31S28T0 advanced engine perfomance operation and diagnosis 2009

Course AgendaLESSON ONE: • Prerequisite Review • Workstation One: MIL ON, Engine Misfire On Vehicle • Workstation Two: MIL ON, Wrench Light On, No Throttle Control Bench • Workstation Thr

Advanced Engine

Performance ­ Diagnosis and

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

INTRODUCTION

ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION

ADVANCED ENGINE PERFORMANCE DIAG & TESTING

Course Description

This is a 4 day course facilitated by an instructor This course is designed to provide hands­on opportunities fortechnicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previouscurriculum courses Each day you will have multiple opportunities to practice selected skills The results of yourwork are recorded on worksheets

Worksheets

All activities and workstations have an accompanying worksheet designed to complement the hands­on activitiesand are identified by number and by name Students will complete the worksheets as they perform each Vehicle,Bench or CMT Workstation

Upon successful completion of this course, you will be able to:

• Identify types of DTCs (Condition and component generated)

• Perform data analysis (Mode 6, PID) during diagnosis

• Perform diagnosis using the scan tool, oscilloscope, breakout box and other tools

• Perform intermittent concern diagnosis

• Perform diagnosis using the symptom chart

Course Agenda

LESSON ONE:

• Prerequisite Review

• Workstation One: MIL ON, Engine Misfire (On Vehicle)

• Workstation Two: MIL ON, Wrench Light On, No Throttle Control (Bench)

• Workstation Three: No Crank (On Vehicle)

• Workstation Four: E85 Bench Calculation and DTC P0133 (CMT)

• Lesson One Written Activity

LESSON TWO:

• Workstation One: MIL On (On Vehicle)

• Workstation Two: IDS Recordings (Bench)

• Workstation Three: Engine Misfire (On Vehicle)

• Workstation Four: IDS Recordings (Bench)

• Lesson Two Written Activity

LESSON THREE:

• Workstation One: Intermittent Stall (On Vehicle)

• Workstation Two: Intermittent Rough Idle (CMT)

• Workstation Three: Intermittent Buck/Jerk (On Vehicle)

• Workstation Four: Intermittent Misfire/Skip

LESSON FOUR:

• Workstation One: MIL ON, Hesitation (On Vehicle)

• Workstation Two: Intermittent Misfire (Bench)

• Workstation Three: MIL ON, Hesitation (On Vehicle)

• Workstation Four: Intermittent Misfire (Bench)

• Lesson Four Written Activity

ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION NOTES

LESSON ONE

LESSON ONE PREREQUISITE REVIEW NOTES

REVIEW

LESSON ONE PREREQUISITE REVIEW

PREREQUISITE REVIEW

DIRECTIONS:

1 When retrieving DTCs, which should you perform first?

A Perform KOEO On­Demand Self Test

B Perform KOER On­Demand Self Test

C Retrieve CMDTCs for the module being tested

D Retrieve all CMDTCs from all modules

2 Data that is captured at the exact time a DTC is generated is known as:

3 Pinpoint test QT1 directs you to test fuel quality How should this be done?

4 In the faults legend below the wiring diagram, circle the faults that would prevent the output device in thiscircuit from operating properly

5 If you suspect high resistance in the circuit, what test could you perform?

9 How does the fuel control system try to compensate for large intake air leaks?

10 An abnormal fuel trim on one bank could be caused by:

11 What could cause abnormal fuel trim readings on both banks?

LESSON ONE PREREQUISITE REVIEW

12 What could cause the upstream O2 sensors to show lean?

19 What is the OBD drive cycle and when should it be performed?

20 What is Mode 6 Data?

LESSON ONE PREREQUISITE REVIEW NOTES

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS NOTES

WORKSTATION ONE MIL ON, Engine Misfire

SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern Use the steps in this worksheet

to determine possible causes, separate those causes into a list of systems and components, then systematicallyeliminate each to come up with the root cause(s) of the concern

