Fuel Injection System - 6.9l Diesel Ford RV Cutaway E350

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during TROUBLE SHOOTING or TESTING procedures.

DESCRIPTION

In this diesel system, a mechanical high pressure rotary pump is gear driven at camshaft speed. Through this method the pump injects a precisely metered amount of fuel into each cylinder at the proper time. The pump is mounted on top of engine and provides necessary timing advance under all operating conditions.

Eight high pressure fuel pipes carry fuel from pump to an injector in each cylinder. All 8 pipes are the same length to ensure that there is no variance in timing. Engine RPM is controlled by a rotary fuel metering valve. As the accelerator pedal is pushed down, a throttle cable opens the metering valve and allows increased fuel delivery. A mechanical fuel pump located on the right side of the engine draws fuel from the fuel tank and delivers it to the injection pump via a fuel filter.

The fuel filter is located between the mechanical pump and injection pump (mounted on side of engine block). Any excess fuel in the supply system is returned to the tank by a fuel return system. A water separator is located in the fuel line between the tank and the mechanical fuel pump. The separator collects water out of the fuel system. When separator becomes about 1/3 full, a warning light on the dash will illuminate. When the warning light illuminates, water should be drained from the separator. The warning light will also illuminate when the key is in the "START" position to serve as a light test.

A solid state glow plug system is used to assist in engine starting and cold operation. A glow plug is located in the pre-chamber for each cylinder. Glow plug current is controlled by the controller module which incorporates the glow plug controller, power relay and afterglow relay into one unit.

Scheme 6

FUEL INJECTION PUMP

The Stanadyne DB-2 twin plunger injection pump contains a low pressure vane-type transfer pump, a high pressure distributor-type injection pump, a centrifugal governor and an injection timing advance mechanism.

The transfer pump output pressure (sometimes referred to as injection pump housing pressure) averages 50-100 psi (3.5-7.0 kg/cm 2 ) depending upon engine speed and application. The plunger injection pump boosts fuel pressure to about 2000 psi (140 kg/cm 2 ). The pump assembly is also equipped with an electric fuel shut-off valve.

INJECTORS

The injectors spray fuel into a pre-chamber as each compression stroke occurs. Injector opening pressure is adjusted with a shim on top of the needle valve return spring. The injector receives a high pressure pulse of fuel which forces open the needle valve, allowing the fuel to pass into pre-chamber.

FUEL SUPPLY SYSTEM

Diesel fuel is drawn through a water separator from the fuel tank by an engine mounted mechanical fuel pump. This pump is driven by an eccentric cam mounted on the crankshaft and puts out about 3 psi to the injection pump. A small screen type filter is located in the fuel tank at the pick-up. Diesel fuel arrives at the center inlet fitting on the injection pump after leaving the filter. A fuel return line is provided to return any excess fuel to the tank.

FUEL INJECTION LINES

High pressure fuel injection lines are routed from injection pump to an injector in each cylinder. The lines are of equal length but are bent differently to maintain equal length, prevent any difference in timing from cylinder to cylinder and aid installation. Lines are not interchangeable and are pre-bent by the manufacturer.

GLOW PLUG SYSTEM

Engine starting is aided by a solid state glow plug system. Function of this system is to pre-heat the combustion chamber to aid ignition of fuel.

System consists of 8 glow plugs, controller module, power relay, "WAIT TO START" indicator light and a wiring harness. Power relay is mounted on top of controller module circuit board. Complete assembly is mounted to rear of intake manifold.

Glow plugs are threaded into each combustion chamber. Glow plugs are small heaters that assist in cold starting. The glow plug controller and relay cycle 12 volts to these 6-volt heaters, which causes them to heat rapidly. After the engine starts, the glow plugs remain on between 4 and 10 seconds during initial starting cycle.

Cold Engine

1. Check and follow correct starting procedure listed on vehicle visor (if available). If vehicle starts okay, return vehicle to owner and explain starting procedure. If vehicle does not start, go to next step. NOTE: If ignition is left on and engine is not started within 2 minutes, the glow plug system must be reset by turning ignition off.
2. Open hood. Listen for click from glow plug power relay when ignition is turned on. If click is heard, go to next step. If no click is heard, go to «GLOW PLUG SYSTEM TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-test) .
3. Loosen one injector line nut 1/2 to one turn while cranking engine. If fuel discharges, go to «GLOW PLUG SYSTEM TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-test) . If no fuel discharges, go to next step.
4. Check ETR solenoid terminal (located at front of injection pump) for dirt, loose connection or damage. While cranking engine, voltage at terminal must be at least 9 volts. If okay, go to next step. If not okay, clean, repair, or replace terminal. After service, repeat this step.
5. Check voltage at cold advance solenoid terminal (located on left rear of injection pump). While cranking engine, voltage at terminal must be at least 9 volts. If okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, clean, repair, or replace terminal. After service, repeat this step.

