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2004 Ford Cab & Chassis F350 Super Duty

2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

HARD START/NO START DIAGNOSTIC PROCEDURES

SERTECA Lunes, 18 de Junio de 2012 01:01:58 01:01:53 a.m. Page 1 © 2005 Mitchell Repair Information Company, LLC.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

Fig. 1: Hard Start/No Start Diagnostic Guide - F-Super Duty/Excursion - Early Build (Built Before 9/2003) Courtesy of FORD MOTOR CO.

SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 2 © 2005 Mitchell Repair Information Company, LLC.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

Fig. 2: Hard Start/No Start Diagnostic Guide - E-Series or F-Super Duty/Excursion - Late Build (Built After 9/2003) Courtesy of FORD MOTOR CO. NOTE:
SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 3 © 2005 Mitchell Repair Information Company, LLC.

A hard start/no start concern with the engine oil temperature (EOT) below 15° C

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

(60° F) perform Step 11 first. 1. VISUAL ENGINE/CHASSIS INSPECTION
Purpose:

The purpose of this test is to check the general condition of the engine and look for obvious causes of a hard start or no start condition. Fuel Oil Coolant Electrical Hoses Leaks Method Visual
Recommended Procedure:

Check

Inspect the fuel system including the fuel tank and the fuel lines for kinks, bends and/or leakage. Inspect for coolant leaks at the radiator and the heater hoses and check the coolant level. Inspect the manifold absolute pressure (MAP) sensor and the intercooler for pinched hoses and leaks. Inspect wiring for correct routing and make sure no rubbing or chafing has occurred. Inspect the engine harness, fuel injector control module (FICM), powertrain control module (PCM) and sensor connectors to make sure they are completely seated and in good condition.
Possible Causes:

Loose or leaking fuel supply lines could cause fuel system to lose prime Kinked or blocked fuel supply lines will create fuel restriction Fuel or oil leaks could contribute to no start conditions Coolant leaks could indicate engine problems Electronic connectors may be damaged or not properly installed causing a no start condition. The camshaft position (CMP) sensor, crankshaft position (CKP) sensor, injection pressure regulator (IPR) and the PCM connectors are the most critical electronic sensors/actuators to inspect in no start situations Pinched or open MAP sensor hose Pinched or open intercooler hose
Tools Required:

Inspection light
SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 4 © 2005 Mitchell Repair Information Company, LLC.

LLC. the oil will appear thin and watery.6. WARNING: SMOKING OR OPEN FLAME OF ANY TYPE MUST NOT BE PRESENT WHEN WORKING NEAR FUEL OR FUEL VAPOR. If the oil level on the dipstick is overfull. Remove the fuel pressure test port plug from the secondary filter housing. Method Visual Recommended Procedure: Check Check for correct oil level using the dipstick with the vehicle on level ground. Install the plug in the outlet port. it is possible the engine was incorrectly serviced or fuel/coolant is diluting the oil and filling the crankcase.0L Diesel 2. Depending on the severity of the leak. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.1 MPa (0-160 psi) Bar 014-00761 or equivalent at the test port to confirm constant fuel pressure. access OSC and command the fuel pump ON. coolant). Miles/hours on oil. Isolate either cylinder head by removing the corresponding fuel line from the fuel filter housing. it may take some time before a leak is noticeable. Refer to SERTECA Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Watch for fuel to drain out of the oil pan drain hole. drain the oil and the fuel filter housing. 10W-30 oil is recommended for cold ambient temperatures. If there is no oil or very little oil in the crankcase. the injectors will not operate. Check the service records for correct oil type and viscosity for the vehicle operating temperature. Page 5 © 2005 Mitchell Repair Information Company. Oil that has had extended drain intervals will have increased viscosity (become thicker) and will make engine cranking more difficult and starting less reliable at temperatures below freezing. If the oil level is overfilled. CHECK ENGINE OIL LEVEL Purpose: The purpose of this test is to verify the oil quality and determine if there is sufficient oil to operate the injectors. Remove the valve cover at the suspect cylinder head and inspect the injector area for leaks. Oil contaminated with diesel fuel will have a diesel fuel odor and will increase the engine oil level. If the engine oil level is above "Max" due to diesel fuel dilution. Install Fuel Pressure Adapter (303-765) and Gauge 0 -1. Inspect the oil for color. . Check Engine Oil Level Check for contaminants (fuel. Single weight or 15W-40 oil is not recommended for cold ambient temperatures. 18 de Junio de 2012 01:01:53 a. correct level. Using the scan tool. Correct grade/viscosity. A milky white oil indicates possible coolant contamination and will have an ethylene glycol odor.m.

