Engine Controls - Tests W/o Codes - 7.3l Diesel (VIN K & M) Ford Econoline E350

INTRODUCTION

Before diagnosing symptoms or intermittent faults, perform steps in F - BASIC TESTING - 7.3L DIESEL (VIN K & M) and G - TESTS W/CODES - 7.3L DIESEL (VIN K & M) articles. Use this article to diagnose existing driveability problems when a hard fault code is not present or vehicle is not equipped with a self-diagnostic system.

Symptom checks can direct technician to malfunctioning component(s) for further diagnosis. A symptom should lead to a specific component or system test and/or adjustment.

Use intermittent test procedures to locate driveability problems that DO NOT occur when vehicle is being tested. These test procedures should also be used if a soft (intermittent) trouble code was present, but no problem was found during self-diagnostic testing.

EVALUATING NORMAL DIESEL EXHAUST SMOKE

The following is a description of what is normal and expected exhaust smoke for a vehicle with a diesel engine. Diesel exhaust smoke can be classified into 2 categories according to the color of the smoke.

Blue/White Smoke

Blue/White smoke may be observed at engine start-up, whether the engine is up to operating temperature or not. This start-up smoke will be observed at all ambient temperatures and should last no longer than a minute after the vehicle is driven.

When ambient temperature is below 50°F (10°C), Blue/White smoke can return after engine warm-up, due to extended idling. This is caused by the combustion chambers cooling down during periods of extended idling.

Heavy Blue/White Smoke

Heavy Blue/White smoke will occur when the engine is operated at wide open throttle with the transmission in Neutral or with a lightly loaded vehicle in any gear. The smoke is a normal characteristic for a diesel engine with a light minimum-maximum governor spring in the fuel injection pump. This results in the following characteristics due to the engine operating above its rated speed (3300 RPM) in a no-load or lightly loaded condition

1. Heavy Blue/White smoke.
2. Fuel injection pump governor hunting resulting in high speed engine RPM surging.
3. Engine sputtering or missing.

The condition can be eliminated by not operating the engine above its maximum full load rated speed of 3300 RPM.

Note. Chassis fuel system air leaks may also cause continuous heavy Blue/White smoke.

Black Smoke

Black smoke occurs whenever the engine is working hard. The engine works hard when it is going up a steep grade, pulling a trailer, carrying a heavy load, or during acceleration. More Black smoke will be observed when operating the vehicle at higher altitudes. If Black smoke is observed while the engine is idling (at low altitude) or under normal driving conditions, the problem should be diagnosed as soon as possible.

ENGINE CRANKS BUT WILL NOT START (ENGINE COLD)

Note. If ignition switch is left in the ON position for an extended period of time or the engine is not started within the 2 minute cycle time, the glow plug system must be reset by turning the ignition switch to the OFF position.

1. Check and follow correct starting procedure. Correct starting procedure is located on driver's side sun visor. If vehicle does not start using correct starting procedure, go to next step. If vehicle starts, testing is complete.
2. With hood open, listen for glow plug module power relay click when ignition switch is turned to ON position. The glow plug module power relay is mounted on top of solid-state glow plug module circuit board. The complete assembly is mounted on rear of intake manifold. If relay clicks, go to next step. If relay does not click, go to «GLOW PLUG TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__glow-plug-testing) under COMPONENT TESTS.
3. Loosen one injector nozzle line nut one-half to one turn. Crank engine and observe injector line. If fuel is discharged from loosened injector line, go to «GLOW PLUG TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__glow-plug-testing) under COMPONENT TESTS. If fuel is not discharged from loosened injector line, tighten injector line nut and go to next step. NOTE: Because or terminology revision, Fuel Shutoff (FS) solenoid is now referred to as Energize-To-Run (ETR) solenoid.
4. Crank engine and check voltage at Energize-To-Run (ETR) solenoid. ETR solenoid terminal is located at front of injection pump. Voltage must be at least 9 volts. Check ETR solenoid terminal for dirt, corrosion, or loose or broken electrical connection. Repair or replace as necessary. If solenoid terminal and electrical connection are okay and at least 9 volts are present while cranking, go to next step. If at least 9 volts is not present, check Red/Light Green wire from ETR solenoid to ignition switch. Repair wire as necessary, and repeat this test. (Scheme 266)
5. Crank engine and check voltage at Cold Advance (CA) solenoid. CA solenoid is located at left rear of injection pump. Voltage must be at least 9 volts. If at least 9 volts are present, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis). If at least 9 volts are not present, verify switching function of Engine Temperature Switch (ETS), located behind thermostat housing. If at least 9 volts are not present at ETS, check Red/Light Green wire from ETS to ignition switch. Repair wire as necessary, and repeat this test. (Scheme 266)

