51S08T2 diesel engine performance diagnosis 2010

• Perform tests to verify and pinpoint air leaks, pre­turbo exhaust leaks, fuel leaks, high­pressure oil leaks andcombustion leaks into the fuel system on a PowerStroke® diesel engine..

Diesel Engine Performance

VERSION 2

IMPORTANT SAFETY NOTICE

NOTE: Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without

notice and without incurring any obligation.

REPAIR TECHNIQUES

Appropriate service methods and 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 performing service with tested, effective techniques Following them will help assure reliability.

There are numerous variations in procedure, 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 the instructions provided in this manual must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts.

NOTE, NOTICE, CAUTION AND WARNING

As you read through this manual, you may come across a NOTE, NOTICE, CAUTION or WARNING Each one is there for a specific purpose A NOTE calls attention to unique, additional or essential information related to the subject procedure A NOTICE identifies a hazard that could damage the vehicle or property A CAUTION identifies a hazard that could result in minor personal injury to yourself or others A WARNING identifies a hazard that could result in severe personal injury or death

to yourself or others Some general WARNINGS that you should follow when you work on a vehicle are listed below.

• ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

• KEEP SOLVENTS AWAY FROM IGNITION SOURCES SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE OR EXPLODE IF NOT HANDLED CORRECTLY.

• USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE.

• MAKE 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 IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION IF YOU HAVE A MANUAL

TRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKS AGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING.

• OPERATE THE ENGINE ONLY IN A WELL­VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE POISONING.

• KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING,

ESPECIALLY THE DRIVE BELTS.

• TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD, TAIL PIPE, THREE­WAY CATALYTIC CONVERTER AND MUFFLER.

• DO NOT SMOKE WHILE WORKING ON A VEHICLE.

• TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON A VEHICLE.

• WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF THE COOLING FAN BLADES!

TOOLS

Commercially available hand tools and equipment are used along with Essential Special Service Tools (ESST) and Rotunda equipment Power tools have become the acceptable industry standard and are used for disassembly only where applicable, unless specified otherwise in the Workshop Manual The only exception to this policy is installing wheels in conjunction with the use of torque sticks, when possible.

Copyright © 2010 Ford Motor Company Produced and Coordinated by

Technical Service Support Operations Ford Customer Service Division

DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION

INTRODUCTION

DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION

DIESEL ENGINE PERFORMANCE DIAGNOSIS

Course Description

This is a four day course facilitated by an instructor This course is designed to provide hands­on opportunitiesfor technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned inprevious curriculum courses Each day you will have multiple opportunities to practice selected skills The results

of your work 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 Computer Workstation

— diesel performance system diagnosis

— service publication navigation

— selected special tool usage

In order to pass the course, you must demonstrate 100% mastery of the skills covered at the evaluated hands­onexercise AND 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:

• Diagnose selected coded, non­coded and intermittent PowerStroke® diesel engine performance concerns

• Set up a PID list, record PIDs and review/analyze PID data related to PowerStroke® diesel engine performanceconcerns

• Perform tests to verify and pinpoint air leaks, pre­turbo exhaust leaks, fuel leaks, high­pressure oil leaks andcombustion leaks into the fuel system on a PowerStroke® diesel engine

• Service the high­pressure oil system and fuel injectors by disassembly and assembly of the top­end of a 6.0LPowerStroke® diesel engine

• Perform visual inspections and selected tests on various components to verify failures

DIESEL ENGINE PERFORMANCE DIAGNOSIS INTRODUCTION Course Agenda

LESSON ONE:

• Prerequisite Review

• Workstation One: Service Publications And Special Tools

• Workstation Two: On­Vehicle PID Selection, Recording And Analysis

• Workstation Three: 6.4L Diesel Temperature And Pressure Rationality PID Graph Analysis

• Workstation Four: 6.4L/6.0L Component Identification (ON­ENGINES)

LESSON TWO:

• Workstation One: 6.4L Diesel Performance Concern Diagnosis Using PID Data Analysis

• Workstation Two: 6.4L Diesel No Start Concern Diagnosis (ON­VEHICLE)

• Workstation Three: 6.0L Lack Of Power Diagnosis Using PID Data Analysis

• Workstation Four: 6.0L High­Pressure Oil System Service (ON­ENGINE)

LESSON THREE:

• Workstation One: 6.0L No Start Diagnosis

• Workstation Two: 6.4L Diesel Stalls / No Crank Concern Diagnosis (ON­VEHICLE)

• Workstation Three: 6.0L Poor Performance / Lack Of Power Using PID Data Analysis

• Workstation Four: Fuel Injector Service And Inspection

LESSON FOUR:

• Workstation One: VGT Turbocharger System

• Workstation Two: 6.4L Diesel Performance Concern Diagnosis (ON­VEHICLE)

• Workstation Three: 6.4L Stalls/No Start Diagnosis Using PID Data Analysis

• Workstation Four: 6.4L EGR Valve Service And 6.0L Component Leak Testing

DIESEL ENGINE PERFORMANCE 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 based on what you learned in the Pre­Requisite Web programs.

