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Contents Wiring diagrams Section: Testing & Diagnostics All sections

Engine Controls - Trouble Shooting - No Codes - Eec-V - Diesel: Other Ford Excursion I

Testing & Diagnostics 6 illustrations ~8012 words

NO CRANK/SLOW CRANK

  1. Preliminary Checks On A/T models, ensure gearshift lever is in Park or Neutral. On M/T models, ensure clutch is fully depressed. On all models, check battery condition and battery connections. Check starter relay connections. Check alarm/anti-theft devices. Check fuses and fusible links. Check ignition switch. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Check Starter Relay Cycle ignition switch and listen for starter relay operation. On Econoline, starter relay is located in right front corner of engine compartment, near battery. On Excursion and F250-550, starter relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, if starter relay clicks when ignition switch is turned to START position, go to step 4 . If starter relay does not click when ignition switch is turned to START position, go to next step.
  3. Check Electrical Accessories Check if any other electrical accessories (headlights, radio, etc.) operate. If other accessories operate, go to next step. If no other accessories operate, check battery and charging system. Repair as necessary.
  4. Check Starting System Secondary Circuits Measure voltage drop in starter secondary circuits. See «STARTERS - ECONOLINE - DIESEL»(ref-139513) or «STARTERS - EXCURSION & F250/F350 SUPER DUTY PICKUPS»(ref-139517) article in STARTING & CHARGING SYSTEMS. If a fault is present, repair as necessary. If no fault is present, go to next step.
  5. Check Starting System Components Check starter, starter relay, starter ground and battery cables. On M/T models, check Clutch Pedal Position (CPP) switch. On A/T models, check Transmission Range (TR) sensor adjustment. Adjust or repair TR sensor as necessary. See «ADJUSTMENTS»(ref-139517-S00591993302002050100000) in STARTERS - EXCURSION & F250/F350 SUPER DUTY PICKUPS article in STARTING & CHARGING SYSTEMS. On all models, if no adjustment or repair is required, check for seized/hydro-locked engine (leaking injectors) or damaged flywheel. Repair as necessary.

STALLS OR QUITS ON ACCELERATION, CRUISE, DECELERATION OR IDLE

  1. Preliminary Checks Ensure engine oil level, engine oil filter (FL-1995), oil API rating (CG4/SH) and viscosity are correct. Check all engine electrical connections. On A/T models, ensure ATF level is correct and torque converter clutch is operating correctly. On all models. ensure engine is not overheating. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Check For Cold Weather Stall If engine restarts after stalling with engine oil temperature less than 32°F (0°C), oil return to oil pan may be too slow. Ensure proper oil viscosity is being used for cold weather conditions. Change oil if necessary. If proper oil viscosity is being used for cold weather conditions, go to next step.
  3. Check For PCM Reset If a PCM reset occurs, the following conditions will be present: Engine will momentarily stumble. PCM will go through a normal key on cycle. Glow plug lamp and glow plugs will be turned on. Accelerator pedal position validation will be attempted. Pedal authority will not be allowed by PCM until accelerator pedal is released and engine returns to idle. If any of these conditions are present, go to «TEST ME: PCM RESET»(ref-139800-S36934423602002062600000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If none of these conditions are present, go to next step.
  4. Check Engine Performance Diagnosis Perform «ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES»(ref-140379-S37643595772002052200000) in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. On M/T models, if no fault is present, test is complete. Return to «SYMPTOM DIAGNOSIS»(ref-140363-S17926710052002052100000) if a symptom still exists. On A/T models, if no fault is present, diagnose possible transmission problem by symptom. See «TROUBLE SHOOTING»(ref-140948-S23504821512002061000000) in DIAGNOSIS - 4R100 article in AUTOMATIC TRANSMISSIONS.