Scheme 266

ENGINE CRANKS BUT WILL NOT START (ENGINE WARM)

1. Check and follow correct starting procedure. Correct starting procedure is located on driver's side sun visor. If vehicle does not start using correct starting procedure, go to next step. If vehicle starts, return vehicle to customer.
2. Loosen one injector nozzle line nut one-half to one turn. Crank engine and observe injector line. If fuel is discharged from loosened injector line, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis). If fuel is not discharged from loosened injector line, tighten injector line nut and go to next step. NOTE: Fuel Shutoff (FS) solenoid is now called Energize-To-Run (ETR) solenoid.
3. Crank engine and check voltage at Energize-To-Run (ETR) solenoid. ETR solenoid terminal is located at front of injection pump. Voltage must be at least 9 volts. Check ETR solenoid terminal for dirt, corrosion, or loose or broken electrical connection. Repair or replace as necessary. If solenoid terminal and electrical connection are okay and at least 9 volts are present while cranking, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis). If at least 9 volts are not present, check Red/Light Green wire from ETR solenoid to ignition switch. Repair wire as necessary, and repeat this test. (Scheme 266)

ENGINE QUITS, STALLS OR STUMBLES

1. Check and/or adjust dynamic injection pump timing. See DYNAMIC INJECTION TIMING in the ADJUSTMENTS - DIESEL article. If injection pump timing and idle speed is correct, go to next step. NOTE: Fuel Shutoff (FS) solenoid is now called Energize-To-Run (ETR) solenoid.
2. Crank engine and check voltage at Energize-To-Run (ETR) solenoid. ETR solenoid terminal is located at front of injection pump. Voltage must be at least 9 volts. Check ETR solenoid terminal for dirt, corrosion, or loose or broken electrical connection. Repair or replace as necessary. If solenoid terminal and electrical connection are okay and at least 9 volts are present while cranking, go to next step. If at least 9 volts are not present, check Red/Light Green wire from ETR solenoid to ignition switch. Repair wire if necessary, and repeat test. (Scheme 266)
3. If engine is hot, go to next step. If engine is cold, crank engine and check voltage at Cold Advance (CA) solenoid. CA solenoid is located at left rear of injection pump. Voltage must be at least 9 volts. If at least 9 volts are not present, verify switching function of Engine Temperature Switch (ETS), located behind thermostat housing. If at least 9 volts are not present at ETS, check Red/Light Green wire from ETS to ignition switch. Repair wire as necessary, and repeat this test. (Scheme 266)
4. If engine is hot, crank engine and check for voltage at Cold Advance (CA) solenoid. CA solenoid is located at left rear of injection pump. Voltage should not be present. If voltage is not present at CA solenoid, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis). If voltage is present, replace engine temperature switch and repeat this step.

ENGINE MISSES

Note. Engine will miss when cold if one or more glow plugs are not heating.

1. If engine misses only when cold, go to «GLOW PLUG TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__glow-plug-testing) under COMPONENT TESTS. If engine misses at normal operating temperature, go to next step.
2. Run engine at RPM which causes misfire. Momentarily loosen injector line nut on one injector one turn or less and tighten connection. Check each cylinder in the same manner. If miss is not isolated to a specific cylinder, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis) . If misfire is isolated to a specific cylinder(s), go to next step.
3. Check injection nozzle line(s) for kinks or restrictions. Replace any line that is kinked or restricted. Remove suspect nozzle(s) from engine and test. See «INJECTION NOZZLE TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__injection-nozzle-testing) under COMPONENT TESTS. Replace any nozzle that does not pass test. If lines and nozzles are okay, go to next step.
4. Perform cylinder compression test. See MECHANICAL CHECKS in SPECIFICATIONS article. If cylinder compression is within specifications, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis) . If cylinder compression is not within specifications, perform CRANKCASE PRESSURE TEST under ENGINE PERFORMANCE DIAGNOSIS. If crankcase pressure is okay, repair or replace valve train as necessary. If crankcase pressure is excessive, overhaul power cylinder as necessary.