The answers will be reviewed in class

1 How can engine maintenance affect 6.0L engine performance?

4 How is the fuel pressure controlled on the 6.4L high pressure fuel system ?

5 What are some unique cooling system differences between the 6.4L and the 6.0L diesel engines?

LESSON ONE PREREQUISITE REVIEW

6 What is the purpose of Coolant Test Strips?

LESSON ONE PREREQUISITE REVIEW

11 What are some unique features and benefits of the Variable Geometry Turbocharger (VGT) used on 6.0LPowerStroke® diesel engines?

12 What type of turbocharger assembly is used on the 6.4L diesel engine?

13 What is the difference between a 6.0L turbo assembly and a 6.4L VGT turbo assembly

14 What are the components of the 6.0L Exhaust Gas Recirculation (EGR) system?

15 List some components of the 6.4L Exhaust Gas Recirculation (EGR) subsystem

16 How does a diesel engine react when an EGR cooler is leaking?

LESSON ONE PREREQUISITE REVIEW

17 When diagnosing a 6.4L Hard Start/No Start, and you discover high engine oil level, what might be the cause?Select all that apply

A Injector leaks

B Injector supply tube

C Leaking fuel rail pressure sensor

D EGR cooler

18 What mechanical and electronic components are used in the 6.4L aftertreatment system after the turbochargerdown­pipe?

LESSON ONE PREREQUISITE REVIEW

19 Identify the components of the 6.4L fuel system by placing each illustration number next to its correct

component below

No Component No Component No Component

8 Fuel Supply Line (low pressure) 6 HFCM 10 Secondary Fuel Filter

4 High Pressure Fuel Supply Line 2 Fuel Tank 9 Fuel Cooler

7 Fuel Return Lines 1 Fuel Injectors 3 High Pressure Fuel Pump

5 Fuel Rail 11 Primary Fuel Filter

20 What two ECM output components are housed within the 6.4L High Pressure Fuel Injection Pump?

21 What is unique about the 6.4L High Pressure Fuel Injection Pump cover gasket?

LESSON ONE PREREQUISITE REVIEW

22 What type of fuel injector is used in the 6.4L engine?

23 Match the numbered Piezo fuel injector components in the illustration below with their names

No Component

4 High Pressure Chamber

2 Control Piston Chamber

LESSON ONE PREREQUISITE REVIEW

25 What special tools are required any time a 6.4L diesel fuel system component is disconnected and the system isopen?

26 What two modules work together to control fuel delivery on a 6.0L PowerStroke® diesel engine? How dothese two modules work together on this engine?

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS NOTES

LESSON ONE WORKSTATION ONE

WORKSTATION ONE SERVICE PUBLICATIONS AND SPECIAL TOOLS

SUMMARY: Use the available service publications to answer questions related to the operation, diagnosis and

service of various diesel engine components

DIRECTIONS: Complete Workstation 1 at the PC workstation.

• Use the 2008 Powertrain Control/Emissions Diagnosis (PC/ED) Manual for 6.4L Diesel Engine, to answerQuestions 1­6

1 Using the Description and Operation section of the 6.4L PC/ED Manual, what type of sensors are the EGT andthe DPF sensors?

2 List all 6.4L Diesel OBD II Monitors shown in the Description and Operation section:

3 Go to the DTC Index in the PC/ED for 6.4L Diesel Engine List the Malfunction Thresholds for P200E below

4 What PC/ED Symptom Chart is used for a 6.4L diesel that runs rough at idle?

5 Go to the chart in the answer above What System/Component check is the easiest to perform?

LESSON ONE WORKSTATION ONE

6 Per the same chart, what procedure and steps must be performed for Preliminary Checks?

• Use the 2008 F­Super Duty Workshop Manual to answer Questions 7­12

7 Locate the procedures for the High Pressure Fuel Pump Removal and Installation in Section 303­04C of theWorkshop Manual What does the Workshop Manual note about the installation of the pump gear retaining bolt?

8 Locate the procedures for both Front Cover and Rear Cover Removal and Installation in Section 303­01C of theWorkshop Manual What special tools are required to service the front and rear oil seals?

LESSON ONE WORKSTATION ONE

11 After servicing the Fuel and Turbocharger Coolant Pump (in Section 303­04E) on a vehicle with a 6.4L dieselengine and refilling the coolant to the proper level, what additional procedure is required?