Scheme 89

Scheme 89: NO-START/NORMAL CRANK, ERRATIC START OR CRANK, HARD START OR LONG CRANK OR STALLS AFTER START
Scheme 89: NO-START/NORMAL CRANK, ERRATIC START OR CRANK, HARD START OR LONG CRANK OR STALLS AFTER START
  1. Preliminary Checks Check engine oil level and quality (CG4/SH). Ensure proper engine oil dipstick is being used. Perform the following in order; «TEST 3: CHECK ENGINE OIL LEVEL»(ref-140379-S30969225812002052200000), «TEST 2: SUFFICIENT CLEAN FUEL»(ref-140379-S27429620982002052200000) and «TEST 4: INTAKE RESTRICTION»(ref-140379-S21744019582002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If no problems are indicated, go to next step.
  2. Check High-Pressure Oil Pump Reservoir Level Check engine oil level in high pressure oil pump reservoir. Reservoir is located on top of engine, near generator. (Scheme 89) Oil level should be within 1" (25.4 mm) of inspection plug. Go to next step.
  3. Attempt To Start Engine Add oil to reservoir if necessary and attempt to start engine. If engine starts and stalls after about 15 seconds, lubrication system is not supplying enough oil to high pressure oil pump reservoir. Perform «HARD START/NO-START - DRY RESERVOIR»(ref-140363-S04882983962002052100000) symptom check. If engine does not stall after about 15 seconds, go to step 5.
  4. Check Fuel Pump Pressure Perform «TEST 8C: ELECTRIC FUEL PUMP PRESSURE TEST»(ref-140379-S26508970512002070900000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If fuel pump pressure is okay, go to next step.
  5. Perform KOEO On-Demand Self-Test Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If any DTC are present, service DTCs as necessary. If no DTCs are present, go to next step.
  6. Perform KOEO Injector Electrical Self-Test Perform «KOEO INJECTOR ELECTRICAL SELF-TEST»(ref-139800-S15778450502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to step 8. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS. If self-test does not run, go to next step.
  7. Repeat KOEO Injector Electrical Self-Test Repeat KOEO INJECTOR ELECTRICAL SELF-TEST for each injector with one injector connector at valve cover 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. Go to «TEST NC: INJECTOR DRIVER MODULE ENABLE»(ref-139800-S29905777452002050900000), step 6) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If power and ground circuits are okay, check for short to ground in IDM or injector circuits. Go to «TEST NA: INJECTOR DRIVE CIRCUIT OPERATION»(ref-139800-S16516760252002050900000), step 29) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair as necessary. If all circuits are okay, go to next step.
  8. Check Parameter Identifications Using scan tool, check Parameter Identifications (PIDs). Perform «TEST 9A: CHECK VPWR WHILE CRANKING»(ref-140379-S12091445942002052200000), «TEST 9B: CHECK RPM SIGNAL WHILE CRANKING»(ref-140379-S06979839612002070900000), «TEST 9C: MONITOR ICP PID WHILE CRANKING»(ref-140379-S00364662852002052200000) and «TEST 9D: CHECK FUEL PULSE WIDTH WHILE CRANKING»(ref-140379-S14254527902002070900000) under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If PID values are within specification, go to next step. If PID values are not within specification, perform appropriate system test under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  9. Check Glow Plug Relay Power Circuit On models with California emissions, a problem may exist in the glow plug system. Check for DTC that may be stored in PCM memory. Perform «QUICK TEST»(ref-139800-S19570345092002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Service any DTCs that are present. On models with Federal emissions, disconnect glow plug relay. Glow plug relay is located on top right side of engine. (Scheme 90) Measure voltage between chassis ground and Black/Orange wire at glow plug relay. If battery voltage is present, go to next step. On Econoline, if battery voltage is not present, repair open in Black/Orange wire or replace Gray fuse links "D" and/or "E". Gray fuse links are located in alternator rectifier system harness, near take off to starter relay. On Excursion and F250-550, if battery voltage is not present, repair open in Black/Orange wire or replace Gray fuse links "C" and/or "D". Gray fuse links are located in alternator rectifier system harness, near take off to starter relay.