ENGINE KNOCKS

1. Ensure all engine driven accessories are operating properly and are not causing knock. Verify that engine is not overheating. If engine is overheating, determine cause and repair as necessary. If engine is not overheating, go to next step.
2. Momentarily loosen injector line nut on one injector one turn or less and tighten connection. Check each cylinder in the same manner. If knock is not isolated to a specific cylinder, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis) . If knock is isolated to a specific cylinder(s), go to next step.
3. Check injection nozzle line(s) for kinks or restrictions. Replace any line that is kinked or restricted. Remove suspect nozzle(s) from engine and test. See «INJECTION NOZZLE TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__injection-nozzle-testing) under COMPONENT TESTS. Replace any nozzle that does not pass test. If lines and nozzles are okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis) .

LOW OIL PRESSURE (WITH PROPER OIL)

1. Using Pressure Tester Kit (014-00761) and Adapter (5633), verify accuracy of oil pressure sender. If oil pressure sender is accurate and operating normally, go to next step. If oil pressure sender is not accurate, replace sender and repeat this step.
2. Change engine oil and filter. Operate engine until engine reaches normal operating temperature. Check oil pressure. If oil pressure is okay, return vehicle to customer. If oil pressure is unsatisfactory, repair or replace lubrication system components as necessary.

BLUE/WHITE SMOKE (ENGINE AT NORMAL OPERATING TEMPERATURE)

1. If engine is not at normal operating temperature, go to next step. If engine is at normal operating temperature and go to step 3).
2. Remove the thermostat and test for proper operation. Replace as necessary. If thermostat is operating properly, replace thermostat housing with integral air bleed valve and repeat step 1). If the thermostat is not operating properly, replace thermostat and repeat step 1).
3. Check engine oil level and add if necessary. If oil level is correct, go to next step. If oil level is too high, drain excess oil. If problem still exists, go to next step.
4. Perform «CHECK FUEL RETURN PRESSURE»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-fuel-return-pressure) test under ENGINE PERFORMANCE DIAGNOSIS. If fuel return pressure is okay, perform entire «ENGINE PERFORMANCE DIAGNOSIS»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__engine-performance-diagnosis) . If fuel return pressure is high, repair or replace fuel return line(s) as necessary.

EXCESSIVE BLACK SMOKE

1. If smoke occurs under light load and/or low altitude, go to next step. If smoke occurs under heavy load, this is normal when going up steep grades, pulling a trailer, maximum load, maximum acceleration or at high altitudes.
2. Visually inspect exhaust system for dents or kinks which could cause restriction. If exhaust system is okay, go to next step. If dents, kinks or restriction is found, repair or replace exhaust system as necessary. If problem still exists, go to next step.
3. Perform «CHECK AIR INTAKE RESTRICTION»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-air-intake-restriction) test under ENGINE PERFORMANCE DIAGNOSIS. If air intake restriction check is okay, go to next step. If air intake restriction is found, replace air filter element and/or repair system and repeat this test.
4. Check and/or adjust dynamic injection pump timing. See DYNAMIC TIMING in ADJUSTMENTS article. If injection pump timing and idle speed is correct, go to next step.
5. Check injection nozzle line(s) for kinks or restrictions. Replace any line that is kinked or restricted. Remove injection nozzles from engine and test. See «INJECTION NOZZLE TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__injection-nozzle-testing) under COMPONENT TESTS. Replace any nozzle that does not pass test. If lines and nozzles are okay, replace injection pump.

ENGINE PERFORMANCE DIAGNOSIS

Note. Repair each problem detected before going on to the next step. If repair corrects the original complaint, it will not be necessary to proceed to the next step. However, if complaint is not corrected, continue with the test until complaint is corrected.

CHECK FOR EXTERNAL LEAKAGE

With engine running, visually inspect for leakage of fuel, engine oil and coolant. Ensure air cleaner is properly installed and dirt is not getting past element. If no leakage is found, go to next test. If leakage is found, repair or replace faulty component(s) as necessary and go to next test.

CHECK EXHAUST SYSTEM

Visually inspect exhaust system for dents or kinks which could cause restriction. If exhaust system is okay, go to next test. If dents or kinks are found, repair or replace faulty component(s) as necessary and go to next test.

