QT1 CARRY OUT A VISUAL INSPECTION
- Access any related TSB information.
- Inspect the air cleaner, inlet ducting, tubes and clamps.
- Inspect all hoses for damage, leaks, cracks, blockage, and proper routing.
- Inspect the fuel system including the fuel tank and the fuel lines for kinks, bends and/or leakage.
- Inspect the wiring harness for correct routing and chafing.
- Inspect the exhaust system.
- Check for correct engine oil level and quality.
- Check the engine coolant for proper level.
QT2 VEHICLE PREPARATION
- Place the transmission gear selector into PARK (automatic transmission) or NEUTRAL (manual transmission).
- Apply the parking brake.
- Block the drive wheels.
- Turn off all electrical loads (radios, lights, A/C, blower, and fans).
Has the vehicle preparation been completed?
QT3 CARRY OUT THE PCM QUICK TEST
Note. If unable to access the PCM or a diagnostic tool communication concern exists, GO to Pinpoint Test AE .
- Connect the diagnostic tool to the data link connector (DLC). Refer to «DIAGNOSTIC TOOL SETUP AND FUNCTIONALITY»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-diagnostic-methods-60l-diesel__diagnostic-tool-setup-and-functionality) .
- Carry out the PCM Quick Test to access and record any key on engine off (KOEO), key on engine running (KOER) and continuous memory DTCs. Refer to «QUICK TEST DESCRIPTION»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-diagnostic-methods-60l-diesel__quick-test-description) .
- Access and record the Freeze Frame Data. Refer to «FREEZE FRAME DATA»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-diagnostic-methods-60l-diesel) .
No DTCs Present Symptom Chart Index
DRIVEABILITY - PERFORMANCE WHILE DRIVING CONCERNS
ADDITIONAL DRIVEABILITY CONCERNS
Chart 1
- Starting Concerns: No Crank/Slow Crank
Carry out the following preliminary checks
- Automatic transmission in PARK or NEUTRAL.
- Clutch pedal fully pressed.
- Battery connections.
- Starter relay connections.
- Battery load test.
- Fuse links.
- Anti-theft.
- Ignition switch.
- PCM connectors not fully seated.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Starter Relay | REFER to STARTING SYSTEM . |
| Check Electrical Accessories | REFER to CHARGING SYSTEM - GENERAL INFORMATION . |
| Check Starting System Secondary Circuits | REFER to STARTING SYSTEM . |
| Check Starting System Components | REFER to STARTING SYSTEM . |
| Check TR Sensor | REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . |
| Check Reference Voltage (VREF) | GO to Pinpoint Test B . |
Chart 2
- Stalls/Quits: Idle, Acceleration, Cruise, Deceleration
Carry out the following preliminary checks
- Engine for correct oil level/quality.
- Electrical connections.
- Automatic transmission - torque converter operation, always applied.
- Automatic transmission fluid (ATF) level.
- Engine overheating.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check For Cold Weather Stall | If the engine restarts after a stall, the oil return to the oil pan may be too slow. CONFIRM the correct grade of oil for frigid conditions. CHANGE the oil if necessary. |
| Check Performance Diagnostics | CARRY OUT the PERFORMANCE DIAGNOSTIC PROCEDURES . |
| Check Torque Converter Operation If Stalls at Idle | REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . |
| Check Air Intake System | Visually INSPECT the air inlet for obstructions/restrictions. REPAIR as necessary. RESET the air filter restriction gauge. |
| Check Reference Voltage (VREF) | GO to Pinpoint Test B . |
| CHECK RPM Signal | CARRY OUT the CHECK THE RPM SIGNAL WHILE CRANKING Test. |
Chart 3
- Starting Concerns: Hard Start/Long Crank/Erratic Start/Erratic Crank, Stall After Start, No Start/Normal Crank
Carry out the following preliminary checks
- Check for correct engine oil level and viscosity.
- Check for sufficient clean fuel.