  10. Check Glow Plug Relay To check glow plug relay, perform «TEST KC: GLOW PLUG SYSTEM (FEDERAL EMISSIONS)»(ref-139800-S25985996452002050900000), step 7) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  11. Check Glow Plugs To check glow plugs, perform «TEST KC: GLOW PLUG SYSTEM (FEDERAL EMISSIONS)»(ref-139800-S25985996452002050900000), step 9) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  12. Check Glow Plug Connectors To check glow plug connectors, perform «TEST KC: GLOW PLUG SYSTEM (FEDERAL EMISSIONS)»(ref-139800-S25985996452002050900000), step 10) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.

Scheme 90

Scheme 90
Scheme 90

ENGINE WILL ONLY IDLE

Note. Vehicle may be equipped with an Electronic Throttle Control (ETC) sensor or an Accelerator Pedal (AP) sensor. ETC sensor has a 10-pin connector and AP sensor has a 3-pin connector. If vehicle is equipped with an AP sensor, it will also be equipped with an Idle Validation Switch (IVS). (Scheme 91) IVS has a 2-pin connector. ETC sensor is mounted above accelerator pedal.

Ensure AP sensor, IVS or ETC sensor is mounted correctly. Ensure connector(s) is properly installed. Ensure floor mats do not interfere with accelerator pedal. Ensure accelerator pedal is not damaged. Repair as necessary. If no problems are found, and vehicle is equipped with an AP sensor and IVS, go to TEST DD: ACCELERATOR PEDAL SENSOR or TEST FE: IDLE VALIDATION SWITCH in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no problems are found, and vehicle is equipped with an ETC sensor, go to TEST QC: ELECTRONIC THROTTLE CONTROL , step 13) in SELF-DIAGNOSTICS - EEC-V - DIESEL article.

Scheme 91

Scheme 91: ENGINE WILL ONLY IDLE
Scheme 91: ENGINE WILL ONLY IDLE

FAST IDLE OR SLOW RETURN TO IDLE

  1. Preliminary Checks Check for binding or stuck accelerator pedal. Check for broken accelerator return spring. Ensure floor mats do not interfere with accelerator pedal. Ensure engine is not being supplied from an external fuel source. Check if engine is reaching normal operating temperature. Ensure power take-off and charge protect devices are disengaged. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Perform Quick Test Perform «QUICK TEST»(ref-139800-S19570345092002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS. If no DTCs are present, go to next step.
  3. Check Accelerator Pedal Check and repair accelerator pedal as necessary. If okay, go to next step.
  4. Check Crankcase Check for overfilled crankcase. If crankcase is not overfilled, go to next step. If crankcase is overfilled, drain crankcase to correct level and determine cause of overfill.
  5. Check Engine Oil For Coolant Check engine oil for coolant. If coolant is not present in engine oil, go to next step. If coolant is present in engine oil, diagnose source of coolant. Repair as necessary.
  6. Check For Fuel Contamination Check fuel for contamination. Perform «TEST 2: SUFFICIENT CLEAN FUEL»(ref-140379-S27429620982002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If fuel is not contaminated, go to next step. If fuel is contaminated, drain and refill fuel system as necessary.
  7. Check Parameter Identifications (PIDs) Warm engine to normal operating temperature. Using scan tool, access and monitor EOT PID. See «PARAMETER IDENTIFICATION MODE»(ref-139800-S09104900802002050900000) under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If EOT sensor value is 100°F (38°C) or more, go to next step. If EOT sensor value is less than 100°F (38°C), replace EOT sensor. EOT sensor is located on left side of engine. (Scheme 90)
  8. Check Turbocharger Remove turbocharger inlet air duct. Inspect turbocharger compressor wheel for damage to blade or for signs that blade has been rubbing turbocharger housing. If damage is present, replace turbocharger. If turbocharger is okay, no problem is indicated. Return to «SYMPTOM DIAGNOSIS»(ref-140363-S17926710052002052100000) if a symptom still exists.