CHECK FOR AIR IN FUEL

1. Install a length of clear PVC hose in place of rubber hose between fuel filter outlet and injection nozzle return system. Run engine at 3000 RPM and check for bubbles in clear hose. Fuel should flow from fuel filter/water separator toward fuel return system. On vehicles with dual tanks, check with tank selector valve in each position for a minimum of 2 minutes.
2. If fuel flow direction is okay and bubbles are less than 1/16" diameter, go to next test. If fuel flow direction is okay and bubbles are greater than 1/16" diameter, go to «FUEL SYSTEM AIR LEAK TESTING»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__fuel-system-air-leak-testing) under COMPONENT TESTS. Repeat this test when air leaks are eliminated. If fuel flow direction is not correct, go to «CHECK FUEL RETURN PRESSURE»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-fuel-return-pressure) test. Repeat this test when fuel flow direction is corrected.

CHECK FOR FUEL CONTAMINATION

Obtain a fuel sample and visually examine fuel in a clear container (including bottom of container) for particles, clouding, or liquid contamination, such as water. If fuel sample is okay, go to next test. If fuel sample is contaminated, replace fuel filter. Clean and/or replace fuel system as necessary. Ensure fuel is clean and go to next test.

CHECK FUEL FOR CETANE VALUE

1. Using Cetane Tester included in Dynamic Timing Meter (078-00200), check cetane value of fuel sample taken in previous test. Temperature of fuel must be 75-95°F (24-36°C) to obtain accurate results. Fill hydrometer container with fuel until hydrometer floats. Spin container gently to break surface tension of fuel. Read number at lowest point of fuel level in hydrometer. Compare readings to «DIESEL FUEL CETANE VALUES»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m) table to determine cetane value. DIESEL FUEL CETANE VALUES Hydrometer Reading Cetane Value .837 50 .846 47 .849 46 .858 43 .862 42 .876 38
2. Cetane value should be a minimum of 40. If cetane value is greater than 40, go to next test. If cetane value is less than 40, inform owner to change fuel source. DO NOT replace fuel injection pump because of low cetane problem.

CHECK FUEL RETURN PRESSURE

Remove fuel return line at junction fitting at left rear of engine. Install Adapter (5663) and Pressure Test Kit (014-00761) to fuel supply pump inlet. (Scheme 267) Connect fuel return hose removed in FUEL FILTER OUTLET PRESSURE test. Run engine at 3300 RPM, with no load and transmission in Neutral or Park. Record pressure reading. On dual tank vehicles, check both tanks. Maximum pressure should not exceed 2 psi at 3300 RPM. If pressure does not exceed 2 psi at 3300 RPM, go to next test. If pressure exceeds 2 psi at 3300 RPM, repair or replace fuel return line(s) as necessary and repeat this test.

FUEL FILTER OUTLET PRESSURE

Remove air bleed orifice hose from fuel filter fitting. Install Adapter (5651) and Pressure Test Kit (014-00761). (Scheme 267) Run engine at 3300 RPM, with no load. Record pressure reading. On dual tank vehicles, check both tanks. Pressure should be a minimum of one psi at 3300 RPM. If pressure is at least one psi at 3300 RPM, go to FUEL PUMP CAPACITY test. If pressure is less than one psi at 3300 RPM, go to next test.

Scheme 267

FUEL SUPPLY PUMP OUTLET PRESSURE

Remove vacuum purge valve from fuel filter adapter. Install Adapter (3019) and Pressure Test Kit (014-00761). (Scheme 267) Ensure hose clamp is closed on sampling hose. Leave adapter from previous test installed and cap end. Run engine at idle, no load. Record pressure reading. On dual tank vehicles, check both tanks. Pressure should be at least 2 psi at idle. If pressure is at least 2 psi at idle, replace fuel filter and repeat FUEL FILTER OUTLET PRESSURE test. If pressure is not less than 2 psi at idle, go to next test.

