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Engine Controls - Diagnostic Methods -- 6.0L Diesel: Other Ford Econoline E350 Super Duty

Testing & Diagnostics ~3099 words

Required Equipment

  1. Rotunda 73III Automotive Meter 105-R0057 or equivalent. Input impedance 10 megohm minimum.
  2. Adapter, Oil Pressure Leak Test 303-756 or equivalent
  3. Adapter, Compression Test 303-757 or equivalent
  4. Adapter, High Pressure Pump Test 303-765 or equivalent
  5. Adapter, High Pressure Rail Test 303-766 or equivalent
  6. Adapter Set, Oil High Pressure Leakage 303-1071 or equivalent
  7. Disconnect Tool, Quick Release Coupling 303-755 or equivalent
  8. ICP/EBC Adapter Cable 418-D003 (D94T-50-A) or equivalent
  9. Pressure Test Adapter Kit 014-00761 or equivalent
  10. Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent.
  11. Rotunda Worldwide Diagnostic System (WDS) 418-FS317, Vehicle Communication Module (VCM) with appropriate adapter cables, or diagnostic tool with functionality described under Diagnostic Tool Setup and Functionality
  12. Pressure Adapter Kit 014-00761 or equivalent

Optional Equipment

  1. R134A Manifold Gauge Set 176-R932A or equivalent.
  2. Non-powered test lamp.
  3. Vacuum/Pressure Tester 164-R0253 or equivalent. Range 101.3 kPa (0.30 in-Hg). Resolution 3.4 kPa (1 in-Hg).

Note. Refer to equipment user manual for details on tool accessories and function.

Communication Error

It is possible to get a test fail error from a diagnostic tool when initiating a test or viewing PIDs. The communication error could be caused by operator error, the vehicle wiring or connectors, or the powertrain control module (PCM) and other control modules connected to the DLC wiring. The PCM responds to a diagnostic tool whenever the diagnostic tool requests a test. Some are normal responses to valid requests. The others are communication error responses. If the diagnostic tool displays any of the test fail error responses, reinitialize the diagnostic tool. If the error is still present, GO to Pinpoint Test AE , after checking the diagnostic tool connections, cable/adapters, and entry of vehicle information. Verify the power take-off system or auxiliary idle control (if equipped) is off when trying to carry out the self-tests.

Output State Control (OSC)

The OSC aids in diagnosing output actuators associated with the PCM. It allows the technician to energize and de-energize most of the system output actuators on command.

Malfunction Indicator Lamp (MIL) DTCs

MIL DTCs are generated to alert the driver that there is a concern with the system or the vehicle is in failure management effects mode (FMEM). MIL DTCs are also used to indicate an emission concern. Non-MIL DTCs indicate a less serious or non-emission related concern with the system.

Special Notes

Before carrying out the Quick Test, always carry out the necessary visual checks and safety precautions listed below.

Visual Check

  1. Inspect the air cleaner and inlet ducting.
  2. Check the system wiring harness for proper connections, bent or broken pins, corrosion, loose wires, and proper routing.
  3. Check the powertrain control module (PCM), sensors, and actuators for physical damage.
  4. Check the engine coolant for proper level and mixture.
  5. Check the transmission fluid level and quality.
  6. Make all necessary repairs before continuing with the Quick Test.

Vehicle Preparation

  1. Carry out all of the safety steps required to start and run the vehicle tests. Apply the parking brake, place the gear selector lever firmly into the PARK position (NEUTRAL on manual transmission), and block the drive wheels.
  2. Turn off all electrical loads - radios, lights, A/C, blower, and fans.
  3. Start the engine and bring it up to normal operating temperature before carrying out the Quick Test.

Retrieve/Clear Continuous Memory DTCs

Connect the diagnostic tool. Turn off all accessories. Turn the air conditioning (A/C) off. 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 self-tests.

  1. Carry out the necessary vehicle preparation and visual inspection. Refer to «QUICK TEST OPERATION.»(ref-232983-S35877238962006052300000)
  2. Refer to the manufacturer's manual for diagnostic tool instructions.

Note. The following steps must be carried out for the powertrain control module (PCM) and the transmission control module (TCM).

  1. Key on, engine off.
  2. Select retrieve/clear continuous memory DTCs.
  3. Follow the operating instructions from the menu.
  4. Record the diagnostic trouble codes (DTCs) and follow the appropriate pinpoint test for continuous memory DTC diagnostics.
  5. After the test, cycle the key to the OFF position before running other tests or driving the vehicle.
  6. Continuous memory DTCs must be cleared after a repair is made.

KOEO/KOER Output State Control (OSC)

Connect the diagnostic tool. Turn off all accessories. Turn the air conditioning (A/C) off. 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 self-tests. The outputs will be limited during KOEO output state control.

