Note. The descriptions and specifications contained in this article were in effect at the time this article was approved for publication. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring 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 article 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 article cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this article 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 article, 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 WELL-VENTILATED 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, THREE-WAY 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!
Preface
This article provides a step-by-step approach for diagnosing driveability, emission, and powertrain control system symptoms. Before beginning diagnosis, it may be helpful to reference any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available. TSB/OASIS information is available on either the Professional Technician Society (PTS) or Motorcraft® website.
This article is used in conjunction with the Diagnostic Information articles, the Service Information articles and Wiring Diagrams. The Diagnostic Information articles, the Service Information articles are used to provide additional diagnostic or component removal and installation information. Refer to the SYSTEM WIRING DIAGRAMS - E350 SUPER DUTY article for vehicle specific wiring information and component, connector and splice locations.
The following is a description of the information contained in each section of the Diagnostic Information articles, and the Service Information articles .
Section 1: Description and Operation
This section contains description and operation information on powertrain control systems and components and provides the technician with a general knowledge of the powertrain control system. Use this section when general information about the powertrain control system is desired.
Section 2: Diagnostic Methods
This section contains information on specific diagnostic tasks that are used during diagnosis. Descriptions of specific diagnostic methods are included, as well as detailed instructions on how to access or carry out the tasks.
Section 3: Symptom Charts
All diagnosis begins in Section 3 with the Powertrain Control Module (PCM) Quick Test. If the PCM Quick Test is completed and no diagnostic trouble codes (DTCs) are retrieved, the technician may be directed to the No DTCs Present Symptom Chart Index in Section 3. The No DTCs Present Symptom Chart Index contains the list of symptoms addressed in this article, and directs the technician to the appropriate chart in the No DTCs Present Symptom Chart. If no PCM DTCs are present and the vehicle symptom is not listed in the No DTCs Present Symptom Chart Index, the technician should go to the appropriate component Diagnostic Information to continue diagnosis.
Section 4: Diagnostic Subroutines
This section contains the Hard Start/No Start Diagnostic Procedures and Performance Diagnostic Procedures that are used to obtain quick diagnostic information. This section also contains the Diagnostic Trouble Code (DTC) Charts and Descriptions.
Section 5: Pinpoint Tests
All pinpoint tests are included in this section. Never enter a pinpoint test unless directed there. When directed to a pinpoint test, always read the information included at the beginning of the pinpoint test.
Section 6: Reference Values
This section contains the Typical Diagnostic Reference Values charts.
How To Use The Diagnostic Procedures
- Use the information about the vehicle driveability or emission concern to attempt to verify/recreate the symptom. Look for any vehicle modifications or aftermarket items that may contribute to the symptom. A check of any applicable TSBs or OASIS messages may be useful if this information is available.
- Go to Powertrain Control Module (PCM) Quick Test . Carry out the PCM Quick Test.
- If the PCM Quick Test is completed and no DTCs were retrieved, go to the No DTCs Present Symptom Chart Index .
- Select the symptom that best describes the vehicle symptom (for multiple symptoms select the one that is most evident). Go to the No DTCs Present Symptom Chart as indicated. If no PCM DTCs are present and the vehicle symptom is not listed in the No DTCs Present Symptom Chart Index, go to the appropriate component Diagnostic Information to continue diagnosis.
- The No DTCs Present Symptom Chart contains areas to be tested for diagnosis of the vehicle symptom. The chart is arranged to place the higher probability or easiest to test items toward the top of the chart. However, the technician is not required to follow this order due to reasons such as variations in vehicle type, vehicle repair history, or technician experience. Follow the instructions in the step (including Preliminary Checks). The System/Component column indicates the areas that are tested. This column may also contain a quick system/component test. The Reference column indicates where to go for the System/Component testing. If the step sends you to a specific area for testing (for example Hard Start/No Start Procedures, a pinpoint test step in this article or Diagnostic Information article), go to the appropriate procedures to continue diagnosis. Follow the directions given in those procedures, including directions to other tests or sections. If a concern is found, repair as directed. If no concern is found and diagnosis in that area is complete, return to the No DTCs Present Symptom Chart to continue as directed. If a quick system/component test is in the System/Component column, the Reference column indicates where to go if the test does not pass.
- During diagnosis, if directed to test a system/component that is not contained on that vehicle, go to the next step.
- If the No DTCs Present Symptom Chart for the vehicle symptom is completed and no concern is found, return to the No DTCs Present Symptom Chart Index to address the next most prominent symptom.
