51S11T0 6 4l diesel engine diagnosis and service 2007

3 - 1WORKSTATION 1: 6.4L DIESEL PERFORMANCE CONCERN DIAGNOSIS USING PID DATA ANALYSIS .... 3 - 2WORKSTATION 2: 6.4L DIESEL PERFORMANCE CONCERN DIAGNOSIS ON-VEHICLE .... 6.4L DIESEL ENGI

6.4L Diesel Engine Diagnosis and Service

Student Guide

51 - Diesel Engine Performance

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.

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 help 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 help avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before begin- ning 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.

DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction

compo-nents, such as brake pads and clutch discs Exposure to excessive amounts of dust may be a potential cancer and lung disease

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, on 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 that I bring to your attention.

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.”

— Repeat vehicle sales

— Repeat service sales

— Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”

6.4L DIESEL ENGINE DIAGNOSIS & SERVICE TABLE OF CONTENTS

INTRODUCTION Intro - 1

6.4L Diesel Engine Diagnosis and Service Intro - 2Course Description Intro - 2Course Requirements Intro - 3Course Objectives Intro - 3Course Agenda Intro - 3

LESSON ONE PREREQUISITE REVIEW 1 - 1

Prerequisite Review Questions 1 - 2

LESSON ONE WORKSTATIONS 1 - 9

Summary 1 - 9WORKSTATION 1: SERVICE PUBLICATIONS AND SPECIAL TOOLS 1 - 10WORKSTATION 2: 6.4L DIESEL AIR MANAGEMENT OPERATION DISCOVERY

ON-VEHICLE 1 - 13WORKSTATION 3: 6.4L DIESEL TEMPERATURE AND PRESSURE RATIONALITY PID

GRAPH ANALYSIS 1 - 16WORKSTATION 4: TURBOCHARGER REMOVAL, INSTALLATION AND SERVICE

(ON-ENGINE) 1 - 19

LESSON TWO WORKSTATIONS 2 - 1

Summary 2 - 1WORKSTATION 1: 6.4L DIESEL LACK OF POWER DIAGNOSIS USING PID DATA ANALYSIS 2 - 2WORKSTATION 2: 6.4L DIESEL NO START CONCERN DIAGNOSIS (ON-VEHICLE) 2 - 5WORKSTATION 3: 6.4L FUEL SYSTEM DIAGNOSIS AND TESTING (CMT WORKSTATION) 2 - 7WORKSTATION 4: HIGH PRESSURE PUMP COVER AND FUEL INJECTOR SERVICE

(ON-ENGINE) 2 - 9

LESSON THREE WORKSTATIONS 3 - 1

Summary 3 - 1WORKSTATION 1: 6.4L DIESEL PERFORMANCE CONCERN DIAGNOSIS USING PID

DATA ANALYSIS 3 - 2WORKSTATION 2: 6.4L DIESEL PERFORMANCE CONCERN DIAGNOSIS ON-VEHICLE 3 - 5WORKSTATION 3: UP-PIPE IDENTIFICATION AND ORDER OF ASSEMBLY 3 - 7WORKSTATION 4: EGR VALVE REMOVAL AND INSTALLATION (ON-ENGINE) 3 - 8

APPENDIX Appendix - 1

Glossary of Acronyms Appendix - 1Special Tools Referenced in This Course Appendix - 3Calculating Torque When Using Wrench Extensions Appendix - 5

6.4L DIESEL ENGINE DIAGNOSIS & SERVICE INTRODUCTION

INTRODUCTION

The 6.4L Diesel Engine Diagnosis and Service course is one of two instructor-led courses in the Diesel EnginePerformance curriculum (Specialty 51) It is intended to be a three-day course facilitated by an instructor Thiscourse is designed to provide hands-on opportunities for technicians to learn and improve their skills using toolsand equipment, and to apply knowledge learned in the 6.4L Diesel Engine Theory and Operation Web-basedcourse and other previous curriculum courses Each day, you will have multiple opportunities to practice selectedskills and/or apply your knowledge to diagnostic situations The results of your work are recorded on worksheets.