  1. Carry out the necessary vehicle preparation and visual inspection. Refer to «QUICK TEST OPERATION.»(ref-232983-S35877238962006052300000)
  2. Refer to the manufacturer's manual for diagnostic tool instructions.
  3. Select KOEO/KOER output state control.
  4. Follow any special instructions on the screen.
  5. Use the diagnostic tool to access output PIDs.
  6. Cycle the output state on the exhaust gas recirculation (EGR), injection control pressure (ICP), fuel injectors, visctronic drive fan (VDF), variable geometry turbocharger (VGT), engine RPM, and fuel pump.
  7. Select PIDs.
  8. Activate OSC.
  9. After the test, cycle the key to the OFF position before running other tests or driving the vehicle.
  10. Clear all of the DTCs.

Accumulating Powertrain Control Module (PCM) Data

Accumulating PCM data can be done in a number of ways. Gather as much data as possible when the malfunction is occurring to prevent misdiagnosis. Data should be accumulated in different operating conditions and based on the customer description of the intermittent fault. Acquisition of PCM parameter identification (PID) data using a diagnostic tool is one of the easiest ways to gather information.

For information on the functions of your diagnostic tool, refer to the manufacturer's manual for diagnostic tool instructions.

Below is a list of the functions available

  1. Selecting and viewing PIDs
  2. Storing PIDs
  3. Recording measurements along with PIDs
  4. Playback of stored PIDs
  5. Peripheral inputs

Comparing PCM Data

After the PCM values have been acquired, it is necessary to determine the fault area. Typically, it requires the comparison of the actual values from the vehicle to the typical values. Refer to CONTROL SYSTEM DIAGNOSTIC SHEET REFERENCE .

Various Data Procedures

Once the fault area is identified, the circuit must be checked to determine if the wiring or component is at fault. Use any of the following methods to diagnose a suspected PCM wire circuit or device. Some methods are particular to a certain type of PCM device.

  1. Change Condition to Cause Response by Input
  2. Change Input and Verify Output Response
  3. Click Testing/Output State Control
  4. Coil Resistance (Solenoids/Relays)
  5. Harness Opens
  6. Harness Shorts

Change Condition to Cause Response by Input

The purpose is to verify the sensor receives and responds to changes.

  1. Access, monitor, and record the appropriate sensor PID(s).
  2. Create the condition or cause the condition to change.
  3. If the value changes appropriately, then it should be operating OK. Examples: View the engine oil temperature (EOT) PID while the engine warms. It should change from a higher voltage (2.6 volts) for a cold engine, to a lower voltage as the engine warms (0.6 volts). Apply and release the accelerator pedal while monitoring the accelerator pedal position (APP) PID for a change of state. Apply and release the brake pedal while monitoring the brake pedal position (BPP) PID for a change of state.

Change Input and Verify Output Response

The purpose is to verify how the PCM and actuator circuit responds to sensor input.

  1. Access and monitor the appropriate sensor PID(s).
  2. Create the condition to cause the input condition to change.
  3. Monitor the change (response) in the actuator PID or the actuator signal circuit with a measuring device. Example: Increase the accelerator pedal position under load, and observe the RPM DSD PID and circuit change.

Coil Resistance (Solenoids/Relays)

The purpose is to measure the resistance value of the device.

  1. Key OFF.
  2. Disconnect the component from the vehicle harness.
  3. Using an ohmmeter, measure across the component terminals in question.

Accessing the PID Data Monitor

  1. Refer to the manufacturer's manual for diagnostic tool instructions.

On-Board Diagnostic (OBD) Pending Diagnostic Trouble Codes (DTCs)

Pending DTCs are DTCs that have only set during one drive cycle and may not have set the malfunction indicator lamp (MIL) yet. These DTCs may be identified using the retrieve pending DTCs feature. Additionally, they are found in the vehicle-specific mode retrieve/clear continuous memory DTCs from the instant that the DTC is set.

This function only reports pending failures that have occurred during the present drive cycle, but does not indicate single failures that occurred on any previous drive cycle.

  1. Refer to the manufacturer's manual for diagnostic tool instructions.

Misfire Monitoring Supported

This menu can be used to determine if the misfire monitoring system is supported on your particular application. All emission-equipped 6.0L diesel vehicles under 14,000 lbs use misfire detection. When selecting this function, a message is displayed on the screen: test not supported by this module or test supported by this module.

Comprehensive Component Monitoring Supported

This menu can be used to determine if the comprehensive component monitoring system is supported on your particular application. All emission-equipped 6.0L diesel vehicles under 14,000 lbs use comprehensive component monitoring. When selecting this function, a message is displayed on the screen: test not supported by this module or test supported by this module.