DIRECTIONS: Read the information in the repair order to start your diagnosis Diagnose the concern and

complete the necessary information on the pages that follow *

Repair Order

Year Model

Customer Concern

Check Engine Light ON, Engine Misfire

Vehicle History/ OASIS results/ TSBs REPAIR HISTORY

PCM Replaced

SPECIAL SERVICE MESSAGES

20044 SERVICE PROCEDURE UPDATE ­ PCED (GAS ENGINES) PINPOINT TEST DV ­ MIL ON P2104, P2107, P2110, P2111,

P2112 DTC

2007­2008 MULTIPLE VEHICLES WHEN DIAGNOSING/REPAIRING MIL ON P2104, P2107, P2110, P2111, P2112 DTC FOR

ELECTRONIC THROTTLE CONTROL, USE THE ONLINE VERSION OF THE PCED MANUAL (GAS ENGINES VERSION) THE

DIAGNOSTIC PROCEDURES UNDER THE "DV" PINPOINT TEST HAVE BEEN UPDATED

EFFECTIVE DATE: 11/13/07

TECHNICAL SERVICE BULLETINS

08–07–06

SPARK PLUG REMOVAL INSTRUCTIONS 4.6L 3V / 5.4L 3V / 6.8L 3V

F­150, MARK LT, F­SUPER DUTY, EXPEDITION, AND NAVIGATOR, WITH 5.4L 3­VALVE ENGINE; MUSTANG, EXPLORER,

MOUNTAINEER, AND EXPLORER SPORT TRAC WITH 4.6L 3­VALVE ENGINE; F­SUPER DUTY, AND F­STRIPPED CHASSIS,

WITH 6.8L 3­VALVE ENGINE MAY EXPERIENCE DIFFICULTY WITH SPARK PLUG REMOVAL THIS MAY CAUSE DAMAGE TO

THE SPARK PLUG AND LEAVE PART OF THE SPARK PLUG IN THE CYLINDER HEAD REFER TO THE SERVICE PROCEDURE

FOR TECHNIQUES TO REMOVE THE SPARK PLUGS AND EXTRACT BROKEN SPARK PLUGS See TSB for complete details

EFFECTIVE DATE: 04/08/2008

08–04–03

MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) ­ P0456

EXPEDITION, NAVIGATOR, E­150 THROUGH E­350, F­150 AND MARK LT MAY EXHIBIT A MIL ON WITH DTC P0456 (VERY

SMALL EVAP SYSTEM LEAK ­ 0.020 IN DIAMETER (.51 MM)) FOLLOW THE SERVICE PROCEDURE STEPS TO CORRECT THE CONDITION.

EFFECTIVE DATE: 04/02/2008

IMPORTANT NOTES:

LESSON ONE WORKSTATION ONE

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of

this concern As you go through your diagnosis, indicate your results for each step by crossing off component(s) andfault(s) that are eliminated Then, next to the fault, write the test step that eliminated it

1 In the SSCC Table, document the system(s) that could cause the concern

SSCC Table

Symptom: Misfire

System: Base engine,

Ignition, Fuel Control

Component: VPWR circuit,

control circuit, PCM, coil

and boot, spark plug

Cause:

2 In the SSCC Table, document the component(s) that could cause the concern Then, use the wiring diagram

to identify the faults that could cause the concern

3 What does the pinpoint test recommend as a repair for this concern?

WORKSTATION TWO MIL ON, Wrench Light ON, No Throttle Control

SUMMARY: In this BENCH workstation, you will diagnose a customer concern Use the steps in this worksheet to

determine possible causes, separate those causes into a list of systems and components, then systematically eliminateeach to come up with the root cause(s) of the concern

DIRECTIONS: Read the information in the repair order to start your diagnosis Verify the customer’s concern.

Diagnose the concern and complete the necessary information on the pages that follow *

Repair Order

Year 2008 Model Edge

Engine 3.5L Trans 6F50 Other

Customer Concern

MIL is ON, Wrench Light is ON, lack of power, little to no throttle control, high idle

Vehicle History/ OASIS results/ TSBs REPAIR HISTORY

No related history.

SPECIAL SERVICE MESSAGES

20380 20380 FORD/LINCOLN/MERCURY VEHICLES WITH REPLACEABLE THROTTLE POSITION SENSOR: TPS REMOVAL

SERVICE PROCEDURE UPDATE.

