Engine Controls Tests W/o Codes - Diesel Ford Econoline I

INTRODUCTION

Note. References to Econoline include Cutaway and RV Cutaway. References to Pickup include Cab & Chassis.

Before diagnosing symptoms or intermittent faults, perform self-diagnostics in SELF-DIAGNOSTICS - DIESEL article. If any Diagnostic Trouble Codes (DTCs) are present, service DTCs as necessary. Use this article to diagnose existing driveability problems when there are no DTCs present.

Note. Some driveability problems may have been corrected by manufacturer with a revised Powertrain Control Module (PCM). Check with manufacturer for latest PCM application.

Symptom checks can direct the 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 the vehicle is being tested. These test procedures should also be used if a continuous memory (intermittent) DTC was present, but no problem was found during KOEO or KOER SELF-TEST.

Note. For specific testing procedures, see SYSTEM & COMPONENT TESTING - DIESEL article. For specifications, see ON-VEHICLE ADJUSTMENTS - TRUCKS or SERVICE & ADJUSTMENT SPECIFICATIONS - TRUCKS article.

SYMPTOM DIAGNOSIS

Symptom checks cannot be used properly unless problem occurs while vehicle is being tested. To reduce diagnostic time, ensure self-diagnostics has indicated no faults exist before diagnosing a symptom. Symptoms available for diagnosis are as follows

1. No Crank/Slow Crank
2. Stalls After Start
3. No Start/Normal Crank Or Hard Start/Long Crank
4. Engine Will Only Idle
5. Slow Return To Idle
6. Rough Idle/Stalls When Engaging Clutch
7. Fast Idle
8. Runs Rough, Misses, Buck/Jerk, Hesitation Or Stumbles
9. Surge (On Acceleration Or Cruise)
10. Loss Of Power/Poor Fuel Economy
11. Malfunction Indicator Light (MIL)
12. Exhaust Smoke
13. Cruise (Speed) Control Inoperative
14. Transmission Control Indicator Light (TCIL)
15. Improper Transmission Shift
16. High Oil Consumption/Leaks
17. Hard Start/No Start - Dry Reservoir

Preliminary Checks

On A/T models, ensure gearshift lever is in Park. On M/T models, ensure clutch is fully depressed. Check battery connections. Check starter relay connections. Check alarm/anti-theft devices. Check fuses and fusible links. Check ignition switch.

Symptom Checks

Perform the following

1. Check starter relay.
2. Check starting system (starter, starter ground and battery cables).
3. Check charging system.
4. Check for seized/hydrostatic locked engine (leaking injectors).
5. Check for defective flywheel/flexplate or seized engine components.
6. Check ignition circuit. In particular, check for ignition starter wire shorting to ground.
7. Check transmission linkage adjustment or Transmission Range (TR) sensor adjustment. See ADJUSTMENTS in AUTOMATIC TRANSMISSION article in TRANSMISSION SERVICING.

Check for engine overheating. Check all wiring harness connectors. Check engine oil level and quality. Check Manifold Absolute Pressure (MAP) sensor hose. Check transmission Torque Converter Clutch (TCC) solenoid.

Perform the following

1. If engine stalls with engine oil temperature at less than 32°F (0°C), oil return to oil pan may be too slow. Ensure proper oil viscosity is being used for frigid conditions.
2. Perform engine performance diagnosis in SYSTEM & COMPONENT TESTING - DIESEL article.
3. On A/T models, if no faults are found after performing engine performance diagnosis, check transmission operation.

Check engine oil level. Ensure proper engine oil dipstick is being used. Check fuel quality. Check air restriction gauge located on air filter housing to determine if air cleaner needs replacement.