Scheme 92

Scheme 92: ROUGH OR ROLLING IDLE OR STALLS WHEN ENGAGING CLUTCH
Scheme 92: ROUGH OR ROLLING IDLE OR STALLS WHEN ENGAGING CLUTCH

Scheme 93

Scheme 93
Scheme 93
  1. Preliminary Checks Check engine oil level. Check for proper engine oil dipstick. Check for proper oil API rating (CG4/SH) and viscosity. Ensure engine oil has been changed within last 5000 miles. Check fuel quality. Check air filter minder to see if filter needs to be replaced. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Perform KOEO On-Demand Self-Test Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  3. Perform KOEO Injector Electrical Self-Test Perform «KOEO INJECTOR ELECTRICAL SELF-TEST»(ref-139800-S15778450502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  4. Check For Aerated Engine Oil Perform «TEST 10A: INJECTION CONTROL PRESSURE TEST (OIL AERATION/POOR IDLE)»(ref-140379-S13562033972002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  5. Check Source Of Aerated Engine Oil Overfill engine oil with 2 qts. (1.9L) of specified oil. Raise rear of vehicle and support 10" from ground. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine and run at Wide Open Throttle (WOT) for 3 minutes. If ICP PID reading is more than 1.75 volts, or more than 1800 psi (12,411 kPa), oil is aerating due to lack of defoaming agents. Change engine oil to meet CG4/SH specifications, ensure engine oil level is correct and go to next step. If ICP PID reading is 1.75 volts or less, or 1800 psi (12,411 kPa) or less, aeration is caused by an injector "O" ring leak or a hole in oil pick-up tube. Repair as necessary.
  6. Injection Control Pressure Test Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine and run at WOT for 3 minutes. If ICP reading is more than 1.75 volt, or more than 1800 psi (12,411 kPa), go to next step. If ICP reading is 1.75 volt or less, or 1800 psi (12,411 kPa) or less, concern is no longer present.
  7. Low Idle Stability Test Perform «TEST 10B: LOW IDLE STABILITY (ICP PRESSURE)»(ref-140379-S28061346972002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  8. Check For Biased ICP Sensor Perform «TEST DC: INJECTION CONTROL PRESSURE SENSOR»(ref-139800-S25044634142002050900000), step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  9. Check Fuel Pump Pressure Perform «TEST 8C: ELECTRIC FUEL PUMP PRESSURE TEST»(ref-140379-S26508970512002070900000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If fuel pump pressure is okay, go to next step.
  10. Check Lubrication Pressure Check engine oil level in high pressure oil pump reservoir. Reservoir is located on top of engine, near generator. (Scheme 89) Oil level should be within 1" (25.4 mm) of inspection plug. Connect a 100 psi (689.5 kPa) oil pressure gauge to high pressure oil pump reservoir. Ensure engine is at operating temperature. With engine idling at 650 RPM, engine oil pressure should be 12 psi (69 kPa) or more. Raise engine speed to 3300 RPM and check engine oil pressure. Engine oil pressure should be 40-70 psi (276-482 kPa). If engine oil pressure is as specified, go to next step. If engine oil pressure is not as specified, check for cause of low oil pressure and repair as necessary.
  11. KOER On-Demand Self-Test Ensure engine is at normal operating temperature. Clear DTCs. Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If DTC P1211 is present, perform «TEST 9C: MONITOR ICP PID WHILE CRANKING»(ref-140379-S00364662852002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If no DTCs are present, go to step 16.
  12. Check Pressure Balance Remove high pressure hose from right cylinder head. (Scheme 92) Using Fuel/Oil/Turbo Protector Cap Set (T94T-9395-AH), install appropriate cap on high pressure hose fitting on right cylinder head. Using plug from Oil High Pressure Leakage Test Adapter Set (303-S626), install plug into high pressure hose. Using scan tool, access and record Injection Pressure Regulator (IPR) PID duty cycle with engine running at 3000 RPM. Turn engine off. Remove cap and plug, and reinstall high pressure hose to right cylinder head. Remove high pressure hose from left cylinder head. (Scheme 93) Using fuel/oil/turbo protector cap set, install appropriate cap on high pressure hose fitting on left cylinder head. Using plug from oil high pressure leakage test adapter set, install plug into high pressure hose. Using scan tool, check IPR PID duty cycle with engine running at 3000 RPM. If difference in IPR PID duty cycles between right and left bank is more than 2 percent, remove cap and plug, and reinstall high pressure hose to left cylinder head. Go to next step. If difference in IPR PID duty cycles between right and left bank is 2 percent or less, replace IPR. Remove cap and plug, and reinstall high pressure hose to left cylinder head.
  13. Check For Leak Source Remove valve cover from cylinder bank with higher IPR duty cycle. With engine idling, check for bubbling around injector bores or oil gallery drain plugs. Or with engine off, apply about 100 psi (689 kPa) of compressed air to high pressure oil gallery. Injector spill spouts may require removal for visibility. If air bubbles are noticeable or leaks are heard, replace "O" rings on injectors or reseal oil galleries as necessary. If no leaks are detected, go to step 16.
  14. Check Rough Idle If a rough idle was present when vehicle was new or after a new high pressure oil pump was installed, go to next step. If a rough idle was not present when vehicle was new or after a new high pressure oil pump was installed, go to step 16.
  15. Check High Pressure Oil Pump Connect right side high pressure hose to left cylinder head and plug left hose. Using scan tool, access and monitor IPR PID duty cycle at idle. Compare this reading with the reading for the left cylinder head taken in step 12). If difference in readings is.2 volt or less, or 2 percent or less, go to next step. If difference in readings is more than.2 volt, or 2 percent, ensure high pressure hoses are clear and replace high pressure oil pump.
  16. KOER Cylinder Contribution Self-Test Perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-139800-S26331301612002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If a faulty cylinder is identified during testing, go to next step. If a faulty cylinder is not identified during testing, go to step 18.
  17. Check For Engine Wear Perform «TEST 11: CRANKCASE PRESSURE TEST»(ref-140379-S38156161392002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If crankcase pressure reading is more than 3 in. H 2 O, or compression pressure is less than 350 psi (2413 kPa) and different from adjacent cylinder by 50 psi (345 kPa) or more, check engine mechanical condition (compression rings, cylinder bores, valves, etc.). Repair as necessary. If crankcase pressure reading is 3 in. H 2 O or less, or compression pressure is 350 psi (2413 kPa) or more and different from adjacent cylinder by less than 50 psi (345 kPa), replace injector in identified cylinder.
  18. Check For Incorrect Injector Application Remove engine valve covers. Ensure correct injectors are installed. Part number is stamped on top of each injector. Replace injector if necessary. If injector numbers are correct for application, cause of rough idle cannot be determined. Compare idle performance to vehicles with similar powertrain.

RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY

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

Scheme 94

Scheme 94: RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK O
Scheme 94: RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK O
  1. Preliminary Checks Check brakes for dragging. Check transmission and axle fluid levels. Ensure transmission and axle bearings have not been overheated. Check for oil in coolant. Ensure engine oil level, viscosity and API rating meets specification. Ensure engine oil has been changed within last 5000 miles. Check air filter minder to see if filter needs to be replaced. Check Manifold Absolute Pressure (MAP) sensor hose for cracks, blockages or disconnection. Check intake manifold for leaks or restrictions. Check fuel quality. See «TEST 2: SUFFICIENT CLEAN FUEL»(ref-140379-S27429620982002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Check vehicles laden weight with operator's expectations of vehicle performance. Check for engine overheating. Check wiring harness connectors for corroded, loose or damaged terminals. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Boost Pressure Test Perform BOOST PRESSURE TEST. Go to «TEST KH: WASTEGATE CONTROL SOLENOID (EXCURSION & F250-550»(ref-139800-S17342430252002050900000), step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  3. Perform KOEO On-Demand Self-Test Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  4. Perform KOEO Injector Electrical Self-Test Perform «KOEO INJECTOR ELECTRICAL SELF-TEST»(ref-139800-S15778450502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  5. Retrieve/Clear Continuous DTCs Perform «RETRIEVE/CLEAR CONTINUOUS MEMORY DTCS»(ref-139800-S16760289892002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Record and clear any Continuous Memory DTCs retrieved. If Continuous Memory DTCs are present for Camshaft Position (CMP) sensor, go to next step. If no Continuous Memory DTCs are present for CMP sensor, go to step 8.
  6. Check Cold CMP Clearance (CMP DTC Present) Remove and inspect CMP sensor for contact with timing disk (visible scratches). CMP sensor is located right on front of engine, above crankshaft pulley. (Scheme 90) If CMP sensor indicates signs of contact with timing disk, go to next step. If CMP sensor does not indicate any signs of contact with timing disk, replace CMP sensor.
  7. Check CMP Clearance To Timing Disk Replace CMP sensor and install a.010" (.254 mm) shim under CMP sensor. If symptom persists, increases shim thickness to.020" (.508 mm). Part No. (F7TZ-12J072-AA).
  8. Check Continuous Memory DTCs If any other Continuous Memory DTCs are present, perform appropriate system test under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no other Continuous Memory DTCs are present, go to next step.
  9. Check For Biased ICP Sensor Perform «TEST DC: INJECTION CONTROL PRESSURE SENSOR»(ref-139800-S25044634142002050900000), step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  10. Check Fuel Pump Pressure Perform «TEST 8C: ELECTRIC FUEL PUMP PRESSURE TEST»(ref-140379-S26508970512002070900000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If fuel pump pressure is okay, go to next step.
  11. Check Fuel Regulator Check fuel regulator valve for sticking or contamination. Check fuel regulator "O" rings for damage. If fuel regulator valve or fuel regulator valve "O" rings require service, replace fuel regulator valve as a unit. If both fuel regulator valve and "O" rings are okay, go to next step.
  12. Check Pump Inlet Restriction Perform «TEST 8D: ELECTRIC FUEL PUMP INLET RESTRICTION»(ref-140379-S40648659382002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  13. Check For Aerated Engine Oil Perform «TEST 10A: INJECTION CONTROL PRESSURE TEST (OIL AERATION/POOR IDLE)»(ref-140379-S13562033972002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If oil aeration problem is indicated, go to next step. If no problems are indicated, go to step 16.
  14. Check Source Of Aerated Engine Oil Overfill engine oil with 2 qts. (1.9L) of specified oil. Raise rear of vehicle and support 10" from ground. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine and run at Wide Open Throttle (WOT) for 3 minutes. If ICP PID reading is more than 1.75 volts, or more than 1800 psi (12,411 kPa), oil is aerating due to lack of defoaming agents. Change engine oil to meet CG4/SH specifications, ensure engine oil level is correct and go to next step. If ICP PID reading is 1.75 volts or less, or 1800 psi (12,411 kPa) or less, aeration is caused by an injector "O" ring leak or a hole in oil pick-up tube. Repair as necessary.
  15. Injection Control Pressure Test Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine and run at WOT for 3 minutes. If ICP reading is more than 1.75 volt, or more than 1800 psi (12,411 kPa), go to next step. If ICP reading is 1.75 volt or less, or 1800 psi (12,411 kPa) or less, concern is no longer present.
  16. Check For Low IDM Power Go to «TEST NA: INJECTOR DRIVE CIRCUIT OPERATION»(ref-139800-S16516760252002050900000), step 29) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  17. Check Lubrication Pressure Check engine oil level in high pressure oil pump reservoir. Reservoir is located on top of engine, near generator. (Scheme 89) Oil level should be within 1" (25.4 mm) of inspection plug. Connect a 100 psi (689.5 kPa) oil pressure gauge to high pressure oil pump reservoir. Ensure engine is at operating temperature. With engine idling at 650 RPM, engine oil pressure should be 12 psi (69 kPa) or more. Raise engine speed to 3300 RPM and check engine oil pressure. Engine oil pressure should be 40-70 psi (276-482 kPa). If engine oil pressure is as specified, go to next step. If engine oil pressure is not as specified, check for cause of low oil pressure and repair as necessary.
  18. KOER On-Demand Self-Test Ensure engine is at normal operating temperature. Clear DTCs. Perform «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If DTC P1211 is present, perform «TEST 9C: MONITOR ICP PID WHILE CRANKING»(ref-140379-S00364662852002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If DTC P0476 is present, go to step 21. If no DTCs are present, perform «TEST 11: CRANKCASE PRESSURE TEST»(ref-140379-S38156161392002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If symptom persists, go to next step.