Note. If no voltage is present in step 5, verify switching function of temperature sensing switch located behind thermostat housing.

Engine At Normal Operating Temperature

1. Check and follow correct starting procedure listed on vehicle visor (if available). If vehicle starts okay, return vehicle to owner and explain starting procedure. If vehicle does not start, go to next step. NOTE: If ignition is left on and engine is not started within 2 minutes, the glow plug system must be reset by turning ignition off.
2. Loosen one injector line nut 1/2 to one turn while cranking engine. If fuel discharges, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If no fuel discharges, go to next step.
3. Check ETR solenoid terminal (located at front of injection pump) for dirt, loose connection or damage. While cranking engine, voltage at terminal must be at least 9 volts. If okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, clean, repair, or replace terminal. After service, repeat this step.

ENGINE QUITS, STALLS OR STUMBLES

1. Check engine idle speed by performing step 17 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If okay, go to next step. If not okay, adjust idle speed. See «ADJUSTMENTS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) .
2. Check ETR solenoid terminal (located at front of injection pump) for dirt, loose connection or damage. While cranking engine, voltage at terminal must be at least 9 volts. If okay, go to step 3 or 4 as required. If not okay, clean, repair, or replace terminal. After service, repeat this step.
3. On COLD engine, check voltage at cold advance solenoid terminal (located at left rear of injection pump) while cranking engine. Voltage must be at least 9 volts. If okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, clean, repair, or replace terminal. After service, repeat this step. NOTE: If no voltage is present in step 3, verify switching function of temperature sensing switch located behind thermostat housing.
4. On HOT engine, check voltage at cold advance solenoid terminal (located at left rear of injection pump) while cranking engine. No voltage should be present. If okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, replace temperature sensing switch. After service, repeat this step.

ENGINE MISSES

1. Determine when engine miss occurs. Engine will miss when cold if one or more glow plugs are not heating. If engine misses only when cold, go to «GLOW PLUG SYSTEM TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-test) diagnosis and testing. If engine misses at normal operating temperature, go to next step.
2. Loosen each injector line nut (one at a time) while engine is running. If miss is isolated to specific cylinder(s), go to next step. If miss is not isolated, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) .
3. Check injector fuel line(s) for kinks or restrictions and test injectors. See «INJECTORS TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__injectors-test) . If lines and injectors are okay, go to next step. If not okay, replace line(s) and/or clean or replace injector(s).
4. Perform cylinder compression test. If engine compression is okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, go to next step.
5. Check crankcase pressure by performing step 20 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If okay, service or replace engine valve train. If not okay, overhaul power cylinder.

ENGINE KNOCKS

1. Check engine front drive components for proper operation. If okay, go to next step. If not okay, service or replace as necessary.
2. Verify that engine is not overheating. If not overheating, go to next step. If engine overheats, service cooling system.
3. Loosen each injector line nut (one at a time) while engine is running. If engine knock is isolated to specific cylinder(s), go to next step. If engine knock is not isolated, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) .
4. Check injection nozzle fuel line(s) for kinks or restrictions and test injectors. See «INJECTORS TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__injectors-test) . If line(s) and injector(s) are okay, go to «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If not okay, replace line(s) and/or clean or replace injector(s).

EXCESSIVE BLUE/WHITE SMOKE

1. Verify that engine coolant temperature stabilizes in normal operating range. If it does, go to step 3. If it does not, go to next step.
2. Remove thermostat, check heat range, and test for proper operation. If thermostat is okay, replace thermostat housing with integral air bleed check valve. Repeat step 1. If not okay, replace thermostat and repeat step 1.
3. Check engine oil level indicator for excessive oil fill. If level is okay, go to next step. If level is not okay, drain excess oil from oil pan. If problem persists, go to next step.
4. Perform fuel return pressure test as described in step 12 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If okay, perform entire engine diagnostic procedure. If not okay, service or replace fuel return line(s) as necessary. After repairs, repeat this step.