Perform the following

1. Check engine oil level in high pressure oil pump reservoir. Oil level should be within 1" (25.4 mm) of top of reservoir.
2. If oil level is low, refill and attempt to start engine. If engine starts after about 15 seconds, high pressure oil pump is not supplying enough oil pressure. Perform «HARD START/NO START - DRY RESERVOIR»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel) symptom check.
3. Perform KOEO ON-DEMAND SELF-TEST. See QUICK TEST in SELF-DIAGNOSTICS -DIESEL article. If any diagnostic trouble codes are present, perform appropriate test.
4. Perform KOEO INJECTOR ELECTRICAL SELF-TEST. See QUICK TEST in SELF-DIAGNOSTICS - DIESEL article. If any diagnostic trouble codes are present, perform appropriate test. If test does not run, repeat KOEO injector electrical self-test for each injector with one injector connector disconnected at a time. If KOEO injector electrical self-test now runs, remove valve cover and inspect disconnected valve cover wiring harness for a pinched or grounded injector wire. If KOEO injector electrical self-test still does not run, check Injector Driver Module (IDM) power and ground circuits. See TEST NC in SELF-DIAGNOSTICS - DIESEL article. Check for short to ground in IDM or injector circuits. See TEST NA, step 29) , in SELF-DIAGNOSTICS - DIESEL article.
5. Check Parameter Identifications (PIDs) during cranking. See CHECK PARAMETER IDENTIFICATION (PID) DURING CRANKING under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
6. Perform GLOW PLUG SYSTEM OPERATION TEST under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
7. Perform fuel pump pressure test. See FUEL PUMP PRESSURE TEST under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.

Perform the following

1. Check if Accelerator Pedal (AP) sensor is mounted correctly. AP sensor is located above accelerator pedal.
2. Check Idle Validation Switch (IVS). See TEST FE in SELF-DIAGNOSTICS - DIESEL article.
3. Ensure floor mats do not interfere with accelerator pedal.
4. Ensure accelerator pedal is not damaged.

Check for binding or stuck accelerator pedal. Check for broken accelerator return spring.

Perform the following

1. Check for floor mat interference.
2. Check for defective accelerator pedal bushing.
3. Check for overfilled crankcase.
4. Check for coolant in oil.
5. Check crankcase for fuel contamination.
6. Check Engine Oil Temperature (EOT) sensor. See TEST DB in SELF-DIAGNOSTICS - DIESEL article. If EOT sensor is okay, perform «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) symptom check.

Check engine oil level. Check for proper engine oil dipstick. Check for proper oil viscosity. Check if engine oil has been changed within 5000 miles. Check fuel quality. Check for intake manifold leaks. Check MAP sensor hose.

Perform the following

1. Perform KOEO on-demand self-test. See QUICK TEST in SELF-DIAGNOSTICS - DIESEL article.
2. Perform KOEO injector electrical self-test. See QUICK TEST in SELF-DIAGNOSTICS - DIESEL article.
3. Check for aerated oil. See INJECTION CONTROL PRESSURE TESTS under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
4. Perform TEST DC in SELF-DIAGNOSTICS - DIESEL article.
5. Check fuel pump pressure.
6. Check for restricted fuel line.
7. Check fuel regulator for blockage.
8. Check engine oil level in high pressure oil pump reservoir. Oil level should be within 1" (25.4 mm) of top of reservoir.
9. Check for engine oil leak.
10. Check engine oil pressure. Should be a minimum of 10 psi at idle. If oil pressure is low, check engine mechanical condition for cause of low oil pressure.
11. Perform INJECTION CONTROL PRESSURE LEAK TEST under HARD START/NO-START DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
12. Perform KOER CYLINDER CONTRIBUTION TEST in SELF-DIAGNOSTICS - DIESEL article.
13. Check for incorrect injector application. Injector part numbers are stamped on top of injector.

Check for binding or stuck accelerator pedal. Check for damaged accelerator return spring. Check if engine is operating at normal operating temperature.

Perform the following

1. With engine at normal operating temperature, check EOT PID reading. See ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - DIESEL article. If EOT PID reading is less than 100°F (38°C), replace EOT sensor.
2. Check for floor mat interference.
3. Check for defective accelerator pedal bushing.
4. Check for coolant in oil.
5. Check for overfilled crankcase.
6. Check crankcase for fuel contamination.

