Engine - Stalls or Runs Rough At Idle
85ford02Article No. 85-2-19
FUEL INJECTION PUMP (6.9L DIESEL) - AUTHORIZED ONENGINE SERVICE PROCEDURES
LIGHT TRUCKS 1983-85 E & F-SERIES
This Technical Service Bulletin Article contains diagnostic and authorized adjustment and service procedures for the following 6.9L diesel engine symptoms:
^ Engine stalls or runs rough at idle.
^ Engine keeps running after ignition key is turned off.
^ Engine won't start.
^ Engine smokes excessively, is noisy, or runs rough.
The following service/installation procedures are also included:
^ Governor cover assembly and gasket replacement.
^ Timing line cover gasket replacement to correct fuel leaks.
^ Transfer pump pressure tap seal replacement to correct fuel leaks.
^ Fuel return line fitting "O" Ring seal replacement to correct fuel leaks.
IMPORTANT
BECAUSE THE FUEL INJECTION PUMP IS A COMPLEX COMPONENT, IT IS IMPORTANT THAT SERVICE PERSONNEL THOROUGHLY REVIEW THE PROCEDURES CONTAINED IN THIS TECHNICAL SERVICE BULLETIN PRIOR TO PERFORMING ANY ON-ENGINE FUEL INJECTION PUMP SERVICES. THE SERVICES AUTHORIZED IN THIS ARTICLE SUPERSEDE PREVIOUS INSTRUCTIONS TO REPLACE RATHER THAN SERVICE FUEL INJECTION PUMPS FOR THE ABOVE SYMPTOMS.
SYMPTOM: Engine stalls or runs rough at idle.
CORRECTIVE ACTION: Check and adjust engine low idle speed as specified on page 27-6 in the 1985 Car/ Truck Shop Manual - Emission/Diagnosis (Book H)
SYMPTOM: Engine keeps running after ignition key is turned off.
Figure 18:
CORRECTIVE ACTION: Check for battery voltage at E.S.O. connector (Figure 18) with the key in the "Off" position.
^ If there is no voltage, replace the Governor Cover Assembly. Refer to Governor Cover Assembly and Gasket removal and installation procedure in this article.
^ If there is battery voltage, service short circuit in wiring. Verify that above condition is corrected.
NOTE
THE COLD IDLE AND H.P.C.A. SOLENOIDS ARE CONTROLLED BY A TEMPERATURE SENSING SWITCH LOCATED IN THE FRONT OF THE RIGHT CYLINDER HEAD. A FUSABLE LINK PROTECTS ALL 3 SOLENOIDS (COLD IDLE, H.P.C.A. AND ELECTRIC SHUT-OFF).
SYMPTOM: Engine won't start.
CORRECTIVE ACTION: Perform E.S.O. solenoid function test as follows:
Figure 18:
1. With E.S.O. and H.P.C.A. solenoid wires disconnected, turn the ignition switch to the run position and touch the red E.S.O. solenoid wire to the solenoid terminal (Figure 18).
NOTE
THE IGNITION SWITCH SHOULD NOT BE LEFT IN THE RUN POSITION WITH THE E.S.O. SOLENOID CONNECTED FOR EXTENDED PERIODS OF TIME WITHOUT STARTING THE ENGINE. DAMAGE TO E.S.O. SOLENOID MAY OCCUR.
2. Clicking is heard/observed:
^ Turn ignition switch off.
^ E.S.O. solenoid is operating properly.
3. Clicking is NOT heard/observed (Figure 18):
^ Check for battery voltage (minimum 10 volts) at E.S.O. Connector (Figure 18) with key in the "run" position. ^^ If battery voltage is present, replace the Governor Cover Assembly. Refer to Procedure in this article. ^^ If battery voltage is not present, service open circuit in wiring, and repeat test from Step 1, above.
TIME
Symptom Operation # Year F-Series E-Series
Engine stalls or runs rough at idle. SP9543B84 1983 1.2 Hrs. 1.5 Hrs.
1984-85 1.4 Hrs. 1.6 Hrs.
Engine keeps running after ignition key is SP9543C84 1983-85 0.3 Hr. 0.2 Hr.
turned off.
Engine won't start. SP9543D84 1983-85 0.3 Hr. 0.2 Hr.
Engine smokes excessively, noisy, or runs SP9543E84 1983-84 0.2 Hr. 0.2 Hr.
rough.