EXCESSIVE BLACK SMOKE

1. Verify under what conditions Black smoke occurs. If under light load and/or low altitude, go to next step. This condition is considered normal when going up steep grades, pulling trailer, under maximum acceleration, or at high altitudes.
2. Check exhaust system condition by performing step 2 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . Record problem and results. If okay, go to next step. If not okay, service or replace exhaust system as necessary. If problem persists, go to next step.
3. Check air cleaner for restrictions by performing step 13 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . Record problem and results. If okay, go to next step. If not okay, replace air filter element and/or service system. After service, repeat this step.
4. Check injection pump dynamic timing by performing step 18 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If okay, go to next step. If not okay, adjust timing. See «ADJUSTMENTS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If problem persists, go to next step.
5. Check fuel line(s) and injector(s) by performing step 19 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . If okay, replace injection pump. If not okay, replace damaged fuel line(s) and/or clean or replace injector(s). If problem persists, replace injection pump.

Glow Plug System Wiring Diagram. Scheme 7

INJECTORS TEST

1. Always use CLEAN calibration fluid in Injector Test Stand (Rotunda 014-00300). Install injector on tester. Open test stand valve slightly and operate handle 8-10 times to bleed air from injector. Close valve.
2. Open tester valve. Slowly lower tester handle and note pressure shown on gauge as injector opens. Repeat several times to obtain accurate reading.
3. Opening pressure for a NEW injector should be 1800-1950 psi (126-137 kg/cm 2 ). If injector opening pressure is below 1425 psi (100 kg/cm 2 ) on a used injector, replace injector.
4. Using test stand, maintain pressure at about 200 psi (14 kg/cm 2 ) below opening pressure. No fuel leakage should occur. Slight wetting of tip after 5 seconds is okay. DO NOT wipe tip with fingers. If leakage occurs, injector(s) must be replaced.

Scheme 8

GLOW PLUG SYSTEM TEST

Note. The following is a series of tests that can be used to diagnose the glow plug system.

Note. The Glow Plug Test below has been updated due to Ford Technical Service Bulletin number 88-11-19.

Glow Plug Test

Refer to Fig. (Scheme 6) for test lamp connections and Glow Plug System wiring harness test points referred to in the Basic Test and the Pinpoint Tests. Perform only those services specified by the Pinpoint Tests.

Operation of the Glow Plug System is completely automatic. If, after completing a specific Pinpoint Test it is determined that a component must be replaced, the glow plugs should be disconnected until system has been re-checked to make sure the Glow Plug System works properly.

Harness Test

Turn ignition off. Remove leads from glow plugs. Squeeze sides of controller protective cover and remove. Check continuity between each glow plug lead and test terminal of controller. If all leads are okay, go to next test. If any or all leads are bad, service or replace harness and go to next test.

Controller Ground Test

Turn ignition off. Check ground circuit by connecting an ohmmeter to ground wire terminal eyelet and ground post on each battery. If resistance is less than one ohm, go to next test. If resistance is more than one ohm, clean or service ground connection and go to next test.

Controller Supply Voltage Test

Turn ignition switch off. Check supply voltage by connecting voltmeter to controller power terminal and ground. If voltage is more than 10 volts, go to next test. If voltage is less than 10 volts, service wiring or recharge battery and go to next test.

Ignition Switch Voltage Test

Connect a voltmeter to ignition terminal on controller and ground. Turn ignition on and all accessories off. If voltage is more than 8 volts, go to next test. If voltage is less than 8 volts, check fusible link, service wiring, or recharge battery and go to next test.

Controller Function Test

Turn ignition off. Check controller function by connecting a 12-volt test light to test terminal on controller. Position test light so it can be viewed from driver's position. Turn ignition on. Note system operation and compare test light times to TEST LIGHT TIMES table. If test light times are within specification, system function is correct. If test light times are out of specification, disconnect power at both batteries and replace controller unit. Repeat this step.

TEST LIGHT TIMES

"Wait To Start" Light Stays On

Disconnect "Wait To Start" light connector at controller. Turn ignition on. If light glows, service wiring to light. If light stays off, disconnect power to both batteries. Replace controller unit.

"Wait To Start" Light Does Not Go On

Disconnect "Wait To Start" light connector at controller. Connect jumper wire from harness side to ground. Turn ignition on. If light glows, go to ENGINE CRANKS BUT WILL NOT START in TROUBLE SHOOTING. If light stays off, replace bulb or service wiring.