RUNS ROUGH, MISSES, BUCK/JERK, HESITATION OR STUMBLES

Note. The Powertrain Control Module (PCM) is equipped with an over RPM/speed limiting function that will shut off fuel delivery when predetermined speed is exceeded.

Check for engine overheating. Check wiring harness connectors for corroded, loose or damaged terminals. Check engine oil level and quality. Check Manifold Absolute Pressure (MAP) sensor hose. On A/T models, check fluid level.

Perform the following

1. Perform «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) symptom check.
2. On A/T models, if no faults are found after performing «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) , check transmission operation.

SURGE (ON ACCELERATION OR CRUISE)

Note. The Powertrain Control Module (PCM) is equipped with an over RPM/speed limiting function that will shut off fuel delivery when predetermined speed is exceeded.

Check engine oil level and quality. Check wiring harness connectors for corroded, loose or damaged terminals.

Perform the following

1. Perform «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) symptom check.
2. On A/T models, if no faults are found after performing «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) , check transmission operation.

LOSS OF POWER/POOR FUEL ECONOMY

Note. The PCM is equipped with an RPM/speed limiting function that will shut off fuel delivery when predetermined speed is exceeded.

Verify symptom occurs under normal driving conditions without engine being under excessive load conditions. Check for binding/dragging brakes. Check wiring harness connectors. Check transmission fluid. Check engine oil level. Check for proper engine oil dipstick. Check for proper oil viscosity. Check fuel quality.

Perform the following

1. Check if engine oil has been changed within 5000 miles.
2. Check air restriction gauge, located on air filter housing, to determine if air cleaner needs replacement.
3. Check for correct Manifold Absolute Pressure (MAP) sensor.
4. Check for intake manifold leaks.
5. Perform KOEO on-demand self-test and KOEO injector electrical self-test. See QUICK TEST in SELF-DIAGNOSTICS - DIESEL article.
6. Check camshaft timing.
7. Check for biased Injection Control Pressure (ICP) sensor. See TEST DC in SELF-DIAGNOSTICS - DIESEL article.
8. Check fuel pressure.
9. Check for restricted exhaust system. See CHECK FOR EXHAUST RESTRICTION under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
10. Check for aerated engine oil. See INJECTION CONTROL PRESSURE TESTS under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
11. Check for biased Exhaust Backpressure (EBP) sensor. See TEST DE in SELF-DIAGNOSTICS - DIESEL article.
12. Perform TEST C in SELF-DIAGNOSTICS - DIESEL article.
13. Perform KOER CYLINDER CONTRIBUTION TEST. See SELF-DIAGNOSTICS - DIESEL article.
14. Check engine mechanical condition.
15. Check turbo boost. See BOOST PRESSURE TEST under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
16. Check MAP sensor. See TEST DH in SELF-DIAGNOSTICS - DIESEL article.
17. Check for biased Engine Oil Temperature (EOT) sensor. See TEST DB in SELF-DIAGNOSTICS - DIESEL article.

Perform the following

1. If MIL is always on, check for Diagnostic Trouble Codes (DTCs). See SELF-DIAGNOSTICS - DIESEL article. If any DTCs are present, perform appropriate test.
2. Cycle ignition switch. If MIL light turns on then goes out (bulb check), no problem is indicated.
3. If MIL is always off, perform TEST NB in SELF-DIAGNOSTICS - DIESEL article.

Perform the following

1. Check Manifold Absolute Pressure (MAP) sensor hose for leaks.
2. Check air restriction gauge, located on air filter housing, to determine if air cleaner needs replacement.
3. Check for correct MAP sensor.
4. Check intake manifold for leaks.
5. Check fuel quality.
6. With ignition on, check PID values for EBP, MAP and BARO sensors. All readings should be within 3 psi (21 kPa) of each other. If any reading is not within 3 psi (21 kPa), perform appropriate test for sensor value that disagrees with other sensor value readings. See SELF-DIAGNOSTICS - DIESEL article.

