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Home >> Ford >> 2003 >> F 550 2WD Super Duty V8-6.0L DSL Turbo VIN P >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Reading and Clearing Diagnostic Trouble Codes >> Reading Diagnostic Trouble Codes >> With Manufacturer's Scan Tool >> Performance Diagnostic Procedures >> Steps 1 - 7

Steps 1 - 7







PERFORMANCE DIAGNOSTIC PROCEDURES










1. Visual Engine/Chassis Inspection

Purpose:
The purpose of this test is to check the general condition of the engine and chassis.

Visual Engine/Chassis Inspection

Fuel Oil Coolant Electrical Hoses Leaks:






- Verify that there are no fluid or pressure leaks.
- Inspect all wire connections for damage.
- Inspect the MAP hose, intercooler hoses and intake for leaks.

Recommended Procedure:
- Inspect for a hole in the MAP sensor hose or a pinched hose.
- Inspect the fuel system, including the fuel tank, fuel pump, fuel filter housing and fuel lines, for kinks, bends or leakage.
- Inspect for coolant leaks at the radiator and coolant hoses. Check the coolant level.
- Inspect wiring for correct routing, and verify no rubbing or chafing has occurred.
- Inspect all sensors, and verify the connectors are properly secured.
- Inspect the intercooler hoses for leaks.

Possible Causes:
- Loose or leaking fuel lines
- Kinked or blocked fuel lines
- Fuel or oil leaks
- Coolant leaks could indicate engine problems
- Pinched or open MAP sensor hose
- Pinched or open intercooler hose
- Improper connections

Tools Required:
Inspection light

2. Sufficient Clean Fuel

Purpose:
The purpose of this test is to verify the fuel quality.

Sufficient Clean Fuel

Sufficient Clean Fuel:






- Check for illumination of the WATER IN FUEL indicator.
- Drain a fuel sample from the fuel conditioning module.
- A cetane rating between 40 and 50 is recommended for optimum performance.

Recommended Procedure:






Open the drain valve on the fuel conditioning module and fill a clear container until it is half full. Close the drain valve.

Observe the WATER IN FUEL indicator. If the indicator is illuminated, the fuel is probably contaminated with water.

Flow out of the drain should be a steady stream. Insufficient flow could indicate fuel supply or fuel system problems.

Inspect the fuel in the container. It should be clear, not cloudy. It also should be free of water and contaminants. Dyed red or blue fuel indicates off-highway fuel.

Some sediment and water may be present in the fuel sample if the fuel filter has not been serviced for a prolonged period of time and/or if the sediment and water have not been drained recently. If that is the case, a second sample may be required to determine fuel quality.

Possible Causes:
- No fuel in tank
- Fuel supply line could be broken or crimped
- Fuel could be gelled (most likely in cold weather with No.2 fuel)
- Pickup tube screen in tank could be clogged

Cloudy fuel indicates that the fuel may not be a suitable grade for cold temperatures.

Excessive water or contaminants may indicate that the tank and fuel system may need to be flushed and cleaned.

Tools Required:
Clear container - approximately 0.95L (1-quart)

3. Check Engine Oil Level

Purpose:
The purpose of this test is to verify oil quality and determine if there is sufficient oil to operate the injectors.

Check Engine Oil Level

Check Engine Oil Level:






- Check for contaminants (fuel, coolant).
- Correct grade/viscosity.
- Miles/hours on oil, correct level.

Recommended Procedure:
Check the oil level using the dipstick with the vehicle on level ground. If there is no oil or very little oil in the crankcase, the injectors will not operate.

If the oil level is overfull, it is possible the engine was incorrectly serviced or fuel is diluting the oil and filling the crankcase. If a substantial amount of fuel is in the oil, it will have a fuel odor.

Inspect oil for color. A milky white oil indicates possible coolant contamination which will have an ethylene glycol odor.

Check service records for correct oil type and viscosity for the vehicle operating temperature. Single weight or 15W-40 oil is not recommended for cold ambient temperatures. 10W-30 oil is recommended for cold ambient temperatures. Oil that has had extended drain intervals will have increased viscosity (become thicker) and will make engine cranking more difficult and starting less reliable at temperatures below freezing. Refer to the lube oil chart in operator's manual for the correct oil selection for temperature conditions.