head gasket. Inspect the air cleaner housing and filter for proper installation. incorrect servicing Oil level high . Possible Causes: Loss of lube oil pressure Oil level low . oil consumption. .6.GENERAL INFORMATION article or Owner Literature for the correct oil selection for temperature conditions. Intake/Exhaust Restriction Inspect the air filter and inlet ducts.1 MPa (0-160 psi) Bar (part of Pressure Adapter Kit 014-00761 or equivalent) Scan tool 3. Page 6 © 2005 Mitchell Repair Information Company.m. a considerable amount of black/blue smoke is produced. LLC. Inspect the air filter restriction gauge to ensure the intake restriction is below the red marks. Inspect the exhaust system. F-Super Duty/Excursion SERTECA Lunes. Inspect the exhaust system for damaged or blocked pipes.0L Diesel the lube oil chart in the ENGINE SYSTEM . 18 de Junio de 2012 01:01:53 a. INTAKE/EXHAUST RESTRICTION Purpose: This purpose of this test is to determine if an air intake or exhaust restriction is contributing to a no start or hard start condition. porosity Tool Required: Adapter 303-765 or equivalent Gauge 0-1. If the engine does start with a high air intake or exhaust restriction. Check for illumination of the air filter restriction indicator (F-Super Duty/Excursion) Method Visual Recommended Procedure: Check Inspect the air cleaner inlet and ducting to verify it is not blocked or collapsed.oil leak.oil cooler.incorrect servicing. fuel dilution from injector O-rings Oil contamination with coolant .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .

. LLC. 3: Identifying F-Super Duty/Excursion Air Filter Restriction Gauge Courtesy of FORD MOTOR CO. Page 7 © 2005 Mitchell Repair Information Company.6. 18 de Junio de 2012 01:01:53 a.m. E-Series SERTECA Lunes.0L Diesel Fig.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .

18 de Junio de 2012 01:01:53 a.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .m.6. . Page 8 © 2005 Mitchell Repair Information Company. 4: Identifying E-Series Air Filter Restriction Gauge Courtesy of FORD MOTOR CO. plastic bags or other foreign material may restrict airflow at the air inlet Misrouted air cleaner ducting On engines recently repaired. LLC. Snow. Possible Causes: NOTE: Reset the air filter restriction gauge after repairing a restriction concern. rags or cap plugs may have been inadvertently left in an air inlet pipe SERTECA Lunes.0L Diesel Fig.

Sufficient Clean Fuel Check for illumination of the WATER IN FUEL indicator. Close the drain valve.6. F-Super Duty/Excursion SERTECA Lunes. Page 9 © 2005 Mitchell Repair Information Company. It should be clear. Inspect the fuel in the container.m. Flow out of the drain should be a steady stream. Dyed red or blue fuel indicates off-highway fuel. a second sample may be required to determine fuel quality.0L Diesel Tailpipe or muffler may have collapsed or been damaged Tools Required: None 4. the fuel is probably contaminated with water. If that is the case. SUFFICIENT CLEAN FUEL Purpose: The purpose of this test is to verify the fuel quality. not cloudy.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . A cetane rating between 40 and 50 is recommended for optimum performance. Insufficient flow could indicate fuel supply or fuel system problems. It also should be free of water and contaminants. After verifying that there is fuel in the tank. 18 de Junio de 2012 01:01:53 a. . drain a sample from the fuel control module. Method Visual Recommended Procedure: Check Open the drain valve on the fuel control module and fill a clear container until it is half full. Observe WATER IN FUEL indicator. If the indicator is illuminated. Some sediment and water may be present in the fuel sample if the fuel filter has not been serviced for a prolonged period of time and/or if the sediment and water have not been drained recently. LLC.

m. . E-Series SERTECA Lunes. Page 10 © 2005 Mitchell Repair Information Company. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .0L Diesel Fig. 5: Identifying Fuel Control Module Drain Valve .F-Super Duty/Excursion Courtesy of FORD MOTOR CO. 18 de Junio de 2012 01:01:53 a.6.

m. Possible Causes: SERTECA Lunes.0L Diesel Fig. 6: Identifying Fuel Control Module Drain Valve .6.E-Series Courtesy of FORD MOTOR CO. Page 11 © 2005 Mitchell Repair Information Company. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . 18 de Junio de 2012 01:01:53 a. .