Test Preparation

The engine performance diagnostic procedure tests those items which are high frequency, easy to diagnose problems, and progresses to the low frequency, hard to diagnose problems. Proper use of this procedure will provide a rapid as well as accurate diagnosis. Connect Pressure Test Kit (Rotunda 019-00002) to components shown. (Scheme 9)

Scheme 9

Diagnostic Procedure

1. With engine running, check for coolant, fuel, oil, and air intake system leaks. If no leaks are detected, go to next step. If leaks are detected, service or replace faulty component(s). If problem persists, go to next step.
2. Check exhaust system for dents or kinks which may cause restrictions. If okay, go to next step. If not okay, repair or replace exhaust system components. After repairs, go to next step.
3. Install a piece of clear hose, in place of rubber hose, between fuel filter outlet and fuel return system. Start and run engine at idle for 2 minutes. Increase engine speed to 3000 RPM and check for bubbles in hose. Go to next step. NOTE: Correct direction of fuel flow is from fuel filter toward fuel return system. Fuel flow in opposite indicates restriction in fuel supply system. On dual tank vehicles, check fuel flow with tank selector in both positions for a minimum of 2 minutes.
4. If fuel flow is correct and bubbles are less than 1/16" (1.6 mm) in diameter, go to next step. If fuel flow is correct, but bubbles are large in diameter, perform «FUEL SYSTEM AIR LEAK DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) and repeat step 3. If fuel flow is incorrect, go to step 12. Repeat step 3, when fuel flow direction is correct.
5. Obtain a fuel sample and visually examine fuel (in a clear container) for dirt/rust particles, clouding, or water contamination. If okay, go to next step. If not okay, replace fuel filter. Clean and/or service fuel system as required. After repairs, go to next step.
6. Using cetane tester included with Dynamic Timing Meter (Rotunda 078-00200), check cetane value of fuel sample. Cetane value must be more than 40. If okay, go to next step. If not okay, perform steps 7, 12, 13, and 16. Also tell owner to use higher rated fuel. DO NOT replace injection pump because of low cetane value.
7. Remove air bleed orifice hose from fuel filter fitting. Install Adapter (5651) and pressure test kit. (Scheme 9) Start and run engine at 3000 RPM, without accessory load. Record pressure reading. On dual tank vehicles, check both tanks. If pressure is one psi (.07 kg/cm 2 ), go to step 9. If not, go to next step.
8. Remove vacuum purge valve from fuel filter adapter. Install Adapter (3019) and pressure test kit. (Scheme 9) Make sure clamp is closed on fuel sample hose. Leave adapter from step 7 installed and cap end. Start and run engine at idle, without load. Record pressure reading. On dual tank vehicles, check both tanks. If pressure is at least 2 psi (.14 kg/cm 2 ), replace fuel filter and repeat step 7. If not, go to next step.
9. Position end of sample hose on Adapter (3019) in a clear, one-quart, graduated container. Follow instructions in step 8 and open sample hose for 30 seconds, allowing fuel to flow into container. Record volume. On dual tank vehicles, check both tanks.
10. Volume should be at least one pint in 30 seconds. If both pressure and volume are okay, go to step 12. If pressure is okay, but volume is not, go to next step. If volume is okay, but pressure is not, replace fuel supply pump and repeat step 7. If both pressure and volume are incorrect, go to next step.
