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Engine Controls - System & Component Testing - Diesel: Other Ford Pickup F250 Super Duty

Testing & Diagnostics ~651 words

Electric Fuel Pump

  1. Ensure fuel tank has fuel. Ensure fuel pump has power and ground. With ignition on, battery voltage should be present at fuel pump for about 20 seconds. If voltage is as specified, go to next step. If voltage is not as specified, perform TEST FK in SELF-DIAGNOSTICS - DIESEL article.
  2. Remove cover and 1/8" pipe plug from top rear of left cylinder head (Econoline), or top front of right cylinder head (Pickup). Install fuel pressure gauge. Check fuel pressure with engine cranking or running. Fuel pressure should be 30-80 psi (207 kPa). If fuel pressure is not 30-80 psi (207 kPa), go to FUEL PUMP PRESSURE TEST under «ENGINE PERFORMANCE DIAGNOSIS»(ref-600-S13289438012000030800000) .

Check Air Filter

Inspect air cleaner assembly for proper installation. Ensure air ducting is not blocked or collapsed. Inspect filter minder on filter housing to ensure intake restriction is below Red marks. Replace filter as necessary.

Oil Aeration/Poor Idle

  1. Connect New Generation Star (NGS) scan tool to Data Link Connector (DLC). Turn A/C off. Using scan tool, access ICP PID from PID/DATA monitor menu. See ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - DIESEL article.
  2. Start engine and raise engine speed to 3400 RPM for 3 minutes. ICP PID reading should be maximum 1250 psi (8619 kPa). If PID reading is not maximum 1250 psi (8619 kPa), change oil and retest.

Low Idle Stability (ICP Pressure)

  1. Ensure engine is at normal operating temperature. Using scan tool, access ICP PID from PID/DATA monitor menu. Start engine and allow it to idle.
  2. Check PID value. PID value should be 400-600 psi (2758-4137 kPa). If PID reading is not as specified, or idle does not stabilize, disconnect ICP sensor. Sensor is located at top left side of engine.
  3. If idle is now stabilized, fault is in ICP sensor circuit. Perform TEST DC in SELF-DIAGNOSTICS - DIESEL article. If idle still does not stabilize, replace Injection Pressure Regulator (IPR) and retest.

CHECK CYLINDER PERFORMANCE

If KOER CYLINDER CONTRIBUTION SELF-TEST under QUICK TEST in SELF-DIAGNOSTICS - DIESEL article has been successfully completed previously, go to CHECK FOR EXHAUST RESTRICTION . If KOER CYLINDER CONTRIBUTION SELF-TEST has not been completed, perform KOER CYLINDER CONTRIBUTION SELF-TEST. Possible causes for failing this test are

  1. Broken compression rings.
  2. Burnt or bent valve.
  3. Bent push rods.
  4. Bent connecting rods.
  5. Damaged rocker arms.
  6. Faulty fuel injector assembly.

No Boost

  1. Wastegate actuator not functioning. See appropriate SELF-DIAGNOSTICS article.
  2. Compress air intake hose collapsed. Repair or replace as required.
  3. Compressor manifold hoses leaking. Tighten hose clamps.
  4. Turbocharger turbine or compressor wheel damage. Replace turbocharger.
  5. Turbocharger bearings seized. Replace turbocharger.
  6. Clogged air cleaner element or restriction upstream of compressor. Repair or replace as required.

Lack Of Power

  1. Low compression. Repair as required.
  2. Wastage actuator not functioning. See appropriate SELF-DIAGNOSTICS article.
  3. Clogged air cleaner element or restriction upstream of compressor. Replace the air cleaner element. Remove the restriction.
  4. Insufficient fuel supply. Repair or replace as required.

Excessive Fuel Consumption (Black Exhaust Smoke)

  1. High fuel pressure or pressure regulator. Repair as required. For more information, see appropriate SELF-DIAGNOSTIC article.
  2. Fuel return line plugged or kinked. Clean or replace as required.
  3. Injectors leaking. Replace injectors.
  4. Powertrain control module malfunctioning. See appropriate SEFL-DIAGNOSTICS article.

Excessive Oil Consumption (Blue, Gray Or White Exhaust Smoke)

  1. Incorrect type or grade of oil. Drain and fill with specified oil.
  2. Extended oil change intervals. Change oil as recommended.
  3. Clogged air cleaner element or restriction upstream of compressor. Repair as required.
  4. Engine wear (piston rings, valve guides). Repair as required.
  5. Turbocharger oil seals leaking. See «TURBOCHARGER INTERNAL OIL LEAK TEST»(ref-600-S34860387932004022600000) under COMPONENT TESTS.
  6. Injector or injector "O" ring leaking. See appropriate SELF-DIAGNOSTICS article.

High Boost

  1. Leak in exhaust system before muffler. Repair as required.
  2. Malfunctioning wastegate. See appropriate SELF-DIAGNOSTIC article.

Bearing Clearance Check

For bearing clearance check, see TURBOCHARGER under AIR INDUCTION in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - DIESEL article.

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