FORD/LINCOLN/MERCURY VEHICLES HAVE A SERVICEABLE THROTTLE POSITION SENSOR (TPS) A NEW SERVICE

PROCEDURE HAS BEEN RELEASED TO REDUCE THE POSSIBILITY OF A BOLT BREAKING DURING TPS REMOVAL CAUSED

BY THE THREAD LOCKER USED PLEASE REFER TO THE ONLINE WORKSHOP MANUAL, SECTION 303­14 FOR UPDATED

REMOVAL PROCEDURE.

EFFECTIVE DATE: 08/12/2008

20211 CROWN VICTORIA AND GRAND MARQUIS ­ AIR CLEANER ASSEMBLY (9600) IDENTIFICATION.

CROWN VICTORIA AND GRAND MARQUIS MAY HAVE INCORRECT AIR CLEANER ASSEMBLY (9600) INSTALLED THAT CAN

RESULT IN POOR ENGINE PERFORMANCE, HARD STARTING AND/OR MULTIPLE DIAGNOSTIC TROUBLE CODES (DTC’S) A

UNIQUE AIR CLEANER ASSEMBLY IS USED ON ALL POLICE (P71) VEHICLES AND IT CAN BE QUICKLY IDENTIFIED BY RIBS

THAT ARE VISIBLE ON THE TOP COVER OF THE AIR CLEANER ASSEMBLY, ALL OTHER VEHICLES HAVE A SMOOTH AIR

CLEANER TOP COVER VERIFY THE CORRECT AIR CLEANER ASSEMBLY HAS BEEN INSTALLED, ESPECIALLY IF A VEHICLE HAS RECENTLY BEEN REPAIRED SUCH AS AFTER AN ACCIDENT, AND IT IS EXPERIENCING SOME OF THE SYMPTOMS

LISTED ABOVE IF THE INCORRECT AIR CLEANER WAS INSTALLED, INSTALL THE CORRECT AIR CLEANER ASSEMBLY,

COMPLETE A PCM RE­SET AND REEVALUATE THE VEHICLE.

LESSON ONE WORKSTATION TWO

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of

this concern As you go through your diagnosis, indicate your results for each step by crossing off component(s) andfault(s) that are eliminated Then, next to the fault, write the test step that eliminated it

1 In the SSCC Table, document the system(s) that could cause the concern

SSCC Table

Symptom: MIL ON, wrench

light ON, no throttle control

System: Air delivery

Cause: Open TPRTN circuit

2 In the SSCC Table, document the component(s) that could cause the concern Then, use the wiring diagram

to identify the faults that could cause the concern

3 Could an obstructed throttle body cause this concern? Why or why not?

4 Review the wiring diagram, what circuit(s)/fault(s) have not been tested?

WORKSTATION THREE

No Crank

SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern Use the steps in this worksheet

to determine possible causes, separate those causes into a list of systems and components, then systematicallyeliminate each to come up with the root cause(s) of the concern

DIRECTIONS: Read the information in the repair order to start your diagnosis Diagnose the concern and

complete the necessary information on the pages that follow *

SPECIAL SERVICE MESSAGES

20144 MULTIPLE VEHICLE LINES – INTERMITTENT PCM, FUEL PUMP, IGN COIL, OR FOG LAMP RELAY

FOCUS, CROWN VICTORIA, GRAND MARQUIS AND TOWN CAR VEHICLES MAY EXHIBIT AN INTERMITTENT NO CRANK,

NO START, NO FUEL PRESSURE ON STARTUP, NO SPARK ON STARTUP OR NO A/C OPERATION ESCAPE, MARINER,

TAURUS, SABLE, EXPLORER, SPORT TRAC, MOUNTAINEER, AND RANGER VEHICLES MAY EXHIBIT A HARD TO DIAGNOSE

INTERMITTENT ABS OPERATION WITH MIL ON, INTERMITTENT FOG LAMPS OR NO A/C OPERATION, DUE TO INTERMITTENT RELAY OPERATION CHECK FOR PROPER INSTALLATION AND FUNCTION OF THE RELATED RELAYS (ENGINEERING PART

# 4F1T­14B192­AA (4­PIN)) IF NORMAL DIAGNOSTICS INDICATE RELAY REPLACEMENT IS NECESSARY, REPLACE WITH

SERVICE PART # F5TZ­14N089­B (5­PIN, EXTRA PIN IS NOT UTILIZED

EFFECTIVE DATE: 02/20/07

20001 SOME VEHICLES MAY EXPERIENCE A NO CRANK, NO START OR NO COMMUNICATION CONCERN AFTER

PROGRAMMING THE ECM, TCM OR IC.