6.4L DIESEL ENGINE DIAGNOSIS AND SERVICE

Course Description

6.4L PowerStroke ® Diesel Engine

6.4L DIESEL ENGINE DIAGNOSIS & SERVICE INTRODUCTION

Course Requirements

Each technician attending this course will be required to pass a combination of hands-on and written evaluations.These will be administered after Lesson 3

 The hands-on evaluation is a pass/fail type It will be conducted with exercises in 6.4L diesel engine

performance diagnosis, and will cover:

– 6.4L diesel engine control system diagnosis

– service publication navigation

– selected special tool usage

In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-on exerciseAND you must answer at least 80% of the written post-test questions correctly

Course Objectives

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

 diagnose concerns in the 6.4L diesel engine air management system

 diagnose concerns in the 6.4L diesel engine low pressure fuel system

 diagnose concerns in the 6.4L diesel engine high pressure common rail fuel system

 diagnose concerns in the 6.4L diesel engine exhaust, emissions and aftertreatment systems

 diagnose concerns in the 6.4L diesel engine control system

 diagnose concerns related to 6.4L diesel engine OBD II monitors

 perform selected service and repair procedures for the 6.4L diesel engine to ensure proper engine

LESSON TWO:

Lesson 1 Workstation Reviews, Lesson 2 Workstations (Lack of Power Concern Diagnosis Using PID Data

NOTES:

LESSON ONE PREREQUISITE REVIEW

LESSON ONE

PREREQUISITE REVIEW QUESTIONS

DIRECTIONS: Answer the following 6.4L diesel engine questions, based on what you remember from the

prerequisite Web-based program The answers will be reviewed in class

1 What fuel type is required in the 6.4L diesel engine? What are some of the reasons this fuel is needed?

NOTE: Ford does not recommend or support using fuels containing more than 5% Bio-diesel.

4 What components or systems could be negatively affected by not using the recommended API ratedengine oil?

_

_

_

_

LESSON ONE PREREQUISITE REVIEW

5 What are some unique cooling system features on the 6.4L diesel engine?

8 Number the following components (1-5) to indicate the order in which air flows through the 6.4L diesel airinlet system.

_ Charge Air Cooler

_ Air Filter

_ Low Pressure Turbocharger

_ Engine Intake Manifold

_ High Pressure Turbocharger

9 What components are involved in controlling glow plug operation on the 6.4L diesel engine?

LESSON ONE PREREQUISITE REVIEW

11 The turbocharger down-pipe has an insulated double wall (air gap) construction to retain heat in theexhaust gas Why is retaining heat in this part of the exhaust system important?

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

9 10

LESSON ONE PREREQUISITE REVIEW

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

_

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

High Pressure Chamber

Control Piston Chamber

22 What special tools are required any time a 6.4L diesel fuel system component is disconnected and thesystem is open?

_

23 Which of the following is the main input used by the ECM for fuel cooling strategy?

A Engine Coolant Temperature (ECT) sensor

B Fuel Temperature Sensor (FTS)

C Cylinder Head Temperature (CHT) sensor

D A thermistor within the HFCM

24 What is indicated by the orange wrap on some of the wiring harnesses in the 6.4L diesel engine compartment? _

_

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS

Workstation: Summary:

1 On a PC with the Service Publications DVD installed, locate various 6.4L diesel engine

information and procedures in the PC/ED manual, Workshop Manual and Wiring DiagramsManual

2 On an F-Series vehicle equipped with a 6.4L diesel engine, select, view and analyze various

air management and fuel management PIDs Change some inputs to view and analyze theresulting changes on selected outputs

3 On a PC, view IDS recordings of various 6.4L diesel temperature and pressure PIDs, and

analyze operating characteristics of the sensors that correspond to these PIDs

4 On a 6.4L diesel engine mounted to a stand, remove and install the turbocharger assembly

Also, disassemble and assemble the two-stage turbocharger assembly while it is on the bench

WORKSTATION 1 SERVICE PUBLICATIONS AND SPECIAL TOOLS

DIRECTIONS: Complete Workstation 1 at the PC workstation, using the service publication files on the

available DVD-ROM

SUMMARY: Use the available service publications on the DVD-ROM to answer questions related to the

operation, diagnosis and service of various 6.4L diesel engine components

 Use the Powertrain Control/Emissions Diagnosis (PC/ED) Manual for 6.4L Diesel Engine, to answer

3 What are the entry conditions for the Diesel Particulate Filter Monitor?

LESSON ONE WORKSTATION 1

 Use the 2008 F-Super Duty Workshop Manual to answer Questions 7-13

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

_

13 Go to “No DTCs Symptom Chart” in the PC/ED manual With a symptom of “Cooling Fan Does Not

Operate,” what is the Pinpoint Test and what are the first two steps?

 Use the 2008 F-Super Duty Wiring Diagrams Manual to answer Questions 14 through 19.