FUEL PUMP CAPACITY

Position end of sample hose on Adapter (3019) in clear, one quart, graduated container. Follow procedures for FUEL SUPPLY PUMP OUTLET PRESSURE test and open clamp on sample hose, allowing fuel to flow into fuel container, for 30 seconds. Record volume. On dual tank vehicles, check both tanks. Volume should be at least one pint in 30 seconds at idle, no load. If pressure and volume are okay, go to CHECK FUEL RETURN PRESSURE test. If pressure is okay and volume is not, go to next test. If volume is okay and pressure is not, replace fuel supply pump and repeat FUEL FILTER OUTLET PRESSURE test. If pressure and volume are both inadequate, go to next test.

CHECK RESTRICTION AT FUEL SUPPLY PUMP

Connect fuel return line removed in FUEL FILTER OUTLET PRESSURE test. Install Adapter (5632) and Pressure Test Kit (014-00761) to fuel supply pump inlet. (Scheme 267) With rear wheels off the ground and transmission in Neutral or Park, run engine at 3300 RPM. Record vacuum reading. On dual tank vehicles, check both tanks. Vacuum reading should be less than 6 in. Hg. If vacuum reading is less than 6 in. Hg, go to next test. If vacuum is greater than 6 in. Hg, repair or replace restricted chassis fuel line(s) and repeat FUEL FILTER OUTLET PRESSURE test.

CHECK AIR INTAKE RESTRICTION

Remove cap on air cleaner test port and install Adapter (5650) and Pressure Test Kit (014-00761) to fuel supply pump inlet. (Scheme 267) Run engine at 3300 RPM, with no load. Record restriction reading. Restriction should not exceed 25" of H2O. If reading is more than 2" of H2O but less than 25" of H2O, remove adapter. Install cap on air cleaner port and go to next test. If reading is 25" of H2O or greater, replace air filter element and check intake system for blockage. Repeat this test. If reading is less than 2" of H2O, correct restriction in fitting on air cleaner test port and repeat this test.

CHECK INJECTION PUMP TRANSFER PRESSURE

1. Remove screw from transfer pump pressure port cover. Install Transfer Pump Pressure Adapter (T83T-9000-A) through cover and "O" ring and into port. Install Pressure Test Kit (014-00761) (Scheme 267) Ensure fittings are tight and not leaking. Run engine at 3300 RPM, with no load and transmission in Neutral or Park. Record pressure reading. Pressure reading should be 90-110 psi.
2. If pressure reading is 90-110 psi, go to next test. If pressure reading is not as specified, replace injection pump. If performance problem still exists after installing new injection pump, check and adjust injection pump dynamic timing. See DYNAMIC INJECTION PUMP TIMING. If problem still exists after adjusting timing, go to next test.

FUEL INJECTION PUMP LEVER (FIPL) SENSOR

This sensor may also be referred to as Throttle Position Sensor (TP or TPS). Faults in FIPL sensor or circuit should set a service code. See QUICK TEST procedure in G - EEC-IV TESTS W/ CODES article. If no service code has been set, see CIRCUIT TEST DQ in G - EEC-IV TESTS W/ CODES article for additional sensor testing and specifications. Ensure none of the following conditions exist

1. Binding throttle or speed control linkage.
2. Idle speed and throttle stop improperly adjusted.
3. Choke/high cam system sticking.

ACCELERATOR LINKAGE ADJUSTMENT

With engine off, ensure throttle lever stop screw contacts injection pump stop at full accelerator pedal depression. If adjustment is correct, go to next test. If adjustment is not correct, adjust or repair throttle linkage as necessary and go to next test.

CHECK ENGINE IDLE SPEED

Using tachometer, check curb idle speed. Idle speed should be 600-700 RPM in Neutral (man. trans.) or Drive (auto. trans.). If idle speed is correct, go to next test. If idle speed is not as specified, adjust as necessary and go to next test.

ENGINE RPM SENSOR (RPMS)

This sensor is used only on diesel engines. Disconnect RPMS electrical connector. Using DVOM, measure resistance across sensor terminals. Resistance should be 2400-2800 ohms. Replace sensor if not as specified. Faults in RPMS or sensor circuit should set a service code. See QUICK TEST procedure in G - EEC-IV TESTS W/ CODES article. If no service code has been set, see CIRCUIT TEST DJ in G - EEC-IV TESTS W/ CODES article for additional sensor testing and specifications.

Note. Engine must be at normal operating temperature of 192-212°F (89-100°C) when checking/setting dynamic timing.