- After any repair, reconnect all components and remove any test equipment. Verify that the vehicle is operating correctly and the original complaint is no longer present. If a DTC was present, clear the DTCs and repeat the Quick Test to verify the repair.
- If a symptom is determined to be intermittent, a careful visual and physical underhood inspection of connectors, wiring harnesses, vacuum lines, and components is required. The Customer Information Worksheet may contain more detailed symptom information. Before an in-depth diagnosis begins, start the engine wiggle wires and tap on components while listening for an indication of a concern (such as an RPM change or a relay clicking).
Information about engine conditions is stored when a DTC that illuminates the malfunction indicator lamp (MIL) is set. This information is called freeze frame data and may be helpful in diagnosing intermittent concerns. Refer to FREEZE FRAME DATA for additional information.
Acronyms and Definitions
Note. This acronyms and definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable section within this article or refer to the appropriate component Diagnostic Information article or Service Information article for additional information.
ABS: Antilock Braking System
A/C: Air Conditioning
A/CC: Air Conditioning Clutch
A/D: Analog-to-Digital
API: American Petroleum Institute
APP: Accelerator Pedal Position
ATF: Automatic Transmission Fluid
BARO: Barometric Pressure
BJB: Battery Junction Box
BPA: Brake Pressure Applied
BPP: Brake Pedal Position
BTDC: Before Top Dead Center
CAC: Charge Air Cooler
CAN: Controller Area Network
CARB: California Air Resources Board
CCM: Comprehensive Component Monitor
Cetane number: 1. The auto-ignition quality of diesel fuel. 2. A rating applied to diesel fuel similar to octane rating for gasoline. 3. A measure of how readily diesel fuel starts to burn (auto ignites) at high compression temperature. Diesel fuel with a high cetane number auto-ignites shortly after injection into the combustion chamber. Therefore, it has a short ignition delay time. Diesel fuel with a low cetane number resists auto-ignition. Therefore, it has a longer ignition delay time.
CKP: Crankshaft Position
CMP: Camshaft Position
DEPM: Diesel Engine Power Monitor
DLC: Data Link Connector
DMM: Digital Multimeter
DTC: Diagnostic Trouble Code
ECT: Engine Coolant Temperature
EEC: Electronic Engine Control
EEPROM: Electronically Erasable Programmable Read Only Memory
EGR: Exhaust Gas Recirculation
EOT: Engine Oil Temperature
EP: Exhaust Pressure
EPA: Environmental Protection Agency
FICM: Fuel Injector Control Module
FLI: Fuel Level Input
FMEM: Failure Mode Effects Management
FP: Fuel Pump
FPM: Fuel Pump Monitor
FSS: Fan Speed Sensor
GPCM: Glow Plug Control Module
GPIL: Glow Plug Indicator Lamp
GPM: Glow Plug Monitor
GVWR: Gross Vehicle Weight Rating
IAT: Intake Air Temperature
ICP: Injection Control Pressure
IFS: Inertia Fuel Shutoff
IM: Inspection Maintenance
IPR: Injection Pressure Regulator
ISO: International Standards Organization
KAM: Keep Alive Memory
KAPWR: Keep Alive Power
km/h: Kilometers per hour
KOEO: Key On Engine Off
KOER: Key On Engine Running
kPa: Kilopascal
LB-ft: Pounds of force per foot
MAF: Mass Air Flow
MAP: Manifold Absolute Pressure
MFDES: Mass Fuel Desired
MIL: Malfunction Indicator Lamp
MPH: Miles per hour
OASIS: On-line Automotive Service Information System
OBD: On Board Diagnostics
O/D: Overdrive
OSC: Output State Control
OSR: On-Board System Readiness
OSS: Output Shaft Speed
PATS: Passive Anti-Theft System
PBA: Parking Brake Applied
PCM: Powertrain Control Module
PID: Parameter Identification
PTO: Power Take Off
PTS: Professional Technician Society
PWM: Pulse Width Modulation
RAM: Random Access Memory
ROM: Read Only Memory
RPM: Revolutions Per Minute
SAE: Society of Automotive Engineers
TCM: Transmission Control Module
TDC: Top Dead Center
TFT: Transmission Fluid Temperature
TSB: Technical Service Bulletin
VDF: Visctronic Drive Fan
VECI: Vehicle Emission Control Information
VGT: Variable Geometry Turbocharger
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
WIF: Water In Fuel
WOT: Wide Open Throttle
VCM: Vehicle Communication Module
VID: Vehicle Identification
See also:
• FREEZE FRAME DATA