REPROGRAMMING CONCERNS MAY BE CAUSED BY THE DLC OR VCM BECOMING DISCONNECTED, LOW BATTERIES

ON THE IDS, OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE IF THERE WAS AN INTERRUPTION DURING

REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT

DELETED IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY

REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR THE MODULE RECOVERY PROCEDURE IS NO

LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE.

TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE

ORIGINAL SESSION ONCE THE IDS IS RE­BOOTED.

EFFECTIVE DATE: 10/10/2007

TECHNICAL SERVICE BULLETINS

No related TSBs

IMPORTANT NOTES:

LESSON ONE WORKSTATION THREE

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of

this concern As you go through your diagnosis, indicate your results for each step by crossing off component(s) andfault(s) that are eliminated Then, next to the fault, write the test step that eliminated it

1 In the SSCC Table, document the system(s) that could cause the concern

2 In the SSCC Table, document the component(s) that could cause the concern Then, use the wiring diagram

to identify the faults that could cause the concern

3 Navigate to the service information and view the wiring diagram for this vehicle What modules are on thenetwork with the PCM?

4 View the wiring diagram What pins provide power to the PCM Power Relay?

6 What else could cause this concern?

• Use the DMM and wiring diagrams and prove that the answer to the previous question is the root cause ofthe concern

• Delete the IDS session

7 Which option did you choose to delete the session?

A hold

B complete

C delete

D abort

LESSON ONE WORKSTATION THREE NOTES

WORKSTATION FOUR PART ONE E85 Bench Calculation

SUMMARY: In this activity, you will use the tools provided to determine the percentage of ethanol in the

vehicle fuel tank

DIRECTIONS: Complete Workstation Four at the BENCH workstation, using the E85 tool kit.

Repair Order

Year 2008 Model Fusion

Engine 2.3L Trans FNR5 Other

Customer Concern

Check Engine Light is ON

Vehicle History/ OASIS results/ TSBs REPAIR HISTORY

None

SPECIAL SERVICE MESSAGES

20697 VEHICLES WITH P035X (OR P0351 ­ P0360) DTC CODES

SOME FORD AND LINCOLN­MERCURY VEHICLES MAY EXHIBIT A P035X CODE THIS COULD BE CAUSED BY A PARTIALLY

CONNECTED IGNITION COIL CONNECTOR, WHICH MAY APPEAR TO BE CONNECTED PULL ON THE CONNECTOR TO

VERIFY IT IS LOCKED IF PARTIALLY CONNECTED THEN UNPLUG AND RECONNECT YOU SHOULD HEAR A AUDIBLE

CLICK OR SNAP WHEN FULLY CONNECTED IF THERE ARE NO ISSUES WITH CONNECTION THEN PROCEED WITH

NORMAL DIAGNOSTICS.

EFFECTIVE DATE: 03/06/2009

20680 GAS ENGINE COIL ON PLUG(COP) DIAGNOSTIC TESTING

WHEN DIAGNOSING COIL ON PLUG (COP) IGNITION PRIMARY CIRCUIT MALFUNCTION DTC’S P035X­P0360 ALWAYS VERIFY HARNESS INTEGRITY USING PCED PINPOINT TEST JF IN RARE INSTANCES COIL DTCS CAN BE A RESULT OF PCM DRIVER FAILURES TO CONFIRM PCM DRIVER FUNCTION USE IDS TOOLBOX OSCILLOSCOPE "ESCAPE PCM DRIVER" TEST TO

VERIFY PCM FUNCTION WITH NO VEHICLE SESSION ACTIVE SELECT TOOLBOX THEN OSCILLOSCOPE FUNCTION.