Service
Governor cover assembly replacement. SP9523A84 1983-85 0.8 Hr. 0.9 Hr.
Timing line cover gasket replacement. SP9598A84 1983-85 0.7 Hr. 0.8 Hr.
Transfer pump pressure tap seal SP9693A84 1983-85 0.5 Hr. 0.6 Hr.
replacement.
Fuel return line fitting "O" Ring seal SP9583A84 1983-85 0.5 Hr. 0.4 Hr.
replacement.
Governor Cover Assembly And Gasket Removal And Installation Procedure
CAUTION:
CLEAN THE TOP OF THE PUMP WITH SOLVENT BEFORE REMOVING THE GOVERNOR COVER ASSEMBLY. EXTREME CARE MUST BE TAKEN TO PREVENT DIRT OR FOREIGN MATERIAL FROM ENTERING THE FUEL PUMP - TO PREVENT PUMP DAMAGE.
Figure 24:
1. Disconnect battery.
2. Disconnect the E.S.O. and H.P.C.A. Solenoid wires from the Governor Cover, and remove fuel return line, 90~ elbow, and fuel return line connector fitting and seal from the top of the Governor Cover (Figure 24).
IMPORTANT:
WHEN REPLACING THE GOVERNOR COVER, YOU MUST REUSE THE RETURN LINE CONNECTOR FITTING (FIGURE 24) TO ASSURE PROPER PUMP OPERATION. USE A NEW CONNECTOR FITTING SEAL (FIGURE 24) WHICH IS INCLUDED WITH GOVERNOR COVER ASSEMBLY OR AVAILABLE SEPARATELY.
Figure 20:
Figure 21:
3. Remove seal wire (Figure 20).
4. Remove three (3) Governor Cover screws and washers (Figure 20).
5. Remove Governor Cover and gasket (Figure 20).
6. Install new Governor Cover Assembly (E3TZ-9K523-A) with a new gasket (seated in the cover groove). Gasket is included with Governor Cover Assembly.
7. Carefully install the Governor Cover Assembly to the pump as follows (Figure 21).
^ Make sure the screws are NOT in the governor cover.
^ Position the governor cover about 1/4 inch forward of its final alignment (toward the front of vehicle and about 1/8 inch above the pump).
^ Move the cover rearward and downward into position so that ARM contacts LINK (Figure 21), being careful not to roll the gasket.
^ With the cover on the pump and before installing the screws, move governor cover forward and backward until preload of the internal spring is felt, indicating that the E.S.O. is NOT binding internally.
^ Re-install the three governor cover screws with one flat washer and one lock washer with each screw. Flat washer must be against the pump cover. Screw with seal wire hole must be in rear position of governor cover (Figure 20). Tighten screws to 4.5 N-m (40 in.lbs.).
Figure 18:
Figure 19:
NOTE:
A LOCK WASHER (INCLUDED WITH GOVERNOR COVER ASSEMBLY) MUST BE INSTALLED BETWEEN THE TERMINAL GROUNDING STRAP (FIGURE 19) AND THE GOVERNOR COVER BEFORE INSTALLING THE SCREW IN THAT CORNER.
^ Turn the ignition switch to the "Run" position and touch the red E.S.O. solenoid wire to the solenoid terminal. A clicking noise should be heard as the wire is connected and disconnected. NOTE: Ignition switch should not be left in "Run" position with E.S.O. solenoid connected for extended periods of time. DAMAGE TO E.S.O. SOLENOID MAY OCCUR (Figure 18).
WARNING:
IF E.S.O. CLICKING IS NOT HEARD/OBSERVED, THE FUEL METERING LINKAGE MAY BE JAMMED IN THE WIDE OPEN POSITION. THE ENGINE MUST NOT BE STARTED IF CLICKING IS NOT HEARD AS A "RUNAWAY" ENGINE CONDITION MAY OCCUR, RESULTING IN SERIOUS ENGINE DAMAGE AND POSSIBLE BODILY HARM. THE ENGINE CANNOT BE SHUT OFF IF IT IS STARTED WITH JAMMED FUEL METERING LINKAGE.
If E.S.O. clicking is NOT heard/observed, DO NOT start engine.
Figure 18:
Figure 21:
^ Check for battery voltage (minimum 10 volts) at E.S.O. connector (Figure 18). ^^ If no voltage, service open circuit in wiring, and repeat solenoid click check. ^^ If voltage is present, continue to next step.