Possible Causes:
- Oil level low - oil leak, oil consumption, incorrect servicing
- Oil level high - incorrect servicing, fuel dilution from injector O-rings
- Oil contamination with coolant - oil cooler, head gasket, porosity

4. Perform KOEO On-Demand Self-Test

Purpose:
The purpose of this test is to determine if the PCM has detected any fault conditions that would cause a performance problem.

Perform KOEO On-Demand Test

KOEO On-Demand Test:






- Use the scan tool.
- DTCs set during this test are current faults.

Recommended Procedure:

NOTE: To ensure that the DTC is a hard fault, first clear Continuous DTCs (be sure to record all DTCs and Freeze Frame information before clearing). Rerun KOEO On-Demand Self Test. If the DTC is set again, a hard fault has occurred.

Connect the scan tool. Turn off all accessories. If the vehicle is equipped with an auxiliary powertrain control module (APCM), it must be turned off to perform the self-test.
- Perform the necessary vehicle preparation and a visual inspection. Refer to Quick Test Operation. Quick Test Operation
- Refer to the scan tool operating manual for instructions.
- Key on, engine off.
- Wait 4 seconds for the transmission control module (TCM), powertrain control module (PCM) and the fuel injector control module (FICM) to initialize.
- Follow the operating instructions from the diagnostic menu.
- Perform a KOEO On Demand Self-Test. Key On Engine Off (KOEO) On-Demand Self Test
- Record the DTCs and Freeze Frame information and refer to the appropriate pinpoint test. P Code Charts

Tools Required:
Scan tool

5. Retrieve Continuous DTCs

Purpose:
The purpose of this test is to determine if the PCM has detected any historical or intermittent fault conditions that would cause a performance problem. The condition that caused a continuous DTC may no longer exist.

Retrieve Continuous DTCs

Retrieve Continuous DTCs:






- Use the scan tool.
- DTCs retrieved during this test are historical faults.

Recommended Procedure:
Connect the scan tool. Turn off all accessories. If the vehicle is equipped with an auxiliary powertrain control module (APCM), it must be turned off to perform self tests.
- Perform the necessary vehicle preparation and a visual inspection. Refer to Quick Test Operation. Quick Test Operation
- Refer to the scan tool operating manual for instructions.
- Key on, engine off.
- Follow operating instructions from the menu.
- Record the continuous DTCs and Freeze Frame information from the PCM and TCM and refer to the appropriate pinpoint test for continuous DTC diagnostics.
- Continuous DTCs must be cleared after a repair is made.

Tools Required:
Scan tool

6a. KOEO Injector Electrical Self-Test

Purpose:

NOTE: Before carrying out the KOEO injector electrical self-test, allow the engine to stabilize at the temperature necessary to recreate the symptom. Access the PCM and record the freeze frame data. The freeze frame data contains information which can be used to recreate original conditions that caused the symptom. Refer to Freeze Frame Data for more information. Freeze Frame Data

NOTE: If unable to perform KOEO Injector Electrical Self-Test (Click Test), disconnect the FICM connector and check injectors for shorts or opens.

The purpose of this test is to determine if the injector coils and valves are functioning by energizing all injectors together and then each injector in numerical sequence (1 through 8).

KOEO Injector Electrical Self-Test

KOEO Injector Electrical Self-test (Click Test):





Cylinder And Fuel Injector:






- Use the scan tool. Injector DTCs will be transmitted after the self-test is completed.
- All injectors will momentarily click, then each injector will click in sequence 1 through 8.

NOTE: Sequence repeats three times.

NOTE: DTCs can be historical if not cleared from a previous test.

Recommended Procedure:
This test determines if the injector circuits and coils are correctly operating. All injectors click simultaneously for approximately 2 seconds, then each individual injector will click for approximately 1 second in numerical order (1 through 8). If an electrical concern is present, a DTC sets and outputs on the data link at the end of the test when requested by a scan tool.

- Turn off all accessories. If the vehicle is equipped with a power take-off (PTO) system or auxiliary idle control, it must be turned off to carry out self-tests.
- Carry out the necessary vehicle preparation and a visual inspection. Refer to Quick Test Operation. Quick Test Operation
- Refer to the scan tool operating manual for instructions.
- Key on, engine off.
- Follow the operating instructions from the menu.
- Perform the KOEO Injector Electrical Self-Test (Click Test).
- Record the DTCs and perform the appropriate pinpoint test.