14 Locate the group of wiring diagrams for Engine Control System - 6.4L Diesel Where is the high-voltagedriver for the fuel injectors located?

LESSON ONE WORKSTATION 2

WORKSTATION 2 6.4L DIESEL AIR MANAGEMENT OPERATION DISCOVERY ON-VEHICLE

DIRECTIONS: Complete Workstation 2 at the on-vehicle workstation, using the IDS with necessary cables and

classroom Service Publications DVD

SUMMARY: In this activity, you are selecting and vewing various 6.4L diesel engine control system PIDs to

analyze engine operating characteristics You are not looking for a concern or “bug” in this activity

 Connect IDS to the vehicle via VCM and necessary cables Connect the IDS VMM to the low fuel pressuretest port on the vehicle with the Pressure/Vacuum Transducer (PVT) adapter Start the engine and let it idle

 Make sure the the PVT selection on IDS is set to “psi.”

 Navigate to Datalogger on IDS, and select the following PIDs: EBP_A, EGRTP#, EGRVP, EGRVPA#, FRP,

MAF_HZ, MAP, MGP, PVT, RPM# and VGTDC# Make your 12 recordings first, then answer the

questions

1 Record PID values at idle in the table below Then command engine idle speed (RPM#) to approximately

1450 rpm and wait about one minute Record the values at 1450 rpm in the appropriate column below

2 Leave engine RPM at approximately 1450 Use Output State Control (OSC) on VGT duty cycle (VGTDC#)and command it to 0% Record the values in the appropriate column below When finished, command

VGTDC# to 40% Record the values in the appropriate column below

D I

P E n g i n e a t I d l e E n g i n e a t ~ 1 4 5 0 R P M

A_PB

E

#PTRG

E

PVRG

E

PRF

ZH_FA

M

PAM

PGM

TVP

MP

R ~690 ~1450

#CDTG

V

D I

P V G T D C # a t 0 % V G T D C # a t 4 0 %

3 List the PID data that changes significantly from the chart in Question #1 to the chart in Question #2 (afteryou took command of VGTDC#):

5 Command VGT duty cycle to 40% and leave engine speed at approximately 1450 rpm Command EGRVPA#

to the values in each column below (0%, 30%, 60%, 90%) Record PID values at each stage

6 What PID values in Question #5 change with EGRVP? Is there a relationship demonstrated in these changes?

_

_

7 While maintaining VGTDC# and RPM Output State Control, cancel EGRVPA# Output State Control mand EGRTP# to the values in each column below (5%, 25%, 55%, 85%) Record the PID values at eachstage in the appropriate column

Com-D I

P

S G N I T T E S

# A P V R G E

%

0 3 0 % 6 0 % 9 0 %

A_P

B

E

#PTR

G

E

PVR

G

E

PR

F

ZH_F

A

M

PA

M

PG

M

TV

P

#MP

R

#CDT

G

V

D I

P

S G N I T T E S

# P T R G E

%

A_P

B

E

#PTR

G

E

PVR

G

E

PR

F

ZH_F

A

M

PA

M

PG

M

TV

P

#MP

LESSON ONE WORKSTATION 2

8 Between what two EGRTP stages do the readings in Question #7 change the most? Why does this happen? _

WORKSTATION 3 6.4L DIESEL TEMPERATURE AND PRESSURE RATIONALITY PID GRAPH ANALYSIS

DIRECTIONS: 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 to open and view twoseparate recording files

 Open IDS

 Select Previous Sessions Open the recording file named LESSON1WS3.

 Select Datalogger and click the check mark Then select Playback Display at the bottom of the screen.

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

 Click on Next Capture Event button to view the second recording

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

1 After recording all readings in the spaces below, answer the remaining questions on this worksheet

LESSON ONE WORKSTATION 3

2 Look at the readings for ECT, EGRT_B, EOT, FRT, IAT and IAT2 Are the temperature readings within 5 oF

of each other at KOEO (Cold)?

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

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

be lower than the other?

8 Examine the pressure readings for BARO, EBP_A and MAP at KOEO (Cold) Are they all reading within 0.5psi of each other? What does this tell you about what the three sensors for these PIDs are reading?

_

_Which of these three PIDs increases during KOER (Hot) operation? Why?

 Exit the current session on IDS (select Hold Session), and open the session called “KNOCK.” The vehicle has

an audible knock that is RPM dependent Power Balance and Relative Compression Tests have been performedand do not indicate a concern at this time View the recording and answer the questions below

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