51S04T0 advanced diesel engine performance diagnosis 2000

Advanced Diesel Engine Performance Diagnosis February, 2000 iDiesel Engine Performance Curriculum .... Day One-3 Workstation 1 – Diesel Engine Performance Table Top Student’s Answer Shee

advanced diesel engine performance

diagnosis

student guide

COURSE CODE: 51S04T0 ORDER NUMBER: FCS-13007-REF

Ford Customer Service Division Technical Training

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 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 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

instructed otherwise for a specific service operation If

you have a manual transmission it should be in

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• Operate the engine only in a well-ventilated 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 hanging 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 THE 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 © 2000 Ford Motor Company Produced and Coordinated by

Technical Support Operations Ford Customer Service Division February, 2000

5. Provide me with a clear and thorough explanation of the service performed.

6. Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied.

7. Be responsive to questions or concerns

I bring to your attention.

1. Make it convenient to have my

vehicle serviced at your dealership.

2. The Service Advisor should

demonstrate a genuine concern for

my service needs.

3. Fix it right the first time.

4. Complete servicing my vehicle in a

timely and professional manner.

Expectation 3

“Fix It Right The First Time, on Time.”

Both service advisors and technicians are important players when it comes to Expectation

It is our goal to help the technician acquire all of the skills and knowledge necessary to

“Fix It Right The First Time, on Time.” We refer to this as “competency.”

Technician’s Role

Acquire the skills and knowledge for competency in your specialty via:

– FordStar Broadcasts – FordStar Broadcasts

– Ford Multimedia Training (FMT) – Instructor Led

– Instructor Led

The Benefits

The successful implementation of expectations means:

– Satisfied customers

– Repeat vehicle sales

– Repeat service sales

– Recognition that Ford and Lincoln/Mercury technicians are “the Best in the

Business”

Advanced Diesel Engine Performance Diagnosis February, 2000 i

Diesel Engine Performance Curriculum Intro-1 Advanced Diesel Engine Performance Classroom Course Intro-2

DAY ONE

Day One Agenda – Morning Day One-1 Day One Agenda – Afternoon Day One-1 Prerequisite Review Questions Day One-3 Workstation 1 – Diesel Engine Performance (Table Top)

Student’s Answer Sheet Day One-11 Workstation 2 – Diesel Engine Performance (On-Vehicle)

Student’s Answer Sheet Day One-13 Workstation 3 – Diesel Engine Performance Bench (FMT)

Student’s Answer Sheet Day One-15 Workstation 4 – Diesel Engine Performance (Bench)

Student’s Answer Sheet Day One-17

DAY TWO

Day Two Agenda – Morning Day Two-1 Day Two Agenda – Afternoon Day Two-1 Workstation 1 – Diesel Engine Performance (Table Top)

Student’s Answer Sheet Day Two-3 Workstation 2 – Diesel Engine Performance (On-Vehicle)

Student’s Answer Sheet Day Two-9 Workstation 3 – Diesel Engine Performance Bench (FMT)

Student’s Answer Sheet Day Two-11 Workstation 4 – Diesel Engine Performance (Bench)

Student’s Answer Sheet Day Two-13

ii February, 2000 Advanced Diesel Engine Performance Diagnosis

Advanced Diesel Engine Performance Diagnosis February, 2000 Intro-1

Planned Training Pathway

Ford Motor Company has identified the skills and knowledge necessary to meet the curriculum goals in theAdvanced Diesel Engine Performance specialty The Planned Training Pathway is a series of courses designed toprovide you with these skills and knowledge The chart above illustrates the courses in this curriculum

Description

The Advanced Diesel Engine Performance Curriculum consists of four courses The self-study courses and FMTcourses are self-paced training programs The Classroom course is hands-on and is facilitated by an instructor.The information in the self-study, FMT, and Classroom courses are designed to prepare you to successfullycomplete the instructor led course You are currently in Course Four of the diesel engine curriculum, AdvancedDiesel Engine Performance Classroom

ENGINE PERFORMANCE CURRICULUM PATH

Diesel Engine Operation – SS

= Self Study (SS)

= Ford Multimedia Training (FMT)

= Instructor Led – Classroom Legend

Diesel Engine Electronics – SS

Prerequisites – Basic Electrical Part 1 – SS – Basic Electrical Part 2 – FMT – Basic Electrical Part 3 – Classroom – Electronics Part 1 – SS

