opened between ­ 10 seconds and the trigger point (0) What should happen to the fuel tank pressure(FTP) under these conditions on a normal system?

2 Does this recording indicate a fault? If yes, explain

Part C: Diagnosing EVAP Concerns Using the IDS

• The PCM sets different DTCs depending on the size of an EVAP leak Prior to diagnosing a concern, you mustverify a leak is present This can be done using the IDS EVAP test or the smoke machine

• Perform a simulated IDS EVAP test Click on the “Active Student” icon on the PC desktop, and select the IDSEVAP Test to perform a simulated leak test (“Toolbox”>”Powertrain”>”Fuel”>”EVAP Test”)

1 According to the EVAP test instructions, this IDS EVAP test may be used to diagnose very small leaks (0.020”)

LESSON ONE WORKSTATION TWO

5 What do the results of this part of the test indicate?

6 What might cause the vacuum to bleed up slowly?

Part D: Diagnosing EVAP Concerns with the Smoke Machine

• To verify small leaks in the EVAP system, the smoke machine can be used

• In this activity, you will use the smoke machine and the Evaporative Emission System Training Aid to diagnoseDTC P0456 (very small leak 0.020”)

1 Prior to using the smoke machine, what solenoid must be energized with the IDS?

• Assume that the valve from the question above has been energized

• Using the smoke machine instructions in the PCED, perform Phase 1 of the EVAP test procedure on theEvaporative Emission System Training Aid

2 Based on the DTC (P0456 – very small leak), which orifice should be used to calibrate the smoke machine?

LESSON ONE WORKSTATION THREE

WORKSTATION THREE Fuel Delivery System Operation and Testing

SUMMARY: This activity demonstrates the relationship between fuel pressure and fuel delivery to the combustion

chamber

DIRECTIONS: Complete Workstation Three at the VEHICLE workstation following the steps in this worksheet.

Part A: Fuel System Recording

• Start vehicle and allow it to idle until the engine reaches operating temperature

• Use the IDS to start a new session

• If the IDS detects a previous session, select the “Cancel” button and continue

• Access Toolbox in the scan tool (“Datalogger” > “Powertrain” > “Engine”)

• Clear the PID list, then select the following PIDs:

FP# (select display units PER#) Fuel pump duty cycle

FRP (select display units PSI) Fuel rail pressure

FUELSYS Status of the fuel system (open loop or closed loop)

LONGFT1 Long term fuel trim, Bank 1

LONGFT2 Long term fuel trim, Bank 2

O2S11 (select display units

VOLTS)

Front oxygen sensor, Bank 1

O2S21 (select display units

VOLTS)

Front oxygen sensor, Bank 2SHRTFT1 Short term fuel trim, Bank 1

SHRTFT2 Short term fuel trim, Bank 2

• Display the PID values Press the “Recording Times” button

• Set the Duration to “30s” and the Pre/Post Trigger at “12s / 18s.”

• Prepare to use Output State Control to increase the FP# PID

• Increase the FP# PID two times (press “+” twice) Press the “Capture” button

• When the recording is finished, allow the PCM to control fuel pressure by pressing the “Control Item Activate”button

• Allow the engine to idle for 15 seconds

• Decrease the FP# PID one time (press “­” once) Press the “Capture” button

• When recording is finished, shut off the engine

• Select “Playback Viewer” to view the recordings you made and answer the following questions (To switchbetween recordings, use the forward and back buttons below the menu button.)

LESSON ONE WORKSTATION THREE

1 What effect does increasing the fuel pump duty cycle have on the system (specifically SHRTFT and O2S)?

2 Why do the O2 sensors start switching again after detecting a rich condition?

3 What effect does decreasing the fuel pump duty cycle have on the system (specifically SHRTFT and O2S)?

4 Why do the O2 sensors start switching again after detecting a lean condition?

• Reset the Keep Alive Memory (KAM) (“Toolbox” > “Powertrain” > “Reset KAM” > “PCM”)

5 What else would reset KAM?

A Turning off the ignition for a minimum of 5 minutes

B Disconnecting the battery for a minimum of 5 minutes

C Clearing DTCs

D Turning the key on and off three times in 10 seconds

Part B: Fuel System Tests

Perform the scan tool fuel system tests: (“Toolbox” > “Powertrain” > “Fuel” > “Fuel System Test”)

• Perform the fuel pressure and leakdown tests

1 Does this vehicle pass the fuel pressure and leakdown test?

Yes No

LESSON ONE WORKSTATION THREE

2 With the key on and engine off, what is the fuel pressure on the mechanical gauge and as shown on the IDS?

Mechanical gauge pressure Fuel pressure displayed by IDS

3 What would cause fuel pressure to leak down?

• Perform the Relative Injector Flow Test

4 Why is the injector test called the Relative Injector Flow Test?

5 Does this vehicle pass the test?

Yes No

6 Use the General Information tab to answer this question: If the flow test results for an injector indicated “LF”,what are some of the possible causes?

• Perform the Engine Running Pressure Test

7 With the engine still running, compare the mechanical gauge pressure to the fuel pressure displayed by the IDSand record their values in the table below

Mechanical gauge pressure Fuel pressure displayed by IDS

8 Why do you think the mechanical pressure gauge and IDS readings are different when the engine is running?

LESSON ONE WORKSTATION THREE

9 Based on the tests you performed, could you rule out the fuel delivery system as a possible cause if this vehiclehad a ”lack of power under acceleration” concern?

Yes No

10 If no, what additional tests should be performed?

LESSON ONE WORKSTATION FOUR

WORKSTATION FOUR Electronic PC/ED and VCT

SUMMARY: In this bench activity you will use the PC/ED to diagnose a concern, and you will learn the operation

of VCT systems

DIRECTIONS: Complete Workstation Four at the BENCH workstation following the steps in this worksheet.

Part A: Electronic PC/ED

• Refer to the 2008 Focus (2.0L,4V) PC/ED manual to complete this worksheet

1 Refer to the Evaporative Emission (EVAP) Leak Check Monitor portion of Section 1: Description and Operation

of the PC/ED When is the EONV test performed?

2 As the fuel tank temperature increases, the pressure in the tank increases and as the temperature decreases avacuum develops

True False

3 What can you find in Section 2 of the PC/ED?

A Vehicle Emissions Control Information (VECI)

B Quick Test Description

C DTC Index

D Reference Value Symptom Chart

4 Refer to the list of PIDs in Section 2 of the PC/ED What is the definition of the PID EVAP_EVAL?

LESSON ONE WORKSTATION FOUR

7 Where in the PC/ED would you find possible causes for DTC P0455?

KOEO (Volt/PSI)

Hot Idle (Volt/PSI)

48 KM/H (30 MPH)

89 KM/H (55 MPH)

Units Mea­ sured/PID

(K)

1.99/111.2 (K)

2.53/93.2 (K)

2.66/87.8 (K)

DCV/DEG F

10 What does the symbol (K) stand for?

LESSON ONE WORKSTATION FOUR Part B: VCT

LESSON ONE WORKSTATION FOUR

3 Refer to Section 1 of the PC/ED List the 4 VCT systems along with a brief description

LESSON ONE WRITTEN ACTIVITY

LESSON ONE WRITTEN ACTIVITY

LESSON ONE WRITTEN ACTIVITY NOTES