Misfire Monitoring Status

This menu can be used to determine the status of the misfire monitoring system on your particular application. All emission-equipped 6.0L diesel vehicles under 14,000 lbs use misfire detection. When selecting this function, a message is displayed on the screen: test complete, or not applicable or test not complete.

Comprehensive Component Monitoring Status

This menu can be used to determine the status of the comprehensive component monitoring system on your particular application. All emission-equipped 6.0L diesel vehicles under 14,000 lbs use comprehensive component monitoring. When selecting this function, a message is displayed on the screen: test complete, or not applicable or test not complete.

Power-Takeoff (PTO) Status

This menu can be used to determine the status of the power take-off (PTO) system or auxiliary idle control on your particular application. Some transmission OBD monitors are disabled during PTO operation. The vehicle must be out of PTO mode to clear P1000. When selecting this function, a message is displayed on the screen: PTO active or PTO inactive.

Accessing Freeze Frame PID Data

  1. Refer to the manufacturer's manual for diagnostic tool instructions.

OBD PID Data Monitor

The PID monitor for OBD offers real time evaluation of several emissions-related parameters. Most of these are related to the HO2S, for which the diesel has no equivalent.

Making Changes to the VID Block

A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool.

Drive Cycle Procedure

  1. Key ON. Do not crank until the WAIT TO START light cycles, or at least 10 seconds, whichever occurs first.
  2. Start the engine. Idle in PARK or NEUTRAL for 40 seconds.
  3. Before continuing, engine oil temperature (EOT) must exceed 60°C (140°F).
  4. The following outlines the appropriate conditions for running certain OBD monitors that require the engine to be under load: Accelerate steadily to third gear (M/T use fourth gear) and hold at 1,500 RPM for 3 seconds. Accelerate steadily from 56 km/h (35 mph) to 105 km/h (65 mph) over approximately 15 seconds (M/T 11 seconds minimum). Repeat Step a three times while maintaining the conditions in Step a Before proceeding, turn all accessories off and disengage tow/haul/overdrive cancel.
  5. Idle the vehicle for 20 seconds in PARK or NEUTRAL.
  6. Key OFF.
  7. Start the engine. Idle in PARK or NEUTRAL for 40 seconds.
  8. Repeat the Quick Test.

Note. If P1000 is present after running the drive cycle

  1. Repeat Step a , being certain to maintain a minimum mass fuel desired (MFDES) of 35 mg/stroke above 2,000 RPM for 11 seconds. Also, maintain a minimum MFDES of 30 mg/stroke above 2,800 RPM for at least 6 seconds.
  2. Repeat Step 8 MFDES must remain below 12 mg/stroke for 11 consecutive seconds.
  1. Refer to the manufacturer's manual for diagnostic tool instructions.

OBD Pending DTCs

Pending DTCs are DTCs that have only set during one drive cycle and may not have set the MIL yet. These DTCs can be identified using the retrieve pending DTCs feature. Additionally, they are found in the vehicle-specific mode retrieve/clear continuous memory DTCs from the instant the DTC is set.

This function only reports pending failures that have occurred during the present or previous drive cycle, but does not indicate single failures that happened on any 2 previous drive cycles.

  1. Refer to the manufacturer's manual for diagnostic tool instructions.

Recreating the Fault

Recreating the fault is the first step in isolating the cause of the intermittent symptom. If freeze frame data is available, it may help in recreating the conditions at the time of a malfunction indicator lamp (MIL) diagnostic trouble code (DTC). Listed below are some of the conditions for recreating the fault.

Engine Type ConditionsNon-Engine Type Conditions
Engine TemperatureAmbient Temperature
Engine RPMMoisture Conditions
Engine Load Engine idle/accel/decelRoad Conditions (smooth, bumpy)

RECREATE FAULT CONDITIONS

Accumulating PCM Data

PCM data can be accumulated in a number of ways. Gather as much data as possible when the malfunction is occurring to prevent misdiagnosis. Data should be accumulated during different operating conditions and based on the customer description of the intermittent fault. Reference the known good data values located in CONTROL SYSTEM DIAGNOSTIC SHEET REFERENCE . This requires recording data in 4 conditions for comparison: 1) Key On Engine Off (KOEO), 2) Hot Idle, 3) 48 km/h (30 mph), and 4) 89 km/h (55 mph). Acquisition of PCM PID data using a diagnostic tool is one of the easiest ways to gather information.

For information on the functions of your diagnostic tool, refer to the manufacturer's manual for diagnostic tool instructions.

Below is a list of the functions available

  1. Selecting and viewing PIDs
  2. Storing PIDs
  3. Recording measurements along with PIDs
  4. Playback of stored PIDs
  5. Peripheral inputs

After the PCM values have been acquired, it is necessary to determine the fault area. Typically, it requires the comparison of the actual values from the vehicle to the typical values. Refer to CONTROL SYSTEM DIAGNOSTIC SHEET REFERENCE .