– Electronics Part 2 – FMT – Electronics Part 3 – Classroom – Networks + Multiplexing Part 1 – SS – Networks + Multiplexing Part 2 – FMT

Advanced Diesel Engine Performance Diagnosis –

Intro-2 February, 2000 Advanced Diesel Engine Performance Diagnosis

Course Description

This is a three-day, hands-on course The course is designed to provide you with maximum practice and

application of diagnostic and repair skills The first day, you will practice these skills on four different

workstations The second day, you will continue to practice on four different workstations designed to enhanceyour ability to correctly diagnose diesel engine concerns Before the end of the course, you will have had eightopportunities to practice your diagnostic and repair skills The results of your work will be recorded on

worksheets

Worksheets

All hands-on activities will be guided by worksheets When you are assigned to a workstation, you will be given

30 to 40 minutes to complete the worksheet Every 30 to 40 minutes, you will move to the next workstation andcomplete another worksheet You will have five minutes to move from one workstation to another

Course Requirements

To meet the requirements of this course, you must satisfactorily complete a hands-on test that includes threeworkstations and a post-test that will both be administered on the third day

Course Objectives

The purpose and the objectives of this course are to enable you to:

l describe the diagnostic process for diesel engine concerns

l locate necessary diagnostic material in service publications and reference manuals

l use a DVOM to perform diagnostic procedures

l use a scan tool to perform self-test routines

l diagnose a mechanical fault that could be perceived as electronic

l diagnose an in-range failure

l diagnose a code-related concern

l use a gauge bar for diesel engine diagnosis

l perform diagnostic tests and procedures on a diesel engine

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-1

The agenda for the day is as follows:

NOTE: Times may be adjusted to coordinate with Training Center normal operating hours.

Start of Class (Course Introduction and Expectations) 8:30 am to 8:45 am

(15 min)Refresher/Questions From Previous Courses 8:45 am to 9:30 am

(45 min)BREAK 9:30 am to 9:40 am

(10 min)Refresher/Questions From Previous Courses (Continued) 9:40 am to 10:45 am

(65 min)BREAK 10:45 am to 11:00 am

(15 min)Refresher/Questions From Previous Courses (Continued) 11:00 am to 11:45 am

(45 min)Preview Workstations 11:45 am to 12:00 pm

(45 min)Second Workstation Rotation (Workstation 1, 2, 3, 4) 1:45 pm to 2:30 pm

(45 min)BREAK 2:30 pm to 2:45 pm

(15 min)Third Workstation Rotation (Workstation 1, 2, 3, 4) 2:45 pm to 3:30 pm

(45 min)Fourth Workstation Rotation (Workstation 1, 2, 3, 4) 3:30 pm to 4:15 pm

(45 min)End of Day One Session 4:30 pm

Day One-2 February, 2000 Advanced Diesel Engine Performance Diagnosis

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-3

1 Q: What basic elements are necessary for a diesel engine to start?

2 Q: What causes white smoke from the exhaust?

Day One-4 February, 2000 Advanced Diesel Engine Performance Diagnosis

3 Q: What causes black smoke from the exhaust?

4 Q: What causes blue smoke from the exhaust?

5 Q: What is the purpose of the Exhaust Backpressure (EBP) system?

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-5

6 Q: What characteristics are essential to diesel fuel?

Day One-6 February, 2000 Advanced Diesel Engine Performance Diagnosis

7 Q: What are the differences between return and returnless fuel systems? (Describe the systems)

8 Q: How can engine oil affect engine performance?

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-7

9 Q: How is the high-pressure oil system controlled?

10 Q: What tests can be performed to diagnose a high-pressure oil system concern?

Day One-8 February, 2000 Advanced Diesel Engine Performance Diagnosis

11 Q: Explain how a HEUI injector operates.

12 Q: What are the benefits of a split-shot injector?

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-9

13 Q: What tests can be performed to diagnose injector-related concerns?

14 Q: What are the inputs and outputs of the IDM?

15 Q: What is necessary for a turbocharger to develop boost?

16 Q: When diagnosing a lack of power situation, what could cause failure of the Turbocharger Boost Pressure

Test?