11. Connect fuel return line removed in step 7. Install Adapter (5632) and pressure test kit to fuel supply pump inlet. With rear wheels off ground, start and run engine (without load) at 3300 RPM. Place transmission in "P" (auto. trans.) or Neutral (man. trans.). Record vacuum reading. On dual tank vehicles, check both tanks. Vacuum should be less than 6 in. Hg. If okay, go to step 7. If not okay, service or replace restricted fuel return line(s) and repeat step 7.
12. Connect fuel return line removed in step 7. Remove fuel return line fitting (located on left rear of engine). Install Adapter (5663) and pressure test kit. Start and run engine (without load) at 3300 RPM with transmission in "P" or Neutral. Record pressure reading. On dual tank vehicles, check both tanks. Pressure should not exceed 2 psi (.14 kg/cm 2 ). If okay, go to next step. If not okay, service or replace restricted fuel return line(s) and repeat this step.
13. Remove cap on air cleaner test port and install Adapter (5650) and pressure test kit. (Scheme 9) Start and run engine at 3300 RPM, without accessory load. Record restriction reading. Reading should not exceed 25 in. of water.
14. If reading is more than 2 in. of water, but less than 25 in. of water, remove adapter. Install cap on air cleaner port and go to next step. If reading is more than 25 in. of water, replace filter element and check air intake system for blockage. After service, repeat this step. If reading is less than 2 in. of water, correct restriction on air cleaner test port and repeat this step.
15. Remove screw from transfer pump pressure port cover. Install Adapter (T83T-9000-A) and "O" ring through cover and into port. Install Adapter (5850) and pressure test kit. Start and run engine (without load) at 3300 RPM with transmission in Neutral. Record pressure reading. If pressure is 90-110 psi (6.3-7.7 kg/cm 2 ), go to next step. If not, replace injection pump. If problem persists, check and adjust dynamic timing. If problem continues, go to next step.
16. With engine off, check that throttle lever contacts injection pump stop when accelerator pedal is fully depressed. If okay, go to next step. If not okay, adjust accelerator linkage. After adjustment, go to next step. NOTE: DO NOT adjust position of full throttle stop screw. Tampering may cause injection pump damage.
17. Start engine and bring to normal operating temperature. Check engine idle speed. See «ADJUSTMENTS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel). If idle speed is correct, go to step 12. If not, adjust idle speed as necessary and then go to step 12.
18. Start engine and bring to normal operating temperature. Check injection pump dynamic timing. See «ADJUSTMENTS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel). Compare value to specification and correct for cetane value and altitude. If timing is correct, go to next step. If not, adjust timing. If problem persists, go to next step.
19. Check injector inlet lines for kinks or restrictions and test injectors. See «INJECTORS TEST»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__injectors-test). If lines and injectors are okay, go to next step. If not okay, replace damaged line(s) and clean or replace injector(s). If problem persists, go to next step.
20. Remove crankcase depression regulator valve and plug opening to prevent blow-by. Remove oil fill cap and install Adapter (5631) and pressure test kit. (Scheme 9) Ensure dipstick is seated in dipstick tube. Start and run engine (without load) at 3300 RPM with transmission in Neutral. Record pressure reading. Pressure should not exceed 6 in. of water. If reading is correct, replace injection pump. If not, problem is mechanical in nature.