- Check for an intake restriction.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Fuel Pump Pressure | CARRY OUT the ELECTRIC FUEL PUMP PRESSURE Test. |
| Check Parameter Identification (PIDs) | GO to HARD START/NO START DIAGNOSTIC PROCEDURES and CARRY OUT Step 10. If a fault is indicated, GO to the appropriate pinpoint test. |
| Check Engine Oil Pressure | REFER to ENGINE - 6.0L DIESEL for specifications. |
| Carry out the KOEO Injector Electrical Self-Test (Click Test) | GO to the appropriate pinpoint test if a fault is indicated. |
| Check Fuel Quality | CARRY OUT the SUFFICIENT CLEAN FUEL Test. |
| Fuel Injector Control Module (FICM) | GO to DIAGNOSTIC METHODS PARAMETER IDENTIFICATION (PID) . Select PIDS: FICMLPWR, FICMMPWR and FICMVPWR. REFER to for correct values. No or low voltage may be caused by circuit integrity at the 12-way connector. |
| Check Glow Plug Module Power Circuit | CHECK the voltage between the glow plug B+ circuits and ground. If battery voltage is not present, CHECK the fusible link and circuitry. |
| Check Glow Plug Control Module | GO to Pinpoint Test AF . |
| Check Glow Plugs | GO to Pinpoint Test AF . |
| Check Glow Plug Connectors | GO to Pinpoint Test AF . |
| Check for Injection Control Pressure (ICP) Sensor Bias | GO to Pinpoint Test Q . |
| Check the Exhaust Gas Recirculation (EGR) System | CARRY OUT the EXHAUST GAS RECIRCULATION (EGR) POSITION Test. |
Chart 4
Note. Heavy external load upon cold start may cause a momentary lack of power.
Carry out the following preliminary checks
- Accelerator pedal position (APP) sensor electrical connection failure.
- Interference from floor mats.
- Accelerator pedal damage.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Accelerator Pedal | GO to the appropriate pinpoint test and CONFIRM that the sensors and wiring are intact. |
| Check the Power Monitor | CHECK the TCM for continuous DTCs. If DTCs P0148 or P2552 are present, GO to the appropriate pinpoint test. |
Chart 5
- Unique Idle Concern: Slow Return to Idle, Fast Idle
Carry out the following preliminary checks
- PCM system check.
- Accelerator pedal for binding, broken return spring, stuck condition (floor mats).
- External fuel source.
- Engine not reaching normal operating temperature.
- Power take-off (PTO), auxiliary idle control, and charge protect devices disengaged.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Accelerator Pedal | REPAIR if needed. |
| Check Crankcase Oil Level | If overfilled, DRAIN the crankcase to the correct level. DETERMINE cause of overfill. |
| Check Engine Oil | If there is coolant or fuel contamination in the engine oil, REPAIR as necessary. |
| Check For Fuel Contamination | CARRY OUT the SUFFICIENT CLEAN FUEL Test. |
| Check Parameter Identification (PIDS) | GO to DIAGNOSTIC METHODS PARAMETER IDENTIFICATION (PID) . SELECT Parameter Identification (PID). WARM engine to normal operating temperature. SELECT the engine oil temperature (EOT) PID. If EOT value is less than 38°C (100°F), INSTALL a new EOT sensor. |
| Check Turbocharger Ducting | REMOVE the turbocharger inlet air duct. INSPECT for debris/contamination. |
| Check EGR Operation | CARRY OUT the EXHAUST GAS RECIRCULATION (EGR) POSITION Test. |
| Check for Biased ICP Sensor | GO to Pinpoint Test Q . |
Chart 6
- Unique Idle Concerns: Rolling Idle, Stalls When Engaging Clutch
- Runs Rough: Idle
Carry out the following preliminary checks
- Check for correct engine oil level.
- Confirm oil change within 12,070 km (7,500 miles).
- Check air intake system: Air filter restriction gauge, inlet for obstruction/restrictions. RESET the air filter restriction gauge.
- Confirm acceptable SAE oil viscosity and API rating of oil.