Day One-10 February, 2000 Advanced Diesel Engine Performance Diagnosis

17 Q: If boost pressure is low, how can turbocharger condition be determined?

18 Q: What is the purpose of the wastegate control system and how does it operate?

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-11

DIESEL ENGINE PERFORMANCE (TABLE TOP)

STUDENT’S ANSWER SHEETNAME: DIRECTIONS: Complete Workstation 1 at your table using the workshop publications available Answer the

following questions

While diagnosing a “No Start/Normal Crank” condition on a 7.3L-equipped vehicle, you are in Section 4

steps 9a, 9b, 9c, 9d of the Diagnostic Subroutines in the 1999 PC/ED.

1 What are you directed to test in these steps?

9a –

9b –

9c –

9d –

2 While in Step 9b, you received a 0 (zero) value What step would you take next?

3 Using the appropriate service publications, what components and/or circuits could cause this value to bepresent?

4 Which Pinpoint test(s) check for continuity of:

A Circuit 796 LB

B Circuit 795 DG

C Circuit 351 BR/W

Day One-12 February, 2000 Advanced Diesel Engine Performance Diagnosis

5 If you had an open S151, what components could be affected?

6 List any DTCs that would be related to an open at S151?

7 What non-electrical conditions may cause code P0340 to be set?

8 What type of sensor is the CMP? What type of signal does the CMP produce?

9 There have been several changes made to sensors/parts How can you determine which sensor/parts are thecorrect ones for the vehicle?

DIESEL ENGINE PERFORMANCE (TABLE TOP) STUDENT’S ANSWER SHEET (Continued)

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-13

DIESEL ENGINE PERFORMANCE (ON-VEHICLE)

STUDENT’S ANSWER SHEETNAME: DIRECTIONS: A 7.3L DIT-equipped vehicle has come in and the customer states, “The Vehicle Runs Rough

at Idle.”

1 Can you verify the concern?

Yes

No _

2 List any TSBs and/or SSMs that are applicable to this concern:

3 When installing a new injector, what precaution should be taken to prevent premature injector wear?

4 Which symptom chart do you feel is most appropriate?

Day One-14 February, 2000 Advanced Diesel Engine Performance Diagnosis

DIESEL ENGINE PERFORMANCE (ON-VEHICLE) STUDENT’S ANSWER SHEET (Continued)

5 Perform the diagnostic steps and record your steps on the following chart Include test description,

test result and action-to-take based upon test result:

DIAGNOSTIC STEPS

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-15

DIESEL ENGINE PERFORMANCE BENCH (FMT)

STUDENT’S ANSWER SHEETNAME: DIRECTIONS: Use the FMT scenario provided to diagnose a vehicle concern utilizing a simulated shop

atmosphere Answer the following questions as you perform a diagnosis for the symptom:

“No Start”

1 By checking fuel pressure at the right cylinder head, what is determined?

2 What are the DTCs (if any) that you receive?

3 If more than one code was retrieved during the KOEO On Demand test, which code should be diagnosedfirst?

4 Code P1663 indicates that the PCM has detected a failure on the FDCS line By using the breakout box and

a DVOM, in the pinpoint tests you performed, what are we trying to determine?

5 What were you testing for in Pinpoint Test (PPT) FJ8?

Day One-16 February, 2000 Advanced Diesel Engine Performance Diagnosis

6 If you found no power at the IDM connector, pin 14, what circuits would you want to check?

DIESEL ENGINE PERFORMANCE BENCH (FMT) STUDENT’S ANSWER SHEET (Continued)

Advanced Diesel Engine Performance Diagnosis February, 2000 Day One-17

DIESEL ENGINE PERFORMANCE (BENCH)

STUDENT’S ANSWER SHEETNAME: DIRECTIONS: Visually inspect the components listed below and fill in the necessary information:

BENCH COMPONENT IDENTIFICATION

Symptom that may

be present if

Day One-18 February, 2000 Advanced Diesel Engine Performance Diagnosis

HEAD GASKETS

1 Measure the thickness of the two head gaskets on the workbench Which gasket is thinner?

2 Explain below any engine operating differences that may occur if a thicker head gasket is replaced by athinner one:

DIESEL ENGINE PERFORMANCE (BENCH) STUDENT’S ANSWER SHEET (Continued)