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F-Series/Excursion Powerstroke 2003.25
6.0L Power Stroke Diesel Engine Diagnostic Guide
Customer Concerns (Please list in this box)
DEALER NAME
ENGINE SERIAL NUMBER
VEHICLE GVW
TRANSMISSION
1. Visual Engine/Chassis Inspection
•
Verify that there are no fluid or pressure leaks.
•
Inspect all wire connections for damage.
•
Inspect MAP hose,intercooler hose,and manifolds for leaks.
Fuel Oil Coolant Electrical Hoses Leaks
Method
Check
Visual
2. Sufficient Clean Fuel
•
Check if WATER IN FUEL indicator has been illuminated.
•
Drain sample from fuel control module housing.
•
Cetane rating between 40-50 is recommended for
optimum performance
Method
Check
Visual
3. Check Engine Oil Level
•
Check for contaminants (fuel, coolant).
•
Correct Grade/Viscosity.
Miles/hours on oil, correct level.
•
Method
Check
Visual
4. Perform KOEO On Demand Test
Use the scan tool.
•
DTCs set during this test are current faults.
•
Diagnostic
Trouble Codes
5. Retrieve Continuous DTC's
Use the scan tool.
•
DTCs retrieved during this test are historical faults.
•
Diagnostic
Trouble Codes
6. KOEO Injector Electrical Self-Test
Use the scan tool.
•
•
All injectors will momentarily click, then individual
injectors will click in sequence 1 though 8.
Injector
Trouble Codes
»
If self test codes are retrieved, go to appropriate PPT.
7. Intake Restriction
•
Check filter minder switch/indicator.
Measure vacuum on clean side of air inlet system
•
at WOT with magnehelic gauge.
Instrument
Spec.
Magnehelic/
Filter Minder
2"-25" H²0
P E R F O R M A N C E D I A G N O S T I C S
IF CONCERN IS FOUND, SERVICE AS
REQUIRED. IF THIS CORRECTS THE
CONDITION, IT IS NOT NECESSARY TO
COMPLETE THE REMAINDER OF THE
DIAGNOSTIC PROCEDURE.
P & A
CODE
AMBIENT TEMPERATURE
8. EGR Position
•
Perform with key on, engine off.
•
Use scan tool to command Output State Control for EGR.
•
Monitor EGR position sensor PID and calculate travel..
Instrument
Scan tool
»
Repair issue causing out of spec. values before continuing.
9. Exhaust Restriction
•
Visually inspect exhaust system for damage
•
Monitor EP with the scan tool with the engine temperature
at 70° C (170° F)minimum at 3,800 RPM in park/neutral.
Parameter
EP
MAX '@ 3800 RPM
10a. Electric Fuel Pump Pressure
Measure fuel pressure at engine filter housing test port.
•
Road Test- engine at full load condition
•
Instrument
0-1.1 Mpa
(0-160 PSI)
Gauge
»
If fuel pressure fails low, Go to step10b.
»
If pressure is above spec, check fuel return lines for restriction.
If no restriction is present, replace fuel pressure regulator valve.
10b. Electric Fuel Pump Inlet Restriction
Measure restriction at fuel pump inlet.
•
Instrument
0-30 " Hg
vacuum
»
If > 6" Hg restriction, check lines between pump and fuel tank.
»
If < 6" Hg, inspect both fuel filters. If filters are OK, check fuel
regulator. If regulator and filters are OK, replace fuel pump.
10c. Fuel Aeration Test
•
Install clear hose on fuel return line at fuel control module.
Refer to shop manual for approved procedure.
Run at WOT for 2 min. Return fuel should be free of bubbles.
•
Method
Check
Visual
»
If air is present in return fuel, inspect fuel system for leaks.
11. Perform KOER On Demand Test
This will test the ICP, EGR and VGT performance.
•
KOER
DTC
CUSTOMER NAME
-NOTE-
MODEL YEAR
CHASSIS STYLE
1863 CLAIM NUMBER
ODOMETER
Spec. Percent
Actual Percent
0% (0.6-1.2 V)
Closed
_______ Closed
90 % - 100%
(4.0-4.52 V)
_______ Open
Open
90 % and 3.2 V
_______ Travel
Travel
Spec.
Measurement
234 kPa (34 PSI)
Spec.
Measurement
310-379 kPa
(45-55 PSI) min.
Spec.
Measurement
6" Hg MAX
Check
VEHICLE SERIAL N0.(VIN)
DATE
TYPE OF SERVICE
PERSONAL
12a. Low Idle Stability (ICP Pressure)
•
Check at low idle, EOT above 70° C (170° F)
•
Monitor ICP and RPM with scan tool.
Parameter
Spec. @ 670 RPM
4.5-5.5 Mpa + .3MPa
ICP
(650-800 PSI + 45 PSI)
Take reading before disconnecting ICP
If engine RPM is unstable, disconnect ICP sensor (ICP will default).
»
If RPM is still unstable, re-connect sensor and go to 12b.
»
If RPM smoothes out, the ICP sensor is at fault.
12b. Injection Pressure Regulator Test
•
Check at low idle, EOT above 70° C (170° F)
Monitor IPR with scan tool.
•
Parameter
Spec. @ 670 RPM
IPR
30 % MAX
»
If duty cycle is below MAX spec go to next step.
»
If duty cycle is above MAX spec, check for system leak with
procedure in Hard Start/No Start section. Test 10c.
13. Boost Pressure Test
•
Carefully inspect intercooler tubes/connections, turbocharger
connections, and MAP hose for signs of damage or leaks.
•
Perform boost test at 3300 RPM.
•
Monitor MGP and RPM with scan tool.
Road Test - select appropriate gear to obtain desired engine
•
speed and full load on engine climbing hill or loaded truck..
3300 RPM
Parameter
Spec. PSI G
MGP
22 PSIG MIN
»
If test fails low, inspect turbo blades for damage.
14. Crankcase Pressure Test
Measure at oil fill tube with 6.0L Crankcase Pressure Tester
•
p/n 303-758, with engine at 70° C (170° F) minimum.
Block breather tube on left valve cover.
•
Measure at WOT with no load at 3,000 RPM.
•
Instrument
Spec.
(0-60" H²0)
8" H²0 MAX
Magnehelic
If more than 8 " H²0, refer to base engine in Shop Manual
15. Oil Aeration Test
•
Run engine at 3000 RPM for 1 minute.
•
Take oil sample from the Oil Pressure Switch port at idle.
Inspect sample for presence of air bubbles.
•
Method
Check
Visual
»
Excessive oil aeration can be caused by depleated oil additives,
pick-up tube leak, front cover seal leak, or upper pan seal leak.
Note: If performance concern still exists, refer to Enhanced Injector
Diagnostics in this section.
COMMERCIAL
Measurement
Measurement
Measurement
Measurement
89
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