- Check fuel quality. CARRY OUT the «SUFFICIENT CLEAN FUEL»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-diagnostic-subroutines-60l-diesel) Test.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Carry out the KOEO Injector Electrical Self Test (Click Test) | GO to the appropriate pinpoint test if a fault is indicated. |
| Low Idle Stability Test/Injection Control Pressure Test | CARRY OUT the LOW IDLE STABILITY (ICP PRESSURE) Test. |
| Check For Biased ICP Sensor | GO to Pinpoint Test Q . |
| Check Fuel Pump Pressure | CARRY OUT ELECTRIC FUEL PUMP PRESSURE Test. |
| Check Lubrication Pressure | REFER to ENGINE - 6.0L DIESEL for specifications. |
| Check Rough Idle | COMPLETE the Performance Diagnostics Form. (1) If rough idle was present when the vehicle was new or after installing a new high-pressure pump, CHECK the high-pressure oil pump. |
| Check For Engine Wear | CARRY OUT CRANKCASE PRESSURE TEST . If the crankcase pressure is greater than 15 mm Hg (8 in H 2 O), REPAIR the engine as necessary. If the crankcase pressure is less than 15 mm Hg (8 in H 2 O), GO to P: Misfire/Injector Driver Circuit Operation STEP P15. |
| Check EGR Operation | CARRY OUT the EXHAUST GAS RECIRCULATION (EGR) POSITION Test. |
| Check Injector Operation | CARRY OUT the INJECTOR INTERRUPT FOR ENHANCED DIAGNOSTICS Test. |
| Check For Aerated Oil | CARRY OUT the OIL AERATION TEST . |
| (1) (Scheme 125) |
Scheme 125
Chart 7
- Lack/Loss Of Power: Acceleration, Cruise
- Runs Rough: Acceleration, Cruise
- Misses: Idle, Acceleration, Cruise
- Buck/Jerk: Acceleration, Cruise, Deceleration
- Hesitation/Stumble: Acceleration
- Surge: Acceleration, Cruise
- Poor Fuel Economy
Carry out the following preliminary checks
- Confirm brakes are not dragging.
- Check for oil in coolant.
- Check for correct engine oil level.
- Confirm acceptable SAE oil viscosity and API rating of oil.
- Confirm oil change within 12,070 km (7,500 miles).
- Check air intake system: check for intake restriction. Air filter restriction gauge/air filter.
- Check the manifold absolute pressure (MAP) sensor hose for holes, blockage, or disconnection.
- Check the exhaust pressure (EP) sensor and tube for holes, blockage, or disconnection.
- Check the intake system for leaks.
- Check for low boost pressure.
- Check for over boost condition.
- Check for sufficient clean fuel.
- Check for air in fuel.
- Compare loaded weight of vehicle with performance expectations.
- Power monitor active.
- Transmission concerns.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Carry out the KOEO Injector Electrical Self Test (Click Test) | GO to the appropriate pinpoint test if a fault is indicated. |
| Check For Biased Injection Control Pressure (ICP) Sensor | GO to Pinpoint Test Q . |
| Check Fuel Pump Pressure | CARRY OUT ELECTRIC FUEL PUMP PRESSURE Test. |
| Check Fuel Regulator | INSTALL a new regulator valve if there is evidence of sticking or foreign material. |
| Check For Aerated Oil | CARRY OUT the OIL AERATION TEST . |
| Injection Control Pressure Test | CARRY OUT the LOW IDLE STABILITY (ICP PRESSURE) Test. |
| Check For Low Fuel Injection Control Module (FICM) Power | GO to Pinpoint Test S . |
| Check Lubrication Pressure | REFER to ENGINE - 6.0L DIESEL for specifications. |
| Check For Biased EP Sensor | GO to Pinpoint Test X . |
| Check For Engine Wear | CARRY OUT the CRANKCASE PRESSURE TEST . |
| Check For Piston Or Valve Leaks | REFER to ENGINE - 6.0L DIESEL . |
| Check For Exhaust Restriction | MEASURE the EP. If the EP is greater than 234 kPa (34 psi) or 2 volts, LOCATE and REPAIR the restriction in the exhaust system. VERIFY the repair. |
| Atmospheric Pressure Rationality Check | GO to DIAGNOSTIC METHODS PARAMETER IDENTIFICATION (PID) . With KOEO, SELECT Parameter Identification (PID). SELECT PIDs: EP, MAP and BARO. If any PID values/readings deviated from atmospheric pressure in your locale by more than 10 kPa (1.5 psi), GO to the appropriate pinpoint test for the sensor with the largest difference. |