SELECT THE ESCAPE PCM DRIVER TEST FOLLOW HOOKUP SCREENS FOR CONNECTING THE CURRENT CLAMP AROUND THE HARNESS AT THE ENGINE POCKET CONNECTOR OF THE PCM MISSING COIL DRIVER PULSES FOR NON­STANDARD

COP COILS CAN BE IDENTIFIED USING IDS POWER BALANCE IF MISSING PULSES ARE OBSERVED FOLLOW PCED

DIAGNOSTICS TO RESOLVE IF ALL COIL PULSES ARE PRESENT DON’T REPLACE THE PCM TEST DISPLAY SCREENS ARE AVAILABLE IN THE ESCAPE DRIVER TEST HELP LIBRARY

LESSON ONE WORKSTATION FOUR

TECHNICIAN NOTES

Diagnostic Step Result

Verify concern Vehicle has check engine light ON

Perform visual inspection Visual inspection completed, no problems found

Check OASIS No TSB’s or SSM’s available for this concern

Check for DTCs P0171 System Too Lean Bank 1

H1 Is DTC P0171 present? Yes Go to H2

H2 Are any other DTC’s present? No Go to H3

H3 Visual inspection Is a concern present? No Go to H4

H4 Vacuum leak Yes, the total fuel correction value is less than 15% Go to H16

H16 Check fuel pressure Is the fuel pressure within range? Yes Go to H17

H17 Fuel system stability, fast leakdown Does the fuel pressure remain within range?

Yes Go to H19

H19 Fuel system stability, slow leakdown Does the fuel pressure remain within range?

Yes Go to H20H20 Check the separation level Did the ethanol/water mixture and gasoline

separate? Yes Go to H21.

H21 Calculate the percentage of ethanol Is any ethanol present in the

fuel? Yes Go to H25 H25 Determine if percentage is less than 25% Is the percentage less

than 25%? No.

Repair as necessary Drain fuel and advised customer which fuel to use.

• The customer has a 2008 2.3L Fusion with check engine light ON and DTC P0171 Some of the pinpointtest steps are completed and are shown in the table below Answer the questions and complete BOTH the

”TECHNICIAN NOTES” Table along with the “SSCC Table”

1 In the SSCC Table, document the system(s) that could cause P0171­System Too Lean Bank 1

SSCC Table

Symptom: Check Engine Light ON

System: Base Engine, Fuel Control, Fuel Delivery, Air Delivery

Component:

Cause:

• Find the cup labeled “Fuel Sample” to perform pinpoint test H20

2 Water mixes with alcohol, but does not mix with gasoline

LESSON ONE WORKSTATION FOUR

WORKSTATION FOUR PART TWO

DTC P0133 CMT

SUMMARY: In this CMT workstation, you will diagnose a customer concern Use the table in this workstation to

document the steps take to diagnose the customers concern

DIRECTIONS: Read the information in the repair order to start your diagnosis Diagnose the concern and

complete the necessary information on the pages that follow

Repair Order

Year 2008 Model Grand Marquis

Engine 4.6L Trans 4R75E Other

Customer Concern

Check Engine Light ON

Vehicle History/ OASIS results/ TSBs REPAIR HISTORY

DIRECTIONS: Diagnose the concern Write in the “TECHNICIAN NOTES” section below each of the steps

you perform and include all critical information such as: wire color, circuit numbers, and measurements thatyou have obtained

TECHNICIAN NOTES

Diagnostic Step Result

Verify concern MIL is ON.

Perform visual

inspection

Visual inspection completed, no problem found.

Check OASIS No TSBs or SSMs available for this concern.

Check for DTCs CMDTC P0133 – O2 Circuit Slow Response (Bank1 Sensor1) – go to

DW1.

DW1 Check for DTCs – CMDTC P0133 – DTC is present, go to DW3.

DW3 Continuous Memory DTCs P0133 and P0153: Carry out the KOER

self-test – DTCs are not present, go to DW4.

DW4 Check the HO2S Response Test Results – No, the indicated value is

not greater than the minimum threshold, go to DW5.

DW5 Check for Unmetered Air Leaks Found air leak at exhaust manifold.

Fix air leak at exhaust manifold.