Before starting diagnostic procedure, verify that fuel tank(s) contain at least half a tank of fuel. Visually inspect fuel lines for obvious problems such as kinked hoses, damaged lines or push-to-connect fittings.

Hard starting, excessive White smoke, poor idle quality, or lack of power under load may be caused by several conditions. One of these conditions is air leaks in the fuel supply system. To perform fuel system air leak diagnosis, the following adapters need to be fabricated. (Scheme 10)

Scheme 10

1. Verify that push-to-connect fitting clip is in place. Verify that fittings are properly installed on tube end by pulling fitting (axially) away from tube.
2. If fitting does pull away, push fitting back on tube until a definite click is heard. Pull and push fitting one more time to verify proper installation. If okay, go to next step. If not okay, service or replace fuel lines, clips, or push-to-connect fittings.
3. Remove rubber fuel return by-pass hose which connects fuel filter outlet fitting by-pass orifice to return lines at injectors. Install a clear hose (to view fuel flow) in place of rubber hose. Lubricate hose with fuel to ease installation. Tighten hose clamps. Start and run engine at 3000 RPM for 2-3 minutes to clear air from system.
4. Observe hose for air bubbles with engine at 3000 RPM. A continuous stream of air bubbles larger than 1/16" (1.6 mm) indicates air in system. A concentration of bubbles of any size, or foam, is unacceptable. If no bubbles are detected, problem is elsewhere in system. Install rubber by-pass hose. If bubbles are detected, go to next step.
5. Observe direction of flow of bubbles. Bubbles should flow from fuel filter outlet fitting to fuel return system. If okay, go to next step for SINGLE tank system, step 8 for DUAL tank system. If not okay, fuel system is restricted. Go to step 7 of «ENGINE PERFORMANCE DIAGNOSIS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) .
6. Check for damage to hose connections at rubber fuel hose from chassis fuel line to mechanical lift pump and at inlet and outlet hoses at water separator. Tighten clamps if necessary.
7. After tightening clamps, start and run engine at 3000 RPM for 5 minutes. Check for air bubbles in clear hose. If no bubbles are detected, problem has been corrected. Install rubber by-pass hose. If bubbles are detected, go to next step.
8. Disconnect water separator inlet hose. Install hose adapter and tighten clamps. Disconnect water separator outlet hose. Install hose adapter and tighten clamps. Start and run engine at 1500 RPM for 5 minutes. Increase engine speed to 3000 RPM for an additional 2 minutes and check for bubbles in hose adapters.
9. On SINGLE tank system, if bubbles are present in inlet hose, service hoses and connections between water separator. After service, repeat step 8. On DUAL tank system, if bubbles are present in inlet hose, go to step 11.
10. On both systems, if bubbles are present in outlet hose only, check hose adapter at water separator inlet for air leaks. Stop engine and drain water separator. See «MAINTENANCE»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) . After draining separator, repeat step 8. If bubbles persist, replace water separator and repeat step 3.
11. Start and run engine at 3000 RPM. Observe clear hose while switching selector valve between tanks. If bubbles are detected in both tank positions, go to step 6. If bubbles are detected in only one position, check push-to-connect fittings as stated in step 1. If okay, go to next step. If not okay, service or replace fittings.
12. Disconnect push-to-connect fittings from fuel tank selector valve for affected tank. Install push-to-connect adapters between fuel lines and selector valve. Start and run engine at 3000 RPM for 2-3 minutes. Run engine an additional 2 minutes and check for bubbles in hose adapters.
13. If no bubbles are detected in either adapter, air leak is between fuel tank selector valve and water separator. Service fuel lines and connections as necessary. After service, repeat step 3.
14. If bubbles are detected in both adapters, air leak is between fuel tank and selector valve. Service fuel lines and connections as necessary. After service, repeat step 3. If bubbles are detected in selector valve outlet adapter only, replace selector valve and repeat step 3.

Removal

1. Open hood. Disconnect battery negative cables from both batteries. On vans, remove engine cover. On all models, remove engine oil filler neck. Remove bolts attaching injection pump to drive gear.
2. Disconnect electrical connectors from injection pump. Disconnect accelerator cable and cruise control cable (if equipped) from throttle lever. Remove air cleaner and cover air intake.
3. Remove accelerator cable bracket, with cables attached, and position out of way. On vans, remove fuel inlet and return lines from fuel filter. Remove filter bracket and filter as an assembly. Cap all openings.
4. On all models, remove fuel line from injection pump inlet and cap fittings. Remove injection pump inlet elbow and fitting adapter. Cap inlet elbow and fitting.
5. Remove fuel return line from injection pump, rotate out of way and cap all fittings. If injector lines are to be removed, loosen line fittings at pump before removing it from engine. Disconnect fuel lines from injectors and cap line fittings and injectors.
6. Using Injection Pump Wrench (T83T-9000-B), remove 3 injection pump retaining nuts. If injection pump is to be replaced, remove injector lines from pump and cap all fittings. Injector lines must be removed in the following order: 5-6-4-8-3-1-7-2. (Scheme 11) Remove injection pump from engine compartment (through passenger's compartment on vans).

Installation

1. To install, reverse removal procedure. Use a new "O" ring on drive gear end of injection pump. Install injector lines AFTER pump is installed. Lines must be installed in the following order: 2-7-1-3-8-4-6-5.
2. Clean old sealant from injection pump elbow threads using clean solvent. Dry thoroughly. Start elbow into injection pump adapter, and then apply a light coating of Teflon pipe sealant.
3. Apply a 1/8" (3 mm) bead of silicone rubber sealant in adapter housing grooves. Join components within 15 minutes of bead application. After this time sealant begins to set and its sealing effectiveness may be reduced.
4. Use new "O" ring on injection pump fitting adapter. Purge injector lines by loosening connector 1/2 to one turn and crank engine until a solid stream of fuel flows from connector. Check and adjust injection pump timing.

Scheme 11

1. Before removing injectors, clean surrounding area and connections with clean fuel or solvent to prevent contamination. Blow area dry with compressed air. Remove fuel line retaining clamps from lines being removed.
2. Disconnect fuel inlet and fuel return "T" fittings from each injector and position out of way. Cap all open connections.
3. Remove injector and copper gasket from engine. Use "O" Ring Remover (T71P-19703-C) to remove gasket if it is not attached to injector tip. DO NOT strike injector tip against any hard surface during removal.
4. Cap both ends of injector and store in a rack such that injector may be installed in original cylinder.