| Check For Biased EOT Sensor | GO to L: Engine Oil Temperature (EOT) Sensor STEP L17. |
| Transmission Concerns | REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . |
| Check EGR Operation | CARRY OUT EXHAUST GAS RECIRCULATION (EGR) POSITION Test. |
| Check Mass Air Flow Performance | GO to Pinpoint Test J . |
| Check Power Monitor | GO to Pinpoint Test AT . |
| Check Turbocharger | CARRY OUT the BOOST PRESSURE TEST . |
| Check Injector Operation | CARRY OUT the INJECTOR INTERRUPT FOR ENHANCED DIAGNOSTICS Test. |
Chart 8
- Malfunction Indicator Lamp (MIL) Concern
- Warning Indicators: MIL
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Carry out the KOEO On-Demand Self-Test and Retrieve/Clear Continuous DTCs | GO to the appropriate pinpoint test. |
| Instrument Cluster Prove-Out | CYCLE the ignition switch to verify MIL illumination. REFER to INSTRUMENT CLUSTER . |
Chart 9
- Exhaust System Concerns: Visible Smoke (No Oil Consumption)
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Preliminary Checks | CARRY OUT preliminary checks. GO to DIAGNOSTIC SUBROUTINES PERFORMANCE DIAGNOSTIC PROCEDURES . CARRY OUT steps 1-4. VERIFY any concerns. |
| Atmospheric Pressure Rationality Check | GO to DIAGNOSTIC METHODS PARAMETER IDENTIFICATION (PID) . With KOEO, SELECT Parameter Identification (PID). SELECT PIDs: EP, MAP and BARO. If any PID values/readings deviate from atmospheric pressure in your locale by more than 10 kPa (1.5 psi), GO to the appropriate pinpoint test for the sensor with the largest difference. |
| Check Color Of Exhaust Smoke | NOTE: Some white tailpipe exhaust smoke is a normal condition at start-up with temperatures below 10°C (50°F) or with an extended idle in a cool climate. START the engine. If the exhaust smoke is white, GO to the next step. If the exhaust smoke is black, CHECK for charge air cooler restrictions. |
| Check White Tailpipe Exhaust Smoke | CARRY OUT the GLOW PLUG SYSTEM OPERATION Test. |
| Check Charge Air Cooler (CAC) for Restrictions | CHECK for any conditions that may restrict air flow through the charge air cooler. DISCONNECT the ducts at the CAC and CHECK for restrictions. CHECK inside of the CAC for restrictions. If there are any restrictions, CLEAN as necessary. VERIFY the repair. |
| Confirm Fuel Quality | If the concern is present, DRAIN the fuel tank. ADD known high quality diesel fuel to tank. If the amount of smoke is decreased, ADVISE the operator of need for a higher quality fuel. |
| Check For Out-of-Range Sensor | NOTE: Make sure the vehicle temperature is stabilized. SOAK the vehicle at ambient temperature for at least 8 hours. Verify no accessories are in use (engine block or oil heaters). CHECK the operation of: intake air temperature (IAT) sensor, manifold air temperature (MAT) sensor, engine oil temperature (EOT) sensor and engine coolant temperature (ECT) sensor. If the sensor temperature readings are not within 12 degrees, REFER to the applicable pinpoint test in PINPOINT TESTS - 6.0L DIESEL . |
| Check For Coolant Leak | REFER to ENGINE COOLING . |
| Check Thermostat Operation | REFER to ENGINE COOLING . |
| Isolate Engine Cylinders Generating Smoke | NOTE: When the vehicle is assembled, gaskets are not installed between the cylinder head and the exhaust manifold. If the exhaust manifold is separated from the cylinder head, gaskets must be installed. REMOVE the exhaust manifold attaching bolts. PRY the manifolds away from the cylinder head. START the engine. If a cylinder is generating excessive smoke, CHECK the compression. If not, TEST the glow plug(s). |
| Check Crankcase Pressure | CARRY OUT the CRANKCASE PRESSURE TEST . |
| Test Glow Plug | REMOVE the glow plug from the smoking cylinder. GROUND the body of the glow plug and INSTALL a jumper wire from the B+ source to the glow plug terminal. If the glow plug tip does NOT become hot, INSTALL a new glow plug. VERIFY the repair. |
| Switch Fuel Injectors | SWITCH injector(s) between a smoking and non-smoking cylinder(s). If the smoke moves with the injector(s), INSTALL new injector(s). VERIFY the repair. If not, REFER to ENGINE - 6.0L DIESEL . |