• Use the 2008 F­Super Duty Wiring Diagrams Manual to answer Questions 14 through 17

14 Locate the group of wiring diagrams for 6.4L Electronic Engine Controls ­ Cell 26–1 Where is the high­voltagedriver for the fuel injectors located?

17 Is there another connector between the Fuel Pressure/Volume Control Valves and the ECM? If “yes,” howmany pins are on this connector? Where is it located?

LESSON ONE WORKSTATION ONE

• Use the Powertrain Control/Emissions Diagnosis (PC/ED) Manual for 2010 6.4L Diesel Engine, to answerQuestions 18­19

18 Go to Pinpoint Test AB What step is the Inverse Injector test?

19 Go to Pinpoint Test ME What wiring and components does this test diagnose?

• Use the 2007 6.0L F­Super Duty PC/ED Manual to answer the following Questions

20 What pinpoint test is used for DTC P0336?

LESSON ONE WORKSTATION TWO

WORKSTATION TWO ON­VEHICLE PID SELECTION, RECORDING AND ANALYSIS

SUMMARY: This activity allows you to select and view various 6.4L PowerStroke® diesel performance

parameters under “normal” conditions You are to create and be able to review KOEO and KOER recordings bysaving them to the IDS You are not diagnosing a customer concern in this activity

DIRECTIONS: Complete Workstation 2 at the VEHICLE workstation, following the steps on this worksheet.

• Perform all preliminary set up tasks for vehicle safety (Block wheels, transmission in Park, set park brake.)

• Connect the scan tool and establish a scan tool session

• Perform KOEO Self­Test and record any DTCs

• Exit Self­Test when finished

• Select Datalogger function Select “Powertrain,” then select “Engine.”

• Press Erasure button This “de­selects” all PIDs

• Select the upper half the PIDs listed on the next page and press “Save Parameter and Display Settings.”

• Arrow left and save file

• Name the file (Your name)

• Name the description (For example: Normal_1, LowPower_2)

• View the PID list and click on the clock

• Perform the “Capture Buffer Setup” Select “30” for duration Pre = “0” and Post = “30”

• Press the “Movie” button

• Wait until “Capture Event 1“ is blue all the way across

• Repeat the above steps for your lower half of the PID list

• View the PID lists and fill in KOEO values on the next page

• Repeat the above steps for your KOER PID values as well It is not necessary to warm up the engine beforemaking your recordings

• Shut off the engine

LESSON ONE WORKSTATION TWO

• View PID list recording and fill in KOER values

PID KOEO KOER PID KOEO KOERAPP % 0% 0% EBP_DSD

(psi)

8.7 psi 3.8 psi

APP _MODE CT CT ECT (deg F) 77 ºF 188.6 ºF

APP 1(volt) 4.09 V 4.09V EGRT_A

DPF (psi) 0 psi 0.21 psi EGT11 ºF 82.4 ºF 343.4 ºF

DPF_REGEN INACTIVE INACTIVE EGT12 ºF 86 ºF 356 ºF

EBP_A (psi) 14.5 psi 16.0 psi EGT13 ºF 86 ºF 429.8 ºF

FLI% 100% 100% SYNC NO YES

FRP (psi) 0 psi 5070.65 psi VGTDC# 10% 95%

• Start engine and select “Live Display”

1 Disconnect the EBP sensor What happens to EBP PID values (EBP_A, EBP_V, EBP _DSD)?

LESSON ONE WORKSTATION TWO

2 Does the EBP_A remain at an almost normal level?

• Reconnect the EBP sensor

3 Command RPM to approximately 1200, then monitor and record the following PID values:

MAF 3.78 kHz IAT2 86 deg F

4 Command VGT duty cycle to 0% and then up to 80% at 1200 RPM What happens to the EBP_A PID at0% and at 80% VGT?

• Release all active commands

7 Why do the two events in Questions 4 and 5 occur?

• Go to PID screen, select “Load Parameters” icon and highlight your file(s)

• Select “Delete File” icon, confirm and exit Datalogger

• Perform a Power Balance Test, then exit

• Perform a Relative Compression Test, then exit

LESSON ONE WORKSTATION TWO

8 What would cause a good Relative Compression reading, but have one weak cylinder on the Power Balance Test?

• Select Datalogger function Select “Powertrain,” then select “Fuel System.”

9 What would be the benefit of having the PIDs grouped in this way?

• Select Datalogger function Select “Powertrain,” then select “Air Management ”

10 What are the “EGRPCT” and “EGRTP#” PID descriptions and values?

• Clear DTCs and delete the session

LESSON ONE WORKSTATION THREE

WORKSTATION THREE 6.4L DIESEL TEMPERATURE AND PRESSURE RATIONALITY PID GRAPH ANALYSIS

SUMMARY: In this activity, you will Complete Workstation 3 at the PC workstation, using the IDS recording

provided by your instructor as reference to perform tasks and to answer questions This activity requires you toopen and view two separate recording files

DIRECTIONS: Open IDS and Select Previous Sessions Open the recording file named “L1W3A”.