DYNAMIC INJECTION PUMP TIMING

1. Bring engine to normal operating temperature. Stop engine and install Dynamic Timing Meter (078-00200) into timing probe hole until it almost touches vibration damper.
2. Attach clamp from Timing Meter Adapter (078-00201) to the line pressure sensor on No. 1 injector nozzle ("F" Series) or No. 4 injector nozzle ("E" Series), and connect to dynamic timing meter. Connect dynamic timing meter to battery and dial in minus 20 degrees offset on meter.
3. Disconnect cold start advance terminal connector from solenoid terminal. With transmission in Neutral and rear wheels raised, start engine. Using Throttle Control Tool (D83T-9000-E), set engine speed to 2000 RPM with no accessory load.
4. Observe injection timing on dynamic timing meter. Injection timing should be 8.5 degrees BTDC at 2000 RPM. Apply battery voltage to cold start advance solenoid. Activating cold start advance solenoid terminal can increase engine speed. Adjust throttle if necessary.
5. Timing at 2000 RPM should be advanced at least one degree before the timing obtained in first timing check. If the advance is more than one degree, and base timing is within 2 degrees of specification, go to next test. If the advance is more than one degree, and base timing is not within 2 degrees of specification, adjust timing. If problem still exists, go to next test. If the advance is less than one degree, replace injection pump and repeat this test.

Note. Perform this test only if engine has an obvious combustion knock or miss.

CHECK INJECTION NOZZLES & INLET LINES

Check injection nozzle inlet lines for kinks or restriction. Repair or replace as necessary. Check injection nozzles. See INJECTION NOZZLE TESTING under COMPONENT TESTS. Replace any injection nozzle that does not pass test. If performance problem still exists, go to next test.

CRANKCASE PRESSURE TEST

Remove crankcase depression regulator valve and securely plug opening to prevent blow-by. Remove oil filler cap, and install Adapter (5631) and Pressure Test Kit (014-00761). (Scheme 267) Ensure dipstick is seated in dipstick tube. Run engine at 3000 RPM, with no load and transmission in Neutral. Record pressure reading. Pressure reading should not exceed 6" of H2O at 3300 RPM. If crankcase pressure is less than 6" of H2O at 3300 RPM, replace injection pump and check and adjust timing. If crankcase pressure is greater than 6" of H2O at 3300 RPM, problem is internal to engine. Repair engine as necessary.

WAIT-TO-START Indicator Stays On

Disconnect WAIT-TO-START indicator connector at glow plug module. (Scheme 268) Turn ignition switch to ON position. If indicator is on, repair wiring to indicator. If indicator is off, disconnect batteries and replace glow plug module.

Scheme 268

WAIT-TO-START Indicator Does Not Turn On

Disconnect WAIT-TO-START indicator connector at glow plug module. (Scheme 268) Connect a jumper wire between harness side of connector and ground. Turn ignition switch to ON position. If indicator is on, go to GLOW PLUG TESTING. If indicator is off, check light bulb and wiring. Repair as necessary.

INJECTION NOZZLE TESTING

1. Prepare Test Stand (014-00300) according to manufacturer's instructions. Fill test stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without bubbles) flows from end of outlet pipe. Close tester valve.
2. Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely. Bleed air from nozzle. Open tester valve and operate tester handle for 8-10 quick strokes to expel air (bleed) from injector nozzle. Fluid should discharge from spray hole in nozzle tip.
3. Check nozzle opening pressure. Close pump valve and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing pump handle speed if necessary to establish consistent readings. A new nozzle should open at 1800-1950 psi (12,411-13,445 kPa). A used nozzle should open at minimum 1425 psi (9825 kPa).
4. Check for tip leakage. Blow nozzle tip dry with filtered compressed air. Operate test pump to maintain pressure at approximately 200 psi (1379 kPa) below opening pressure obtained in step 3). Wetting of nozzle tip is acceptable as long as a drop does not fall within 5 seconds.
5. After testing is completed, make sure to open pump valve to release built-up pressure. Remove nozzle, cap tip and inlet. If nozzle passes opening and leakage test, it is suitable for further service in engine. If nozzle does not pass both tests, replace nozzle.

FUEL SYSTEM AIR LEAK TESTING

Note. Before starting this test procedure, verify that the fuel tank(s) contain at least a half tank of fuel. The fuel level compensates for the range of vehicle attitudes that may uncover the fuel sender pick-up hose or sender by-pass in the fuel tank when the fuel level is low. Visually inspect fuel system for obvious problems such as kinked hoses, damaged lines or push-connect fittings. Make necessary repairs before continuing.