White Smoke (Water In Combustion)

Perform the following

1. Check glow plug system operation.
2. Check engine mechanical condition. Check for cylinder head and intake manifold gasket leaks. Check for cracked/porous cylinder head and engine block.
3. Perform ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.

Black Smoke

Perform the following

1. Apply vacuum to MAP sensor. If MAP sensor does not hold vacuum, replace MAP sensor.

Perform the following

1. If ABS light is on, service ABS system as necessary.
2. If BRAKE warning light is on, go to TEST FF in SELF-DIAGNOSTICS - DIESEL article.
3. Check PBA, BPA, CPP, BOO, SCCS M and VSS Parameter Identification (PID). See ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - DIESEL article. If any PID value is incorrect, perform appropriate test.
4. Perform «LOSS OF POWER/POOR FUEL ECONOMY»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel__loss-of-powerpoor-fuel-economy) symptom check.

Perform the following

1. If TCIL is flashing and Malfunction Indicator Light (MIL) is also on, perform «MALFUNCTION INDICATOR LIGHT (MIL)»(/ford/econoline/i-1985-2013/remont/testing-diagnostics/#engine-controls-tests-wo-codes-diesel) symptom check.
2. Check TCIL circuit. See AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

Preliminary Check

Check transmission fluid level and condition.

Perform the following

1. Check TR, SCCS M, 4X4L and VSS Parameter Identification (PID). See ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - DIESEL article. If any PID value is incorrect, perform appropriate test.
2. Check for transmission codes. See FORD 4R100 ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. Service codes as necessary.

Check for external engine oil leaks. Check for proper oil dipstick. Check for proper oil viscosity.

Perform the following

1. Perform ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
2. Check engine mechanical condition. Check valves, valve guides, valve stem oil seals, intake manifold gaskets, cylinder head oil drain passages and piston rings.

Perform the following

1. Perform INJECTION CONTROL PRESSURE TESTS under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - DIESEL article.
2. Check engine oil level in high pressure oil pump reservoir. Oil level should be within 1" (25.4 mm) of top of reservoir. Drive vehicle for 10 miles. Recheck high pressure oil pump reservoir. If oil level is low, check oil reservoir and engine front cover for oil leakage. Repair as necessary.
3. Allow vehicle to sit overnight. Recheck engine oil level in high pressure oil pump reservoir. If oil level is low, remove high pressure oil pump. Check for high pressure oil pump gasket for signs of internal oil leak. Check high pressure oil pump reservoir for casting porosity. Repair as necessary.

INTERMITTENT PROBLEM DIAGNOSIS

Intermittent fault testing requires duplicating circuit or component failure to identify problem. These procedures may lead to the computer setting a fault code (on some systems), which may help in diagnosis.

If problem vehicle does not produce fault codes, monitor voltage or resistance using a DVOM while attempting to reproduce conditions causing intermittent fault. A status change on DVOM indicates a fault has been located.

Use a DVOM to pinpoint faults. When monitoring voltage, ensure ignition switch is in ON position or engine is running. Ensure ignition switch is in OFF position or negative battery cable is disconnected when monitoring circuit resistance. Status changes on DVOM during test procedures indicate area of fault.

Intermittent Simulation

To reproduce the conditions creating an intermittent fault, use the following methods

1. Lightly vibrate component.
2. Heat component.
3. Wiggle or bend wiring harness.
4. Spray component with water.
5. Remove/apply vacuum source.

Monitor circuit/component voltage or resistance while simulating intermittent. If engine is running, monitor for self-diagnostic codes. See SELF-DIAGNOSTICS - DIESEL article. Use test results to identify a faulty component or circuit.

See also:
• HARD START/NO START - DRY RESERVOIR
• LOSS OF POWER/POOR FUEL ECONOMY