Possible Causes:
- Open or shorted injector circuit
- Injector connector
- Injector coils
- FICM power or ground circuit
- FICM

Tools Required:
Scan tool

6b. Power Balance Test

Purpose:

Note: Before carrying out the power balance test, allow the engine to stabilize at the temperature necessary to recreate the symptom. Access the PCM and record the freeze frame data. The freeze frame data contains information which can be used to recreate original conditions that caused the symptom. Refer to Freeze Frame Data for more information. Freeze Frame Data

Note: The contributing power cylinders that immediately follow the non-contributing power cylinders in the firing order may be affected. The affected power cylinders may not be able to fully recover the crankshaft speed, causing them to display below average contributing power cylinders and to be incorrectly identified as the non-contributing power cylinder. Therefore only the cylinders that deviate the most from the average should be identified as the non-contributing power cylinder. Single or inconsistent non-contributing power cylinder traces may be caused by a natural variation in the crankshaft speed and should be ignored.

The purpose of this test is to determine if the injector coils and spool valves are operating correctly by observing individual cylinder contribution while running the Power Balance test.

Power Balance Test

Note: Disregard any DTCs set as a result of the Power Balance test.
- Use the scan tool to carry out the Power Balance test.
- Monitor individual cylinder contribution and record the consistently non-contributing power cylinders.
- Carry out the check valve test.
- If the operational bank cylinders operate erratic, install a new check valve.

Cylinder And Fuel Injector:






6.0L Engine, Cylinder and Fuel Injector Location

Recommended Procedure:

Note: If the engine does not start during this procedure verify the batteries are fully charged, plug in the block heater and cycle the key several times to activate the glow plugs.

This test identifies non-contributing power cylinders and determines if the injector spool valves are correctly operating.
- Turn off all accessories. If the vehicle is equipped with a power take-off (PTO) system or auxiliary idle control, it must be turned off to carry out the Power Balance test.
- Refer to the scan tool operating manual for instructions.
- Key in OFF position.
- Key ON, engine running.
- Start the Power Balance test and monitor the cylinder power contribution for 8 seconds. Identify and record the non-contributing power cylinders.
- While the Power Balance test is running, use the output state control to turn off the idle compensation strategy. Monitor power contribution for 8 seconds, identify and record the non-contributing power cylinders.
- With the idle compensation strategy turned off, increase the engine speed to between 800 and 900 RPM. Monitor power contribution for 8 seconds and identify and record the non-contributing power cylinders.
- Install a new fuel injector for the cylinders identified as non-contributing power cylinders, refer to Fuel Charging and Controls. Air may be present in the high pressure oil rail after the repair. It may be necessary to operate the vehicle for 24-32 km (15-20 miles) to remove excess air.
- Carry out the check valve test. To isolate bank 2 check valve disconnect all injectors on bank 1.
- Start the Power Balance test and monitor the cylinder power contribution while the symptom is occurring. Engine misfires should be constant on the four disconnected cylinders. The operational cylinders should be contributing evenly. Carry out the check valve test for bank 1 check valve.
- If the operational bank cylinders operate erratic, install a new check valve.

Possible Causes:
- Fuel injector o-ring seals
- Fuel injectors
- Oil change past due

Tools Required:
Scan tool

7. Intake Restriction

Purpose:
This purpose of this test is verify an air intake or exhaust restriction is not contributing to a low power condition. If the engine does have a high air intake restriction, a considerable amount of black or blue smoke may be produced.

Intake Restriction

Intake Restriction:






- Check air filter minder switch or indicator.
- Measure the vacuum on clean side of air inlet system at WOT with magnehelic gauge.

Recommended Procedure:










Inspect the air cleaner inlet and ducting to assure that it is not blocked or collapsed. Inspect the air cleaner housing and filter for proper installation.

Inspect for any indication of water intrusion into air cleaner/filter.

If necessary, use Pressure Adapter Kit 014-00761 or equivalent to install a Magnehelic (R) gauge on the port on the air cleaner and measure restriction at high idle.

Possible Causes:
- Snow, plastic bags or other foreign material may restrict airflow at the air inlet
- Misrouted air cleaner ducting
- On engines recently repaired, rags or cap plugs may have been inadvertently left in an air inlet pipe

Tools Required:
Magnehelic (R) gauge (part of Pressure Adapter Kit 014-00761 or equivalent)

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