Check Hose Push-Connect Fitting Connections

1. Verify that push-connect fitting clips are in place. Pull fittings away from tube end axially along tube, to ensure proper connection.
2. If fitting does pull away from tube, push it back on until a click sound is heard. Pull on fitting again to verify connection is complete. Repair or replace defective fittings, fuel lines, clamps or push-connect fittings as necessary.

Check For Bubbles Or Foam

1. Remove rubber fuel return by-pass hose which connects fuel filter outlet fitting by-pass orifice to return lines at fuel injection nozzles. Install a 12" (305 mm) length of 3/16" clear polyvinyl chloride hose in place of rubber hose just removed. Ensure hose clamps are installed and tightened.
2. Run engine at approximately 3000 RPM for 2-3 minutes to clear air from system that was introduced when hose was installed. Observe clear fuel hose for air bubbles at 3000 RPM. Any continuous stream of bubbles larger than 1/16" indicates air ingestion. A moving concentration of bubbles of any size, or foam, is unacceptable.
3. If moving concentration of bubbles of any size or foam is not observed, problem is elsewhere in system. Remove polyvinyl chloride hose and install original hose. If moving concentration of bubbles of any size or foam is observed, go to next test.

Check Direction Of Flow

Observe direction of flow of bubbles. Bubbles should flow from fuel filter outlet fitting to fuel injection nozzle return system. If bubbles flow in direction described, go to next test for single tank systems. For vehicles with dual tank system, go to CHECK FUEL FILTER/WATER SEPARATOR FOR BUBBLES test. If bubbles do not flow in direction described, fuel system is restricted. Go to FUEL FILTER OUTLET PRESSURE test under ENGINE PERFORMANCE DIAGNOSIS.

Check Hose Connections

Check for damage to hose connections at rubber fuel hose from chassis fuel line to mechanical fuel pump and at inlet and outlet hoses at water separator. Tighten hose clamps to 8-13 INCH lbs. (1-1.5 N.m). After tightening hose clamps, run engine for 5 minutes at 3000 RPM and check for air bubbles in polyvinyl chloride hose. If bubbles are not observed, problem is resolved. Replace polyvinyl chloride hose with original hose. If bubbles are still observed, go to next test.

Scheme 269

1. Disconnect fuel filter/water separator inlet hose. Install hose adapter, and tighten hose clamps to 8-13 INCH lbs. (1-1.5 N.m). (Scheme 269) Disconnect fuel filter/water separator outlet hose. Install hose adapter, and tighten hose clamps to 8-13 INCH lbs. (1-1.5 N.m). NOTE: Disconnect hoses and install adapters one at a time to prevent hose mix-up.
2. Operate engine at 1500 RPM for 5 minutes to develop steady fuel flow. Then operate engine at 3000 RPM for an additional 2 minutes and check for bubbles in hose adapters.
3. If air bubbles are present in inlet hose (single tank system), repair hoses and connections between fuel filter/water separator as necessary. Repeat this test to confirm repair. If air bubbles are present in inlet hose (dual tank system), go to next test.
4. If air bubbles are present in outlet hose only, check hose adapter at fuel filter/water separator inlet for air leaks. Turn engine off and operate fuel filter/water separator drain. Repeat this test to confirm repair. If bubbles are still present, replace fuel filter/water separator. Repeat «CHECK FOR BUBBLES OR FOAM»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-for-bubbles-or-foam) test.

Operate Selector Valve (Dual Tank System)

Start and run engine. Observe polyvinyl chloride hose while switching selector valve between tanks. If bubbles are present in both tank positions, go to CHECK HOSE CONNECTIONS test. If bubbles are present in only one tank position, go to next test.

Check Selector Valve Connections

Check push-connect connectors for tightness. If connectors are tight, go to next test. If connectors are not tight, repair or replace push-connect connectors as necessary and go to next test.