  19. Check Pressure Balance Remove high pressure hose from right cylinder head. (Scheme 92) Using Fuel/Oil/Turbo Protector Cap Set (T94T-9395-AH), install appropriate cap on high pressure hose fitting on right cylinder head. Using plug from Oil High Pressure Leakage Test Adapter Set (303-S626), install plug into high pressure hose. Using scan tool, access and record Injection Pressure Regulator (IPR) PID duty cycle with engine running at 3000 RPM. Turn engine off. Remove cap and plug, and reinstall high pressure hose to right cylinder head. Remove high pressure hose from left cylinder head. (Scheme 93) Using fuel/oil/turbo protector cap set, install appropriate cap on high pressure hose fitting on left cylinder head. Using plug from oil high pressure leakage test adapter set, install plug into high pressure hose. Using scan tool, check IPR PID duty cycle with engine running at 3000 RPM. If difference in IPR PID duty cycles between right and left bank is more than 2 percent, remove cap and plug, and reinstall high pressure hose to left cylinder head. Go to next step. If difference in IPR PID duty cycles between right and left bank is 2 percent or less, replace IPR. Remove cap and plug, and reinstall high pressure hose to left cylinder head.
  20. Check For Leak Source Remove valve cover from cylinder bank with higher IPR duty cycle. With engine idling, check for bubbling around injector bores or oil gallery drain plugs. Or with engine off, apply about 100 psi (689 kPa) of compressed air to high pressure oil gallery. Injector spill spouts may require removal for visibility. If air bubbles are noticeable or leaks are heard, replace "O" rings on injectors or reseal oil galleries as necessary. If no leaks are detected, perform «KOER CYLINDER CONTRIBUTION SELF-TEST»(ref-139800-S26331301612002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair as necessary.
  21. Check For Biased EBP Sensor Perform «TEST DE: EXHAUST BACKPRESSURE SENSOR»(ref-139800-S25918183312002050900000), step 21) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Repair circuits or replace EBP sensor as necessary. If EBP sensor is okay, go to next step.
  22. Check For Exhaust Restriction (KOER DTC P0476) Go to «TEST KB: EXHAUST BACKPRESSURE REGULATOR»(ref-139800-S23052145182002050900000), step 7) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Unplug EOT sensor to cause EBP valve to stay open. Using scan tool, access EBP PID from PID/DATA MONITOR & RECORD menu. Start engine and allow it to idle. Briefly accelerate engine speed to Wide Open Throttle (WOT) while monitoring EBP PID. If EBP PID is more than 25 psi (172 kPa), go to next step. If EBP PID reading is 25 psi (172 kPa) or less, go to step 24.
  23. Exhaust Backpressure Operation Test Inspect exhaust system for damage. Observe EBP valve operation while repeating KOER ON-DEMAND SELF-TEST. See «KOER ON-DEMAND SELF-TEST»(ref-139800-S14230959502002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If EBP valve cycles and then opens completely (tang against stop), check EBP adjustment. (Scheme 94) If EBP valve does not cycle and then open completely, go to next step.
  24. Check Electrical System Perform «TEST KB: EXHAUST BACKPRESSURE REGULATOR»(ref-139800-S23052145182002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article to ensure exhaust backpressure regulator and wiring are okay. Repair as necessary. If exhaust backpressure regulator and wiring are okay, go to next step.
  25. Check For Engine Wear Perform «TEST 11: CRANKCASE PRESSURE TEST»(ref-140379-S38156161392002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If crankcase pressure reading is more than 3 in. H 2 O, go to next step to check engine mechanical condition. If crankcase pressure reading is 3 in. H 2 O or less, go to step 27.
  26. Check For Piston Or Valve Leaks Check engine compression. If compression reading is less than 350 psi (2413 kPa) and different from adjacent cylinders by 50 psi (345 kPa) or more, repair engine mechanical condition as necessary. See appropriate article in ENGINES. If compression reading is 350 psi (2413 kPa) or more and different from adjacent cylinders by less than 50 psi (345 kPa), replace affected injector.
  27. Check For Exhaust Restriction (No DTC) Perform «TEST 13: EXHAUST RESTRICTION»(ref-140379-S26419809212002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If EBP PID value is more than 34 psi (234 kPa), or more than 2 volts, locate and repair restriction in exhaust system. If EBP PID value is 34 psi (234 kPa) or less, or 2 volts or less, go to next step.
  28. Check Fuel Injector Oil Discharge Remove valve covers. Monitor oil flow out of fuel injector spill spouts with engine at idle. If injector(s) have low oil flow from spill spouts, replace affected injector(s). If all injectors have good oil flow from injector oil spill spouts, turn ignition off and go to next step.
  29. Atmospheric Pressure Rationality Check Turn ignition on. Using scan tool, monitor EBP, MAP and BARO PIDs. PID values should not deviate from atmospheric pressure by more than 1.5 psi (10 kPa). If all PID values are within specification, go to next step. If any PID value is not within specification, perform appropriate system test for the sensor with the largest difference. If EBP PID value is not within specification, see «TEST DE: EXHAUST BACKPRESSURE SENSOR»(ref-139800-S25918183312002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If MAP PID value is not within specification, see «TEST DH: MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-139800-S32178981282002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If BARO PID value is not within specification, see «TEST DG: BAROMETRIC PRESSURE SENSOR»(ref-139800-S17915024452002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  30. Check For Biased EOT Sensor Perform «TEST DB: ENGINE OIL TEMPERATURE SENSOR»(ref-139800-S01453986862002050900000), step 13) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Allow vehicle to cool overnight. DO NOT start engine. Turn ignition on. Using scan tool, monitor EOT and IAT sensor PIDs. If EOT and IAT sensor values are within 11°F (6°C) of each other, go to next step. If EOT and IAT sensor values are not within 11°F (6°C) of each other, check EOT sensor wiring. See If EOT sensor wiring is okay, replace EOT sensor.
  31. Check EOT Sensor Start and warm up engine to 59-158°F (15-70°C). Remove fill plug from high pressure oil pump reservoir. Reservoir is located on top of engine, near generator. (Scheme 89) Using an A/C thermometer, measure temperature of oil in high pressure oil pump reservoir. Using scan tool, monitor EOT sensor temperature reading. If readings between EOT sensor and A/C thermometer (oil temperature) are not within 5.4°F (3°C) of each other, check EOT sensor wiring. See «TEST DB: ENGINE OIL TEMPERATURE SENSOR»(ref-139800-S01453986862002050900000), step 14) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If EOT sensor wiring is okay, replace EOT sensor. If readings between EOT sensor and A/C thermometer (oil temperature) are within 5.4°F (3°C) of each other, verify concern. See «ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES»(ref-140379-S37643595772002052200000) in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article.