| Black Smoke | Check for air in the fuel. Test with a clear line at the pump inlet. REFER to FUEL TANK AND LINES for removing fuel lines. |
| Check EGR Operation | CARRY OUT EXHAUST GAS RECIRCULATION (EGR) POSITION Test. |
| Check Mass Air Flow Performance | GO to Pinpoint Test J . |
| NOTE |
|---|
| Some white tailpipe exhaust smoke is a normal condition at start-up with temperatures below 10°C (50°F) or with an extended idle in a cool climate. |
| NOTE |
|---|
| Make sure the vehicle temperature is stabilized. SOAK the vehicle at ambient temperature for at least 8 hours. Verify no accessories are in use (engine block or oil heaters). |
| NOTE |
|---|
| When the vehicle is assembled, gaskets are not installed between the cylinder head and the exhaust manifold. If the exhaust manifold is separated from the cylinder head, gaskets must be installed. |
Chart 10
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check ABS Light | REFER to ANTI-LOCK CONTROL . |
| Check Brake Warning Light | GO to Pinpoint Test AI if light is on. |
| Road Test | GO to DIAGNOSTIC METHODS PARAMETER IDENTIFICATION (PID) . SELECT Parameter Identification (PID). SELECT PIDs: PBPP, BPP1, BPP2, CPP/TCS, SCCS and VSS. DRIVE the vehicle and engage the speed control system. COMPARE the VSS to the speedometer. If the diagnostic tool does not display the correct values for each PID selected, GO to the appropriate pinpoint test. |
| Check Speed Control | If the speed control drops out when climbing hills, the engine power is not adequate to hold the hill. If it does not drop, GO to CHART NUMBER: 7. |
| Check Vehicle Load | If the vehicle load is too heavy to hold hills, CONFIRM the condition with VSS PID. If it holds hills, GO to CHART NUMBER: 7. |
Chart 11
- Warning Indicators: Tow Haul, Overdrive (OD) Cancel
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Tow Haul, OD Cancel | REFER to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS . |
Chart 12
- Automatic Transmission Shift Concerns: A/T Upshift, A/T Downshift, Engagement
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Check Automatic Transmission | REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . |
Chart 13
- Oil System Concerns: High Oil Consumption, Leaks
Carry out the following preliminary checks
- External leaks (rocker cover gasket, crankshaft seals).
- Correct oil viscosity and API rating. Refer to the Owner's Literature.
- Check air intake system: Air filter restriction gauge.
- Loads do not exceed maximum gross vehicle weight (GVW).
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Verify High Oil Consumption | CONFIRM the oil consumption through maintenance records or other documentation. If records are not available, have the customer log oil consumption for 1,450 km (900 miles). If the oil consumption rate is NOT greater than 0.95 liter (1 quart) per 1,450 km (900 miles), no problem exists. RETURN the vehicle to the customer. |
| Check Base Engine | CARRY OUT the CRANKCASE PRESSURE TEST . |
| Isolate Turbocharger | REMOVE the air duct at the turbocharger compressor housing outlet. REPEAT the crankcase pressure test. If the crankcase pressure decreases, INSTALL a new turbocharger. VERIFY the repair. If not, CHECK the turbocharger for an oil leak. REFER to FUEL CHARGING AND CONTROLS - TURBOCHARGER . |
OIL SYSTEM CONCERNS REFERENCE - HIGH OIL CONSUMPTION, LEAKS
Chart 14
Cooling System Concerns: Cooling Fan Does Not Operate
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Fan Clutch Components | GO to Pinpoint Test AH . |
| Cooling System | REFER to ENGINE COOLING . |
Chart 15
Cooling System Concerns: Cooling Fan Always On
Note. This chart is intended to only diagnose a cooling fan that always runs with a cool engine and the A/C and defroster off.
| SYSTEM/COMPONENT | REFERENCE ( PINPOINT TESTS - 6.0L DIESEL unless noted) |
|---|
| Fan Clutch Components/Circuits | GO to Pinpoint Test AH . |
| Cooling System | REFER to ENGINE COOLING . |