Analyzing PCM Data

Once the fault area is identified, the circuit must be checked to determine if the wiring or component is at fault. When making circuit and component measurements, make sure all accessories and dome and hood lamps are off. Use any of the following methods to diagnose a suspected PCM wire circuit or device. Some methods are particular to a certain type of PCM device.

  1. Change Condition to Cause Response by Input
  2. Change Input and Verify Output Response
  3. Click Testing/Output State Control (Solenoids/Relays)
  4. Coil Resistance (Solenoids/Relays)
  5. Harness Opens
  6. Harness Shorts

Change Conditions to Cause Response by Input

The purpose is to verify the sensor receives and responds to changes.

  1. Access, monitor, and record the appropriate sensor PID(s).
  2. Create the condition or cause the condition to change.
  3. If the value changes appropriately, then it should be operating OK. Examples: The engine oil temperature (EOT) should change from a higher voltage (2.6 volts) for a cold engine, to a lower voltage as the engine warms (0.6 volts). Apply and release the accelerator pedal while monitoring the accelerator pedal position (APP) PID for a change of state. Apply and release the brake pedal while monitoring the brake pedal position (BPP) PID for a change of state.

The purpose is to verify how the PCM and actuator circuit respond to sensor input.

  1. Access, monitor, and record the appropriate sensor PID(s).
  2. Create the condition or cause the input condition to change.
  3. Monitor any change (response) in the actuator PID or actuator signal circuit with a measuring device.

The purpose is to measure the correct resistance value of a device.

  1. Key OFF.
  2. Disconnect the component from the vehicle harness.
  3. Using an ohmmeter, measure across the component terminals.

Glow Plug Lamp Cycles On/Glow Plugs Recycle/Engine Stumble/Stalls/No Accelerator Pedal Authority Until Return to Idle Position

A PCM reset occurs when the PCM momentarily reboots or is turned off and on while the engine is operating. If the condition occurs a single time, the engine momentarily stumbles and the PCM goes through a normal key on cycle, including turning the glow plug lamp and glow plugs on, and also attempts to validate the accelerator pedal position. If the pedal is not at the idle position when this fault occurs, pedal authority is not allowed by the PCM until the accelerator pedal is released and the engine returns to idle.

Probable Causes

  1. Momentary loss of power to the PCM or fuel injection control module (FICM): power relays, shorted or open harness, intermittent connectors, grounds.
  2. Momentary short to ground of VREF: shorted harness or connector, sensor (sensors that use VREF include exhaust pressure (EP) sensor, injection control pressure (ICP) sensor, manifold absolute pressure (MAP) sensor, barometric pressure (BARO) sensor, accelerator pedal position (APP) sensor, and exhaust gas recirculation (EGR) sensor).

Procedures

  1. Check all power and ground connections for the PCM and FICM.
  2. Inspect the CMP sensor and CKP sensor harness connectors and the harness for a signal short to ground condition.
  3. Remove and inspect the camshaft position (CMP) sensor and crankshaft position (CKP) sensor for possible damage.
  4. If the PCM reset condition is repeatable, disconnect the following sensors one at a time and operate the engine to determine if the reset reoccurs: EP sensor, ICP sensor, MAP sensor, APP sensor, EGR sensor. Inspect each harness, including the connector, upon removal.

Note

  1. The suspect circuit must be isolated before testing.
  2. When disconnecting any harness connector, always inspect for damaged or pushed-out pins, corrosion, and loose wires. Repair as necessary.
  3. The digital multimeter (DMM) must be set to the correct scale.
  4. The techniques do no apply in all situations; therefore, it is necessary to carry out each pinpoint test step accurately and completely.
  5. General resistance and voltage values are specified below. Always use the pinpoint test values if they differ.
  6. Always turn the key to the OFF position unless directed otherwise by the pinpoint test.

Each of the following procedures requires the powertrain control module (PCM) and component to be disconnected to isolate the harness.

Open Circuit (Continuity)

Disconnect the appropriate PCM harness. Measure the harness resistance between the suspect circuit at the harness connector and the appropriate PCM harness pin. The resistance must be less than 5 ohms.

Shorts to Ground

Measure the harness resistance between the suspect circuit at the harness connector and a reliable ground (B-, chassis or power ground [PWR GND] at the PCM harness). The resistance must be greater than 10,000 ohms.

Shorts to Power

Key ON to power up the circuit. Measure the voltage between the suspect circuit at the harness connector and a reliable ground. The voltage must be less than 0.2 volt.

More articles — Engine Controls - Diagnostic Methods -- 6.0L Diesel