^ Remove the governor cover. Check engagement of E.S.O. and internal governor components (Figure 21).
^ Re-install the cover carefully following the previous instructions in Step 7, and observe that E.S.O. clicking is heard.
Figure 20:
If E.S.O. clicking is heard/observed:
^ Turn off ignition switch.
^ Connect the E.S.O. and H.P.C.A. wires.
^ Re-install original return line connector fitting, with a new connector fitting seal (E3TZ-9E583-A).
^ Re-install the fuel return line (Figure 20).
^ Start engine and check for leaks.
^ If no leaks are evident, install new seal wires (included in Governor Cover Assembly)(Figure 20), and crimp the seal.
Figure 22:
TIMING LINE COVER GASKET REPLACEMENT
TIMING LINE COVER GASKET REPLACEMENT PROCEDURE
NOTE: THIS PROCEDURE TO REPAIR LEAK AT TIMING LINE COVER.
1. REMOVE TWO (2) TIMING LINE COVER SCREWS.
2. REMOVE TIMING LINE COVER (USE RAGS TO CATCH THE DIESEL FUEL WHICH WILL DRAIN FROM THE PUMP HOUSING). DISCARD THESE RAGS FROM THE ENGINE COMPARTMENT.
3. REMOVE TIMING LINE COVER GASKET.
4. INSTALL NEW GASKET (E3TZ-9F598-A).
5. INSTALL TIMING LINE COVER.
6. INSTALL TWO (2) TIMING LINE COVER SCREWS AND TIGHTEN TO 2 N-m (17.5 IN.LBS.).
Figure 23:
TRANSFER PUMP TAP SEAL
TRANSFER PUMP PRESSURE TAP SEAL REPLACEMENT PROCEDURE
NOTE: THIS PROCEDURE IS USED FOR THE FOLLOWING:
^ TO REPAIR LEAKS AT THE TRANSFER PUMP PRESSURE TAP.
^ EACH TIME THE LOCK PLATE SCREW IS REMOVED (DURING TRANSFER PUMP PRESSURE CHECK).
1. REMOVE TRANSFER PUMP END CAP LOCKING PLATE SCREW, LOCKING PLATE AND "O" RING SEAL FROM HYDRAULIC HEAD, USING 5/32" HEX KEY WRENCH.
2. INSTALL NEW LOCKING PLATE "O" RING SEAL (E3TZ-9N693-B).
3. INSTALL LOCKING PLATE.
4. INSTALL LOCKING PLATE SCREW AND TIGHTEN TO 8.5 N-m (75 IN.LBS.).
Figure 24:
RETURN LINE CONNECTOR FITTING INSTALLATION
RETURN LINE CONNECTOR FITTING "O" RING SEAL REPLACEMENT PROCEDURE
NOTE: THIS PROCEDURE IS USED FOR THE FOLLOWING:
^ TO REPAIR FUEL LEAKS AT THE RETURN LINE CONNECTOR FITTING.
^ EACH TIME THE RETURN LINE CONNECTOR FITTING IS REMOVED FROM THE PUMP (WHEN REPLACING THE GOVERNOR COVER ASSEMBLY).
1. DISCONNECT FUEL RETURN PIPE AND REMOVE 90~ ELBOW.
2. REMOVE RETURN LINE CONNECTOR FITTING FROM GOVERNOR COVER, 3. REMOVE RETURN LINE CONNECTOR FITTING "O" RING SEAL AND DISCARD.
4. INSTALL NEW FITTING "O" RING SEAL (E3TZ-9E583-A).
5. INSTALL RETURN LINE CONNECTOR FITTING AND TORQUE TO 11.3 N-m (100 IN.-LBS.) MINIMUM.
6. INSTALL 90~ ELBOW AND CONNECT FUEL RETURN LINE.
PART NUMBER PART NAME CLASS
E3TZ-9K523-A Governor Cover C
Assembly
E3TZ-9E583-A Return Line Connector C
Fitting Seal
E3TZ-9F598-A Timing Line Cover Gasket C
E3TZ-9N693-8 Locking Plate "O" C
Ring Seal
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: (Shown in beginning of Article)
TIME: (Shown in beginning of Article) DLR. CODING: Basic Part No. 9A543 Codes: J3, L3, J7, L7, J4, L4, 41,28 (as applicable)