1. Clean injector bore in cylinder head thoroughly before installing injector. Remove protective cap from tip. Coat threads with anti-seize compound. Install a new copper gasket on injector using a small amount of grease to retain gasket on injector.
2. Install injector into cylinder head bore and tighten. Remove caps from fuel lines and fittings. Install fuel inlet and return "T" fittings on injector. Install 2 new "O" rings on each "T" fitting. Connect fuel line to injectors.
3. Install fuel line retainer clamps and tighten. Purge injector lines if needed by loosening connector 1/2 to one turn and cranking engine until a solid stream of fuel flows from connector. Run engine and check for fuel leaks.

Removal & Installation

1. Disconnect negative battery cables. Unscrew filter from adapter. Clean gasket surface from adapter to prevent contamination. Lightly coat filter sealing gasket with clean fuel. DO NOT add fuel to filter.
2. Screw new filter onto adapter until seal contacts flange. Tighten filter another 180-300 degrees. Clean any fuel spills and connect battery cables. Start engine and check for leaks.

Static Timing

1. Remove fast idle bracket and solenoid from injection pump. Loosen 3 nuts attaching fuel injection pump to pump mounting adapter with Injection Pump Wrench (T83T-9000-B).
2. Install Injection Pump Rotator (T83T-9000-C) on front of pump. Rotate pump to align injection pump mounting flange timing mark with pump mounting adapter timing mark. (Scheme 12)
3. Remove rotator and tighten mounting nuts. Visually check timing to ensure that marks are still aligned after tightening nuts. Install fast idle bracket and solenoid.

Scheme 12

Dynamic Timing

Correct timing specifications vary with cetane value of fuel. Before performing timing test, determine cetane value as follows

Scheme 13

1. Obtain a small fuel sample from injection system. Temperature of fuel must be 75-95°F (24-35°C) to obtain accurate results.
2. Fill hydrometer container included with Dynamic Timing Meter (078-00200) with fuel until hydrometer floats. Spin container gently to break surface tension of fuel.
3. Read number at lowest point of fuel level in hydrometer. Compare reading to «DIESEL FUEL CETANE VALUES»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) chart to determine cetane value. DIESEL FUEL CETANE VALUES Hydrometer Reading Cetane Value.837 50.846 47.849 46.858 43.862 42.876 38
4. Start and warm engine to normal operating temperature. Coolant temperature MUST be 192-212°F (89-100°C) to obtain correct dynamic timing. Stop engine and connect dynamic timing meter clamps to battery.
5. Rotate offset angle control knob clockwise until it stops. Reading on degree scale should be MINUS (-)170 degrees or greater. Rotate offset control knob counterclockwise until it stops. Reading on degree scale should be zero degrees or a positive number.
6. If readings are incorrect, have dynamic timing meter calibrated at an authorized service center. If readings are correct, stop engine and install magnetic pick-up probe of dynamic timing meter into timing pointer probe hole. (Scheme 13)
7. Set dynamic timing meter to MINUS(-) 20 degrees. Remove No. 1 cylinder glow plug. Make sure that sight glass in luminosity probe is clean. Install luminosity probe in place of glow plug and tighten to 12 ft. lbs. (16 N.m). (Scheme 13) Connect photocell over luminosity probe and connect to timing meter.
8. Disconnect cold start advance solenoid connector from terminal. Raise and support rear wheels. Place transmission in Neutral and start engine. Using Throttle Controller (014-00302), set engine speed at 1400 RPM with no accessory load. Read injection timing on meter. NOTE: It is important that all degree readings show a MINUS (-), indicating ATDC, on timing meter. Any plus (+) readings, indicating BTDC, will cause poor engine performance and may cause engine damage.
9. If injection timing is not within 2 degrees of value indicated in «DYNAMIC INJECTION TIMING SPECIFICATIONS»(/ford/rv-cutaway-e350/1987-1987/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) chart, timing must be adjusted. If timing is incorrect, stop engine and loosen pump retaining nuts (keeping nuts snug).
10. Using injection pump rotator, rotate pump clockwise to retard timing or counterclockwise to advance timing (as viewed from front of engine). Tap rotator with rubber mallet as needed to rotate pump.
11. Moving timing mark.030" (.75 mm) is equal to 2 degrees of timing. Retighten nuts. Recheck timing using meter. Repeat step 10 as needed to obtain correct timing. Remove timing meter and other test equipment. Reinstall glow plug using anti-seize compound on threads.