• Your group CMT score: _

LESSON ONE WORKSTATION FOUR NOTES

LESSON ONE WRITTEN ACTIVITY

LESSON ONE WRITTEN ACTIVITY NOTES

LESSON ONE WRITTEN ACTIVITY Misfire Diagnosis

1 What systems can cause a single cylinder misfire?

LESSON ONE WRITTEN ACTIVITY Misfire Diagnosis Flow Chart

NOTE: On some vehicles, the Misfire Profile can be reset by clearing the Keep Alive Memory (KAM) On some

newer vehicles, use the IDS to reset the Misfire Profile by selecting: TOOLBOX>POWERTRAIN>SERVICEFUNCTIONS>MISFIRE MONITOR NEUTRAL PROFILE CORRECTION

CAUTION: Operating the vehicle for an extended period of time after resetting the Misfire Profile may cause catalyst damage.

IDS Data Analysis

1 Write the Fuel System Status (CL, CL­Fault, OL, OL­Drive, OL­Fault), next to its description in the table below

Fuel System Status Description

CL-Fault Fault with upstream O2 sensor on dual bank vehicles

OL-Fault Fault with upstream O2 sensors, primary coil failure and possible FMEM

(misfire) strategy

Closed Loop (CL) The PCM is using the O2 sensors to maintain stoichiometric air/fuel ratio

Open Loop (OL) The PCM is ignoring the O2 sensors

OL-Drive PCM is ignoring the O2 sensors due to driving conditions, such as heavy

acceleration, extended idle, or catalyst over­temp protection

2 What does this IDS Recording button do?

3 What does this IDS Recording button do?

LESSON ONE WRITTEN ACTIVITY

4 What does this IDS Recording button do?

5 What does this IDS Recording button do?

6 What does this IDS Recording button do?

UEGO Operation

• Universal Exhaust Gas Oxygen (UEGO) Sensors provide a reading of the oxygen content with greater accuracyand speed than a conventional exhaust gas oxygen sensor In a conventional oxygen sensor, voltage is created asoxygen ions pass from the outside air, through the sensor, into the exhaust Voltage below 45V indicates lean,

or lots of oxygen in the exhaust, and voltage above 45V indicates rich, or not much oxygen in the exhaust Howrich or lean cannot be determined with a conventional sensor

• The UEGO sensor, sometimes referred to as a wide band sensor, can indicate how rich or lean the air fuelratio actually is The UEGO Sensor is basically a conventional sensor with a “Pumping Cell” added on top.With a conventional oxygen sensor, when a difference in oxygen content exists, the oxygen moves across thesensor and a voltage is created Conversely, applying a voltage can cause a flow of oxygen across the sensorceramic This is the basis for the pumping cell

• The UEGO sensor contains a detection cavity connected to the exhaust The PCM measures the voltage betweenthe detection cavity and a reference chamber containing oxygen using what is known as a Nernst cell whichcreates voltage like a conventional oxygen sensor The PCM then tries to maintain the voltage in the Nernst cell

at 45V by applying voltage to a pumping cell to “pump” oxygen into or out of the detection cavity Unlike aconventional oxygen sensor that receives oxygen through the wiring for the reference chamber, the UEGO’sreference chamber is sealed

• When the air fuel ratio is rich, the PCM will apply voltage in one direction to pump oxygen ions from theexhaust stream into the detection cavity When the air fuel ratio is lean the PCM reverses polarity to pumpoxygen ions from the detection cavity back into the exhaust stream

• Like a conventional oxygen sensor, the UEGO utilizes a heater to allow the sensor to warm up quickly to enterclosed loop Unlike a conventional sensor it also uses a circuit which contains a fixed resistor used to adjustthe output of the sensor for a precise reading This resistor may be part of the oxygen sensor’s wiring harnessdepending on design You should never attempt a wiring repair to the sensor harness

• The PCM monitors the pumping voltage level and polarity required to maintain the 450 mV potential difference

in the Nernst cell and generates a PID (O2S11_CUR/O2S21_CUR) that indicates current flow in milliamps

LESSON ONE WRITTEN ACTIVITY

1 Which PID(s) have the most value during diagnosis of a fuel control concern? Select all that apply