Select Datalogger and click the check mark Then select Playback Display at the bottom of the screen KOEO isRecording 1 and KOER is Recording 2

Observe the specific readings for all PIDs shown below at the 0­second mark of the KOEO and KOER recording,and write the readings in the appropriate spaces in the worksheets

After recording the readings in the pages below, answer the remaining questions on these worksheets

1 Look at the readings for ECT, EGRT_B, EOT, FRT, IAT and IAT2 Are the temperature readings within 5degrees F of each other at KOEO (Cold)?

PID: KOEO (Cold): KOER (Hot):

2 Which PID is higher than the others at KOEO (Cold)?

3 At KOER (Hot), what other temperature PID(s) is close to Engine Coolant Temperature (ECT)? Is this normal?

LESSON ONE WORKSTATION THREE

4 At KOER (Hot), why is the IAT2 PID showing a higher temperature than IAT?

6 At KOER (Hot), how much temperature difference is there between EGRT_A and EGRT_B? Why would one

be lower than the other?

7 Where are the three exhaust gas temperature sensors located? Why might the temperature readings increasefrom EGT11 to EGT 13 as shown in the PIDs?

LESSON ONE WORKSTATION THREE

8 Examine the pressure readings for BARO, EBP_A and MAP at KOEO (Cold) Are they all reading within 1.5psi of each other? What does this tell you about what the three sensors for these PIDs are reading?

PID: KOEO (Cold): KOER (Hot):

BARO 14.5 psi 14.5 psi

EBP_A 14.5 psi 16.0 psi

MAP 14.5 psi 14.79 psi

9 What do the KOER (Hot) values for FRP and FRP_DSD# tell you about the current fuel control on this engine?

PID: KOEO (Cold): KOER (Hot):

do not indicate a concern at this time View the recording and answer the questions below

12 Go to the 1­second mark on the new recording and record the values for Short Fuel Trim (SFT):

Cylinder 1 -3.12% Cylinder 2 25%

Cylinder 3 0% Cylinder 4 9.37%

Cylinder 5 12.5% Cylinder 6 22%

Cylinder 7 12.5% Cylinder 8 -78.13%

LESSON ONE WORKSTATION THREE

13 What did you observe of the SFT values from cylinder to cylinder in the above reading?

LESSON ONE WORKSTATION FOUR

WORKSTATION FOUR 6.4L/6.0L COMPONENT IDENTIFICATION (ON­ENGINES)

SUMMARY: In this activity, you are identifying components and tools and related pinpoint tests on the 6.4L

engine and identifying tools and components and functions on the 6.0L engine Two components can have thesame pinpoint test

DIRECTIONS: Complete Workstation 4 at the engines on stands, using the Coffee Table Books for component

locations, and Service Information DTC Charts, Description and Operation for the other columns and for the toolidentification An engine tag may have a connector number along with a component number If so, search theWiring Diagrams for the specific component associated with the connector

1 Fill in this 6.4L worksheet as you identify each component and it’s pinpoint test

No Component Pinpoint Test

1 Engine Oil temperature (EOT) sensor L

2 Engine Coolant Temperature (ECT) Sensor K

3 Exhaust Gas Recirculation (EGR) valve W

4 Manifold Absolute Pressure (MAP) sensor E

5 EGR Cooler Inlet Temperature sensor AZ, WA

6 Fuel Rail Temperature (FRT) sensor MC

7 Fuel Rail Pressure (FRP) sensor MB

8 Camshaft Position Sensor V

9 Crankshaft Position Sensor D

10 Exhaust Pressure (EP) sensor X

LESSON ONE WORKSTATION FOUR

2 Fill in this 6.0L worksheet as you identify each component’s function

No Component Function

1 Secondary fuel filter filters fuel a second time down to 4

microns

2 Fuel check valves prevents fuel spikes

3 ICP sensor measures HP oil pressure in the rail

4 IPR valve controls HP oil pressure in the rail

5 IAT2 measures manifold air temp

6 Crankshaft trigger wheel signals crank speed and position

7 Engine oil cooler cools engine oil

8 HP oil rail acts as a reservoir for high pressure oil

and connects the injectors to the stand pipes

LESSON ONE WORKSTATION FOUR

• Using the Service Information, fill in the blanks below

3 What essential tool(s) are required to service the 6.4L turbo seals?

LESSON ONE WORKSTATION FOUR NOTES

LESSON TWO

LESSON TWO

LESSON TWO

NOTES

LESSON TWO WORKSTATIONS

LESSON TWO WORKSTATIONS

LESSON TWO WORKSTATIONS NOTES