DYNAMIC INJECTION TIMING SPECIFICATIONS

DYNAMIC INJECTION TIMING SPECIFICATIONS

CURB IDLE SPEED

1. Start and run engine until it reaches normal operating temperature. Place transmission in Neutral (man. trans.) or "D" (auto. trans.). Ensure that curb idle adjusting screw is against stop. If not, adjust accelerator linkage.
2. Using Photoelectric Tachometer (099-00001), check curb idle speed. Adjust idle speed to specification as indicated on Emission Tune-Up Decal in engine compartment. Use curb idle screw on side of pump for adjustment. (Scheme 14)
3. With transmission in "P" (auto. trans.) or Neutral (man. trans.), rev engine momentarily. Shift back into specified gear and recheck idle speed. Readjust if necessary.

FAST IDLE SPEED

1. Start and run engine until it reaches normal operating temperature. Disconnect wiring harness from fast idle solenoid. Apply battery voltage to solenoid to activate it. Rev engine momentarily to set solenoid plunger. Fast idle speed should be 875-900 RPM.
2. Adjust fast idle speed if necessary by turning solenoid plunger. Rev engine and recheck fast idle speed. Readjust if necessary. Remove battery voltage from solenoid and reconnect harness. (Scheme 14)

Scheme 14

VACUUM REGULATOR VALVE

The vacuum regulator valve provides vacuum signals to control automatic transmission shift points. Vacuum setting of valve should be checked periodically, using the following procedure. Engine MUST NOT be running during this procedure.

Scheme 15

1. Disconnect 2-port vacuum connector from vacuum regulator valve, located on left side of injection pump. (Scheme 15) Remove throttle cable from pump throttle lever, located on right side of pump.
2. Remove throttle return spring and reposition. Place end of spring over throttle lever ball stud and other end over throttle cable support bracket. Attach a hand-held vacuum pump to upper port of vacuum regulator valve.
3. Attach vacuum gauge to lower port (labeled "TRANS") of regulator valve. Apply and maintain 20 in. Hg vacuum to vacuum regulator valve. It will be necessary to increase vacuum as regulator valve bleeds off.
4. Cycle throttle lever 5 times from idle to wide open throttle with vacuum applied. Insert Gauging Block (T83T-7B200-AH) between pump boss and wide open throttle stop. (Scheme 16)
5. Repositioned spring should hold throttle lever stop against block. Vacuum gauge attached to regulator valve should indicate 6-8 in. Hg. If not, adjust regulator valve.
6. To adjust valve, loosen vacuum regulator valve screws and rotate valve until vacuum gauge reads 7 in. Hg. Tighten screws. If valve cannot be adjusted to specification, replace regulator valve and repeat adjustment procedure.
7. Remove gauging block. Reconnect throttle return spring in original position and connect throttle cable. Apply 20 in. Hg vacuum to vacuum regulator valve and while maintaining vacuum, cycle throttle lever 5 times from idle to wide open throttle.
8. Vacuum gauge must indicate at least 13 in. Hg with throttle at idle. If reading is less than 13 in. Hg, replace vacuum regulator valve and repeat adjustment procedure. If reading is correct, remove vacuum pump and gauging block. Attach vacuum connector.

Scheme 16

WATER SEPARATOR

Water separator should be drained every 5000 miles or when warning light illuminates. Diesel fuel can damage asphalt and painted surfaces. Always place a drain pan under water separator to collect fuel. To drain conditioner, use the following procedure

1. On pickups, stop vehicle and turn engine off. Open hood. Grasp pull ring and pull upward until it stops. Hold ring in this position for about 15 seconds or until water is completely drained. Release pull ring.
2. On vans, stop vehicle and turn engine off. Raise plastic cover on drain handle bracket located on floor pan, to right of driver's seat. Grasp handle and pull firmly upward until it hits stop.
3. Hold handle in this position for about 15 seconds or until water is completely drained. After water is drained, push handle in to close cover on drain handle bracket.
4. Check water separator to verify draining has stopped. Water separator is located inside of driver's side frame rail, in line with front wheel.
5. On all models, restart engine and check warning light. If warning light is still lit, fuel system needs to be checked or repaired. The only serviceable item on the separator is the water level sensor.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING
• GLOW PLUG SYSTEM TEST
• INJECTORS TEST