CHECK ENGINE INDICATOR LIGHT CONCERNS

  1. Perform KOEO On-Demand Self-Test If CHECK ENGINE Light is always on, check for Diagnostic Trouble Codes (DTC). Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  2. Run Bulb Check Cycle ignition switch. If CHECK ENGINE light illuminates then goes out (bulb check), no problem is indicated. If CHECK ENGINE light is always off or always illuminated, go to «TEST NB: CHECK ENGINE LIGHT»(ref-139800-S36193977492002050900000) , step 3) (Econoline), or step 1) (Excursion and F250-550) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.

EXHAUST SMOKE

  1. Preliminary Checks Perform «TEST 1: VISUAL ENGINE/CHASSIS INSPECTION»(ref-140379-S20173578632002052200000) , «TEST 2: SUFFICIENT CLEAN FUEL»(ref-140379-S27429620982002052200000) , «TEST 3: CHECK ENGINE OIL LEVEL»(ref-140379-S30969225812002052200000) and «TEST 4: INTAKE RESTRICTION»(ref-140379-S21744019582002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Atmospheric Pressure Rationality Check Turn ignition on. Using scan tool, monitor EBP, MAP and BARO PIDs. PID values should not deviate from atmospheric pressure by more than 1.5 psi (10 kPa). If all PID values are within specification, go to next step. If any PID value is not within specification, perform appropriate system test for the sensor with the largest difference. If EBP PID value is not within specification, see «TEST DE: EXHAUST BACKPRESSURE SENSOR»(ref-139800-S25918183312002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If MAP PID value is not within specification, see «TEST DH: MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-139800-S32178981282002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If BARO PID value is not within specification, see «TEST DG: BAROMETRIC PRESSURE SENSOR»(ref-139800-S17915024452002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  3. Check Color Of Exhaust Smoke Start engine and allow it to idle. If White exhaust smoke exists, go to next step. If Black smoke exists, check for charge air cooler restrictions. Repair as necessary.
  4. Check White Tailpipe Exhaust Smoke Perform «TEST 10: GLOW PLUG SYSTEM OPERATION»(ref-140379-S20051798802002052200000) under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If fault is indicated, repair as necessary. If no fault is indicated, go to next step (Excursion and F250-550) or go to step 6 (Econoline).
  5. Check Charge Air Cooler (CAC) For Restrictions Check for conditions that may restrict airflow through CAC. Disconnect ducts at CAC and check for restriction in ducts and inside of CAC. Repair as necessary. If no restrictions are present, go to next step.
  6. Confirm Fuel Quality Drain fuel tank and add known high quality diesel fuel to fuel tank. If amount of exhaust smoke decreases, advise vehicle operator on need for higher quality fuel. If amount of exhaust smoke does not decrease, go to next step.
  7. Check For Out Of Range Sensor Connect scan tool to Data Link Connector (DLC). DO NOT start engine. Using scan tool, access Engine Oil Temperature (EOT) sensor, Intake Air Temperature (IAT) sensor and Manifold Air Temperature (MAT) sensor PIDs. Turn ignition on. If EOT, IAT and MAT sensor PIDs are within plus or minus 11°F (6°C) of each other, go to next step. If EOT, IAT and MAT sensor PIDs are not within plus or minus 11°F (6°C) of each other, verify wiring harness and connectors are okay. For an EOT sensor that is out of range, see «TEST DB: ENGINE OIL TEMPERATURE SENSOR»(ref-139800-S01453986862002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. For an IAT sensor that is out of range, see «TEST DA: INTAKE AIR TEMPERATURE SENSOR»(ref-139800-S04767036712002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. For a MAT sensor that is out of range, see «TEST DI: MANIFOLD AIR TEMPERATURE SENSOR (EXCEPT ECONOLINE)»(ref-139800-S31121139532002050900000) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  8. Check For Coolant Leak Check engine for internal coolant leak. Using a pressure tester, pressurize cooling system. Start engine and allow it to idle. Note pressure gauge reading. If pressure increases immediately, check cylinder head and block for cracks. If pressure does not increase immediately, use pressure tester and pump cooling system up to pressure specified on pressure cap. If pump gauge vibrates, compression or combustion gas leak into cooling system may exist. Determine cause of internal leak and repair as necessary. See appropriate article in ENGINES. If pump gauge does not vibrate and no internal coolant leak is detected, go to next step.
  9. Check Manifold Intake Air Heater (MIAH) Operation PCM will activate intake air heater during long idle periods under the following conditions. Ambient Temperature Must Be Less Than 32°F (0°C) Engine Oil Temperature Must Be Less Than 131°F (55°C) Vehicle Power (VPWR) Must Be 11.8-15.0 Volts Parking Brake Must Be Applied On M/T Models Gearshift Lever Must Be In Park Or Neutral On A/T Models Glow Plugs Must Be Off Allow engine to cool if necessary, then start engine. If MIAH operates correctly, go to next step. If MIAH does not operate correctly, go to TEST KL: MANIFOLD INTAKE AIR HEATER under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V -DIESEL article.
  10. Check Engine Thermostat Operation Remove and inspect thermostat for corrosion and proper seating of valve. Replace thermostat as necessary. If no problem is indicated, suspend thermostat in a container filled with a 50/50 mixture of coolant and water. Place a thermometer in container. Do not allow thermostat or thermometer to touch bottom of container. Heat water until thermostat begins to open. Read temperature on thermometer. This is the initial opening temperature and should be 192°F (89°C). Continue heating water until thermostat is fully open and note reading. This is the full open temperature and should be 219°F (104°C). If either reading is not to specification, replace thermostat. If both readings are to specification, thermostat is okay. Reinstall thermostat and top off coolant. Go to next step.
  11. Isolate Engine Cylinders Generating Smoke Allow engine to cool. Remove bolts retaining exhaust manifold to cylinder head(s). Pry exhaust manifold away from cylinder head(s). Start engine and monitor smoke from exhaust ports in cylinder head. If an individual cylinder is generating excessive smoke, go to next step. If more than one cylinder is generating excessive smoke, go to step 13 .
  12. Check Smoking Cylinder(s) Compression Perform cylinder compression test on cylinders that emit smoke. If compression reading is less than 350 psi (2413 kPa) and different from adjacent cylinders by 50 psi (345 kPa) or more, repair engine mechanical condition as necessary. See appropriate article in ENGINES. If compression reading is 350 psi (2413 kPa) or more and different from adjacent cylinders by less than 50 psi (345 kPa), go to next step.
  13. Glow Plug Test Remove glow plug from smoking cylinder. See «GLOW PLUGS»(ref-142317-S15022280612002072900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - ECONOLINE, EXCURSION & F250-550 - DIESEL article. Install a jumper wire between ground and body of removed glow plug. Install another jumper wire between battery voltage and glow plug terminal. If glow plug tip becomes hot, go to next step. If glow plug tip does not become hot, replace glow plug and verify repair.
  14. Switch Fuel Injectors Remove jumper wires and reinstall glow plugs. Switch injector(s) between smoking and non-smoking cylinder(s). See «FUEL INJECTORS»(ref-142317-S09461879552002072900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - DIESEL article. Start engine and monitor smoke from exhaust ports. If smoke from cylinder moved with injector(s), replace affected injector(s). If smoke did not move with injector(s), repair engine mechanical condition as necessary. See appropriate article in ENGINES.

