51S08T0 diesel engine performance 2004

Day 1 – Slide 45 Camshaft Position Sensor CMP – 7.3L Diesel • The PCM receives engine rotational position information from the Camshaft Position CMP sensor.. Day 1 – Slide 50 • The 6.0L

diesel engine performance

diesel engine performance

student reference book

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 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

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

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

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

• 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 REVERSE (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

CUSTOMER EXPECTATIONS

Expectation 3

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

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

#3

Why

Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they

would decide to return to a dealer to buy a vehicle and get their vehicles serviced

Technician Training

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:

– Self Study – Self Study

Customer Expectations: Service

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

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

Day 1 – Slide 1

Day 1 – Slide 2

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Day 1 – Slide 10

• Typical automotive/light truck gasoline engine compression ratio is 9:1

• Our medium/heavy duty diesel engine compression ratio is typically 18:1

Day 1 – Slide 11/12

Day 1 – Slide 14

WARNING: If the longer glow plugs are installed into an engine with updated pistons, glow

plug to piston contact will result, resulting in catastrophic engine damage

Day 1 – Slide 15

• Battery voltage drops to around 10V during cranking with glow plugs ON

• Glow plugs remain ON after engine starts (approximately 25 seconds)

Day 1 – Slide 16/17

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Day 1 – Slide 20/21

Day 1 – Slide 22/23

Day 1 – Slide 24/25

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Day 1 – Slide 30

7.3L

• No Glow plug sleeve

6.0L

• Uses stainless steel glow plug sleeves

• Uses stainless steel injector sleeves

Day 1 – Slide 31

Day 1 – Slide 32

7.3L

• Can type oil filter located on the left rear lower corner of the engine

6.0L

• Cartridge-type filter located on the top of the engine

• When the oil filter is removed, the oil filter housing drain valve is automatically opened to drain most of the oil from the housing

Day 1 – Slide 33

Day 1 – Slide 34/35

Day 1 – Slide 36

• The fuel injectors are electronically controlled and hydraulically actuated

• This high-pressure oil is used to actuate the hydraulic portion of the injectors

• If the oil pressure is too low the injector will not function properly, causing an engine

performance concern

Day 1 – Slide 37

• As combustion begins, the injectors spray a larger amount of fuel to continue combustion

• The purpose of this is to help the fuel burn more completely, aiding in more dispersed

Day 1 – Slide 39

Day 1 – Slide 40

• Not a split-shot injector, oil enters from the top, which is controlled by an electronically activated spool valve moving side to side

• The lower half of the 6.0-liter HEUI operates very much like the 7.3 liter HEUI

• The upper part of the 6.0-liter HEUI is what’s unique

• High-pressure motor oil enters from the top of the injector

•

Day 1 – Slide 41

Day 1 – Slide 42/43

Day 1 – Slide 45

Camshaft Position Sensor (CMP) – 7.3L Diesel

• The PCM receives engine rotational position information from the Camshaft Position (CMP) sensor

• The CMP is a hall-effect device

• The PID “RPM” is generated by the PCM from the CMP signal

Day 1 – Slide 46

Camshaft Position (CMP) Sensor

• The CMP sensor is a variable reluctance sensor, which will respond to a rotating trigger protruding from the camshaft

• The trigger is a single 9.525 mm diameter peg approximately 18 camshaft degrees wide, projecting 3-5 mm from the camshaft

• The sensor will produce a sine wave in response to the peg as it passes the sensor

Day 1 – Slide 47

• F250 through 550 uses Ford Hardware/Software

• F650/750 uses International Hardware/Software

NOTES

Day 1 – Slide 48/49

Day 1 – Slide 50

• The 6.0L Powerstroke diesel injectors are powered by lubricating oil which is pressurized

by a swashplate pump (Rexroth pump) in the engine valley

• The pump output pressure ranges from 3,102 to 20,685 kPa (450 psi to 4,000 psi)

• Oil pressure is controlled by the Powertrain Control Module (PCM) through the Injector Pressure Regulator Valve

• The PCM controls pressure in the oil rail by opening (relieving pressure) and closing

(increasing pressure) the IPR valve

Day 1 – Slide 51



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Day 1 – Slide 57

• Has a separate fuel pump and fuel filter/heater/water separator

• Pump located under vehicle and filter/heater/water separator on the top of the engine

• Fuel is drawn from the fuel tank through the primary filter (the screen on the fuel tank

sending unit) by the electric fuel pump

• Pressurized fuel, approximately 310-550 kPa (45-80 psi), is supplied to the secondary filter (the fuel filter housing located in the V on top of the engine) by means of the electric pump