Scheme 270

Scheme 271

1. Disconnect push-connect fittings from fuel tank selector valve for affected tank. Install push-connect fitting adapters between fuel lines and selector valve. (Scheme 270)and (Scheme 271).
2. Run engine at 3000 RPM for 2-3 minutes to clear any air ingested during adapter installation. Run engine an additional 2 minutes and observe transparent fuel lines in adapters.
3. If bubbles are not present in either adapter, air leak is between fuel tank selector valve and fuel filter/water separator. Repair or replace lines and connectors as necessary. Repeat «CHECK FOR BUBBLES OR FOAM»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-for-bubbles-or-foam) test.
4. If bubbles are present in both adapters, air leak is between fuel tank and selector valve. Repair or replace fuel lines or connectors as necessary. Repeat «CHECK FOR BUBBLES OR FOAM»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-for-bubbles-or-foam) test.
5. If bubbles are present in selector valve outlet adapter only, replace fuel tank selector valve and repeat «CHECK FOR BUBBLES OR FOAM»(/ford/econoline-e350/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wo-codes-73l-diesel-vin-k-m__check-for-bubbles-or-foam) test.

GLOW PLUG TESTING

Note. For additional glow plug testing, see I - SYSTEM/COMPONENT TESTS - DIESEL article.

Check Glow Plugs

With ignition off, disconnect glow plug connectors at glow plugs. Connect a 12-volt test light between a convenient power source and each glow plug terminal. If test light illuminates, go to next test. If test light does not illuminate, replace glow plug and go to next test.

Check Harness

With ignition off, disconnect glow plug connectors at glow plugs. Squeeze sides of glow plug module protective cover and remove cover. Using an ohmmeter or test light, check continuity between each glow plug lead and test terminal of glow plug module. (Scheme 268) If all leads check okay, go to next test. If any lead has an open circuit or is shorted to ground, repair or replace lead as necessary, then go to next test.

Check Control Unit

Ensure ignition switch is off. Measure resistance between glow plug module ground wire terminal eyelet and negative battery terminal of each battery. (Scheme 268) If less than one ohm is indicated, go to next test. If greater than one ohm is indicated, clean or repair ground connection then go to next test.

Check Supply Voltage

Ensure ignition switch is off. Measure voltage between glow plug module positive terminal and ground. (Scheme 268) If voltage is 10 volts or more, go to next test. If voltage is less than 10 volts, repair power supply wiring or recharge battery, then go to next test.

Check Voltage From Ignition Switch

Connect voltmeter positive lead to glow plug module ignition terminal. (Scheme 268) Connect volt-meter negative lead to ground. Turn ignition switch to ON position. If voltage is 8 volts or more, go to next test. If voltage is less than 8 volts, check fusible link, repair wiring or recharge battery as necessary. Go to next test.

Scheme 272

1. With ignition off, connect a 12-volt test light between glow plug module test terminal and ground. (Scheme 268) Position test light so that it can be seen from driver's seat. Turn ignition switch to ON position and monitor test light. Compare test light times to chart. (Scheme 272) Total test light ON time includes time from the beginning of the initial ON cycle to the end of the last ON-OFF cycle measured in seconds. NOTE: The WAIT-TO-START indicator and/or test light may not illuminate if engine temperature is at or near operating temperature.
2. If test light times are within specifications, system is functioning correctly and test is complete. If test light times are not within specifications, disconnect both batteries and replace glow plug module. Repeat FUNCTIONAL TEST.

GLOW PLUG FAILURE ANALYSIS

The following are examples of glow plug failure. Each example gives a different clue to glow plug failure analysis

1. There is no visible damage, but glow plug is electrically open (Scheme 273) This indicates an internal heating element failure.
2. Glow plug tip that is missing can be caused by incorrect timing or poor fuel quality (Scheme 274)
3. Multiple, distorted glow plugs are usually caused by electrical overheating (Scheme 275) A complete evaluation of the glow plug control system should be made.

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

See also:
• I - SYSTEM/COMPONENT TESTS - DIESEL
• GLOW PLUG TESTING
• ENGINE PERFORMANCE DIAGNOSIS
• INJECTION NOZZLE TESTING
• CHECK FUEL RETURN PRESSURE
• CHECK AIR INTAKE RESTRICTION
• FUEL SYSTEM AIR LEAK TESTING
• DIESEL FUEL CETANE VALUES
• FUEL FILTER OUTLET PRESSURE
• FUEL PUMP CAPACITY
• FUEL SUPPLY PUMP OUTLET PRESSURE
• CHECK FOR BUBBLES OR FOAM
• CHECK HOSE CONNECTIONS