CRUISE (SPEED) CONTROL CONCERNS

  1. Check ABS Light Turn ignition on and observe ABS light. ABS light should illuminate for a couple of seconds, then turn off (bulb check). If ABS light operates as specified, turn ignition off and go to next step. If ABS stays on, service ABS system as necessary. See appropriate ANTI-LOCK article in BRAKES.
  2. Check Brake Warning Light Turn ignition on and observe BRAKE warning light. Brake warning light should illuminate for a couple of seconds, then turn off (bulb check). If BRAKE warning light operates as specified, go to next step. If BRAKE warning light remains illuminated, see «TEST FF: PARKING BRAKE APPLIED SWITCH»(ref-139800-S23967657732002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  3. Perform KOEO On-Demand Self-Test Perform «KOEO ON-DEMAND SELF-TEST»(ref-139800-S08685095592002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, see go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  4. Perform KOER Switch Self-Test Perform «KOER SWITCH SELF-TEST»(ref-139800-S12315474462002050900000) under QUICK TEST in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If no DTCs are present, go to next step. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS.
  5. Road Test Using scan tool, access and monitor PBA, BPA, CPP, BOO, SCCS_M, VSS and VS SET PIDs from PID/DATA MONITOR & RECORD menu. See «PARAMETER IDENTIFICATION MODE»(ref-139800-S09104900802002050900000) and «DRIVER OPERATED CONTROLS CHECK»(ref-139800-S41904787112002050900000) under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. Drive vehicle and operate speed control system. Compare VSS PID value to speedometer value. If scan tool displays the correct PID value for each PID selected, go to next step. If scan tool displays an incorrect PID value for any PID selected, perform appropriate test listed in PARAMETER IDENTIFICATION VALUES table under DRIVER OPERATED CONTROLS CHECK under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.
  6. Check Speed Control If speed control drops out while driving up hills, engine power is not adequate to hold hill, go to next step. If speed control does not drop out when climbing hills, go to «RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY»(ref-140363-S03225242312002052100000) symptom.
  7. Check Vehicle Load If vehicle is too heavy to hold hills, vehicle speed dropped 10 MPH below set speed causing speed control disengagement. Confirm condition with scan tool. Access and monitor VSS and VS SET PIDs. If vehicle is able to hold hills, see «RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY»(ref-140363-S03225242312002052100000) symptom.

TRANSMISSION CONTROL INDICATOR LIGHT

  1. 1) Check Transmission Control Indicator Light (TCIL) Turn ignition on. If TCIL is flashing, perform «QUICK TEST»(ref-139800-S19570345092002050900000) procedures in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If any DTCs are present, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-139800-S20833503472002050900000) in SELF-DIAGNOSTICS - EEC-V - DIESEL article and perform appropriate SYSTEM TESTS. If no DTCs are present, go to next step.
  2. 2) Check TCIL Symptom Toggle Transmission Control Switch (TCS) on and off several times to operate TCIL. If TCIL remains on, or remains off with TCS operation, go to appropriate symptom under «SYMPTOM DIAGNOSIS (ELECTRONIC)»(ref-140948-S09964266192002061000000) under TROUBLE SHOOTING in FORD 4R100 DIAGNOSIS article in AUTOMATIC TRANSMISSIONS. If TCIL goes on and off with TCS operation, TCIL is okay.

AUTOMATIC TRANSMISSION UP OR DOWNSHIFT, OR ENGAGEMENT CONCERNS

  1. Check Transmission Fluid Ensure engine is at normal operating temperature. Check transmission fluid level and condition while engine is running and transmission in Park or Neutral. If fluid is okay, go to next step. If fluid level is low or fluid needs to be changed, service transmission as necessary.
  2. Check PIDs Using scan tool, access and monitor TR, SCCS M, 4X4L and VSS PID from PID/DATA MONITOR & RECORD menu. See «PARAMETER IDENTIFICATION MODE»(ref-139800-S09104900802002050900000) and «DRIVER OPERATED CONTROLS CHECK»(ref-139800-S41904787112002050900000) under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - DIESEL article. If scan tool displays the correct PID value for each PID selected, perform steps in «RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY»(ref-140363-S03225242312002052100000) symptom. If scan tool displays an incorrect PID value for any PID selected, perform appropriate test listed in PARAMETER IDENTIFICATION VALUES table under DRIVER OPERATED CONTROLS CHECK under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - DIESEL article.

HIGH OIL CONSUMPTION/LEAKS

  1. Preliminary Checks Check for external engine oil leaks. Check for proper engine oil dipstick. Check for proper oil API rating (CG4/SH) and viscosity. Check air filter minder to see if filter needs to be replaced. Ensure vehicle is not overloaded. Repair any problems as necessary. If no problems are indicated, go to next step.
  2. Verify High Oil Consumption Confirm high oil consumption by reviewing vehicle maintenance records. If maintenance records are not available, have vehicle operator log oil consumption for 900 miles. Normal oil consumption rate is one quart or less per 900 miles. If oil consumption rate is within specification, no problem exists. If oil consumption rate is higher than specification, go to next step.
  3. Check For Oil In Fuel Remove fuel filter housing cover and check color of fuel. Fuel filter housing is located on top of engine. If fuel is Black in color (engine oil is present in fuel), go to next step. If fuel is not Black in color, go to step 5 .
  4. Check Fuel Injector "O" Rings Remove each injector and inspect middle "O" ring. See «FUEL INJECTORS»(ref-142317-S09461879552002072900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - DIESEL article. Replace "O" rings as necessary, and verify repair. If injector "O" rings are okay and oil consumption has been excessive since vehicle was new, replace fuel injectors. If injector "O" rings are okay and oil consumption has not been excessive since vehicle was new, go to next step.
  5. Check Engine Mechanical Components Perform «TEST 11: CRANKCASE PRESSURE TEST»(ref-140379-S38156161392002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If crankcase pressure reading is more than 3 in. H 2 O, go to next step to check turbocharger mechanical condition. If crankcase pressure reading is 3 in. H 2 O or less, engine mechanical condition is okay at this time.
  6. Isolate Turbocharger Remove air duct at turbocharger compressor housing outlet and repeat «TEST 11: CRANKCASE PRESSURE TEST»(ref-140379-S38156161392002052200000) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. If crankcase pressure readings decrease, replace turbocharger and verify repair. If crankcase pressure readings do not decrease, check turbocharger for oil leak. See TURBOCHARGER under OVERHAUL in appropriate article in ENGINES.

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