Note. The descriptions and specifications contained in this article were in effect at the time this article was approved for publication.
IMPORTANT SAFETY NOTICE
Appropriate repair 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 carrying out diagnosis and repair with tested, effective techniques. Following them will help to establish reliability.
There are numerous variations in procedures, techniques, tools, and parts for repairing 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.
NOTES, CAUTIONS, AND WARNINGS
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 you 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.
- 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 it 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 inch x 4 inch or larger) 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.
- 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, 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 radiator 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) information when this is available.
This article is used in conjunction with service information articles and SYSTEM WIRING DIAGRAMS . The service information articles are used to provide additional diagnostics or component removal and replacement information. Refer to SYSTEM WIRING DIAGRAMS for vehicle specific wiring information and component, connector, and splice locations.
The following is a description of the information contained in each of the ENGINE PERFORMANCE articles.
DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION contains information on powertrain control systems and components. This article is designed to give the technician a general knowledge of the powertrain control system. It should be used when general information about the powertrain control system is desired.
DIAGNOSTIC METHODS
DIAGNOSTIC METHODS 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. This article provides the technician with step-by-step instructions for carrying out routine diagnostic tasks.
SYMPTOM CHARTS
All diagnosis begins in with the QT: 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 . The No DTCs Present Symptom Chart Index contains the list of symptoms addressed, and will send the technician to the appropriate 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 refer to the appropriate service information article to continue diagnosis.
DIAGNOSTIC SUBROUTINES
DIAGNOSTIC SUBROUTINES contains the Hard Start/No Start and Performance Diagnostic Procedures that are used to obtain quick diagnostic information. This article also contains the Powertrain Diagnostic Trouble Code (DTC) Charts. The SYMPTOM CHARTS - 6.0L DIESEL article will direct the technician to these tests when required.
PINPOINT TESTS
All the pinpoint tests are included in PINPOINT TESTS. Never enter a pinpoint test unless directed there. When directed to a pinpoint test, always read the information included at the beginning of the test.
REFERENCE VALUES
REFERENCE VALUES contains the Control System Diagnostic Sheet Reference Chart and the Diagnostic Trouble Code (DTC) Descriptions Chart.
WHAT'S NEW IN 2005
For the 2005 model year
- the EGR throttle position actuator has been deleted.
- F-Super Duty and E-Series vehicle communication (PCM to diagnostic tool and PCM to vehicle module) is controller area network (CAN) protocol.
- Excursion diagnostic tool to PCM communication is CAN with PCM to vehicle module international standards organization (ISO) or standard communication protocol (SCP).
- F-Super Duty/Excursion vehicles without a mass air flow (MAF) sensor have a stand alone intake air temperature sensor (IAT) sensor.
How To Use The Diagnostic Procedures
- Use the information about the vehicle driveability or emission concern (from the write-up or Customer Information Worksheet) to attempt to verify/re-create the symptom. Look for any vehicle modifications or aftermarket items that may contribute to the symptom. A check of any applicable TSBs may be useful, if this information is available.
- Go to «QT: POWERTRAIN CONTROL MODULE (PCM) QUICK TEST»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-symptom-charts-60l-diesel) . 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»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-symptom-charts-60l-diesel__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 Index that is 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 service information article 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 will be tested. This column may also contain a quick system/component test. If a quick system/component test is in the System/Component column, the Reference column will indicate where to go if the test failed. If the step contains a test procedure or question (without a reference outside the step), carry out the test step/answer the question and continue as directed. 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 a service information article), go to the procedures. Follow the directions given in those procedures, including directions to other tests or service information article. If a fault is found, repair/replace as directed. If no fault is found and diagnosis in that area is complete, return to the Symptom Chart and continue as directed.
- During diagnosis, if directed to test a system/component that is not contained on that vehicle, go to the next step.
- If the Symptom Chart for the vehicle symptom is completed and no fault is found, return to the Symptom Chart Index to address the next most prominent symptom.
- After repair, restore the vehicle by reconnecting any components and removing any test equipment. Verify that the vehicle is operating properly and the original complaint is eliminated. If a DTC was present, repeat the Quick Test to verify the repair and clear any Continuous Memory DTCs.
Note. If a symptom is determined to be intermittent, 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.