Day 1 – Slide 58

• Located on the fuel pickup unit

• Screens fuel before it is drawn into the fuel pump

• Helps warm the fuel and maintain a controlled fuel temperature

• The regulator relieves the pressure, sending fuel back to the fuel tank

Day 1 – Slide 60

• Horizontal Fuel Conditioning Module (HFCM) contains the water sensor, heater, filter, and fuel pump

• Located on the frame rail (driver’s side)

• The Aux fuel filter/fuel pressure regulator is located on the top of the engine

• A Diesel Thermo Recirculation Module (DTRM) recirculates fuel that returns from the

engine-mounted fuel filter back into the fuel filter instead of back into the tank

Day 1 – Slide 61/62



NOTES

Day 1 – Slide 63



Day 1 – Slide 64

• At high engine speed and load conditions, boost pressure can increase significantly

• Excessive boost pressures can damage engine components and reduce engine

performance

• The PCM uses MAP sensor input to adjust wastegate solenoid duty cycle

Day 1 – Slide 66

• The VGT controls boost pressure by adjusting the position of a set of vanes in the turbine housing

• Opening and closing the vanes changes the physical size of the turbine housing

• Closing the vanes allows the performance of a small turbocharger

• Opening the vanes allows the performance of a large turbocharger

• This design allows better boost control and performance across all speeds

Day 1 – Slide 67

Day 1 – Slide 69

• A variable capacitor sensor that is supplied a 5-volt reference signal by the PCM and

returns a linear analog voltage signal that indicates pressure

• Measures the pressure in the LH exhaust manifold

• The sensor feedback signal is used for variable geometry turbo (VGT) and exhaust gas recirculation (EGR) valve control

NOTES

Day 1 – Slide 70

• The 6.0L diesel engine uses an Exhaust Gas Recirculation or EGR system

• The EGR system allows a controlled amount of exhaust gasses to be routed back into the combustion chamber with intake air for the purpose of lowering combustion temperatures

− Lower combustion temperatures have the effect of lowering NOx emissions and noise

• EGR system operation is controlled electronically by the PCM during steady-state cruise when exhaust pressure is higher than intake manifold pressure

Day 1 – Slide 71

• The EGR valve is a proportional solenoid design with a built-in position sensor

• The EGR valve receives a duty cycle signal from the PCM and sends a variable resistance voltage signal back to the PCM to indicate actual position

• The EGR valve has two valves connected by a common shaft

• With the EGR valve open, IAT2 will rise

Day 1 – Slide 72

• The EGR system on the 6.0L engine uses an EGR cooler to lower the temperature of

exhaust gasses before they are blended with intake air

• The cooler is an air-to-liquid heat exchanger mounted to the engine under the intake

manifold

• The exhaust gas flows through several small tubes contained within the cooler housing

• Engine coolant is also routed through the cooler housing

• The hot wire is maintained at 392°F (or 200°C) above ambient temperature (as measured

by a constant cold wire)

• Air passing over the hot wire cools the wire

Day 1 – Slide 74

• Uses a throttle body (with some having a throttle plate)

• The purpose of the throttle body assembly is to improve the flow of EGR gasses to the intake manifold by lowering intake manifold pressure during EGR events

• The throttle body houses a throttle plate, an actuator, and position sensor

Day 1 – Slide 75

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• Check the Symptom Charts when beginning diagnosis

• Section 3 in the PC/ED

• Find the symptom in the Symptom Chart Index

Day 1 – Slide 81

• Always perform the preliminary checks as listed in the Symptom Chart

Day 1 – Slide 82

• Start at the top of the chart and follow the directions

Day 1 – Slide 83

• The Diagnostic Trouble Code (DTC) Descriptions are found at the end of Section 4

• Find the DTC you received during the self test and go to the appropriate Pinpoint Test

• You should always read the “Introduction” to the Pinpoint Test before proceeding to the test step

• The “Introduction” typically contains component descriptions, circuit functions, connector pinouts, Cautions and Warnings, and expected component values

• Follow the directions listed in the procedure

• If the vehicle passes the test, return to the Symptom Chart

Day 1 – Slide 85

Day 1 – Slide 86

• When directed to a Pinpoint Test, pay close attention to the title of the test

− The Symptom Chart doesn’t necessarily send you to the first step in the pinpoint test

Day 1 – Slide 87

• Always start with the pinpoint test introduction

− Here you can find component descriptions, circuit functions, connector pinouts,

Cautions and Warnings, and expected component values

• You must scroll down until you find the appropriate test step

− Follow the test step instructions

• You may have to complete several pinpoint test steps before identifying the fault or

Day 1 – Slide 88

• Proceed to the next logical check

Day 1 – Slide 89

• Think about what the test step is telling you to do, and why

• In this example, if the fuel pressure checks out OK, there is no need to check for a fuel pump inlet restriction (10b.)

• Return to the Symptom Chart