Tools Required: Clear container .approximately 0. F-Super Duty/Excursion SERTECA Lunes. Fuel pump will run for 20 seconds at initial key on and then pressure will decrease. Excessive water or contaminants may indicate that the tank and fuel system may need to be flushed and cleaned.1 MPa (0-160 psi) gauge Recommended Procedure: Specification 310 kPa (45 psi minimum) Measurement Verify there is fuel in the tank and battery voltage at the fuel pump. Using a digital multimeter. 2 fuel) Pickup tube screen in tank could be clogged Restricted fuel filters Cloudy fuel indicates that the fuel may not be a suitable grade for cold temperatures. 18 de Junio de 2012 01:01:53 a.m.95L (1-quart) 5. Check the fuel pump power and ground circuits. Electric Fuel Pump Pressure Verify there is fuel in the tank.6. Measure the fuel pressure at the engine fuel filter housing test port with a 0-101 MPa (0-160 psi) gauge.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . ELECTRIC FUEL PUMP PRESSURE Purpose: The purpose of this test is to verify there is sufficient fuel pressure for starting. GO to PINPOINT TEST M: FUEL PUMP MONITOR/CONTROL . Battery voltage will be present for approximately 20 seconds after the ignition key is turned on. Page 12 © 2005 Mitchell Repair Information Company. measure the voltage between the fuel pump power and ground circuits. .0L Diesel No fuel in the tank Fuel supply line could be broken or crimped Fuel could be jelled (most likely in cold weather with No. If no voltage is present. Instrument 0-1. LLC.

. 18 de Junio de 2012 01:01:53 a. 7: Identifying Electric Fuel Pump Connector .6.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .F-Super Duty/Excursion Courtesy of FORD MOTOR CO. Page 13 © 2005 Mitchell Repair Information Company.0L Diesel Fig.m. LLC. E-Series SERTECA Lunes.

6. 18 de Junio de 2012 01:01:53 a. Page 14 © 2005 Mitchell Repair Information Company. If fuel pressure is below the specification of 310 kPa (45 psi).1 MPa (0-160 psi) Bar 014-00761 or equivalent. Remove the plug from the front of the fuel filter housing. Measure fuel pressure in crank or run.0L Diesel Fig. LLC. SERTECA Lunes. Install Adapter 303-765 and Gauge 0-1. .E-Series Courtesy of FORD MOTOR CO.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .m. 8: Identifying Electric Fuel Pump Connector . go to the next step to verify no restriction.

ELECTRIC FUEL PUMP INLET RESTRICTION Purpose: SERTECA Lunes.6. 18 de Junio de 2012 01:01:53 a. .0L Diesel Fig.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Possible Causes Fuel pump relay Inertia switch Tools Required: Adapter 303-765 or equivalent Gauge 0-1. LLC. 9: Removing Plug From Front Of Fuel Filter Housing Courtesy of FORD MOTOR CO.m. Page 15 © 2005 Mitchell Repair Information Company.1 MPa (0-160 psi) Bar (part of Pressure Adapter Kit 014-00761 or equivalent) 6.

. If filters are OK. Electric Fuel Pump Inlet Restriction Measure restriction at fuel pump inlet. Page 16 © 2005 Mitchell Repair Information Company. Install Fuel Pump Adapter 310-111 or equivalent between the fuel inlet line and the electric fuel pump. If regulator and filters are OK.0L Diesel The purpose of this test is to isolate the cause of low fuel pressure. Perform KOEO On-Demand Test Use the scan tool. Diagnostic Trouble Codes (DTCs) Recommended Procedure: SERTECA Lunes. inspect both fuel filters. If restriction is less than 152 mm Hg (6 in Hg).m. Instrument (0 -30 in Hg) Vacuum Recommend Procedure: Specification 6 in Hg maximum Measurement Remove the fuel line to the inlet side of the fuel pump. inspect the fuel regulator valve. If restriction is greater than 152 mm Hg (6 in Hg).2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . PERFORM KEY ON ENGINE OFF (KOEO) ON-DEMAND SELF-TEST Purpose: The purpose of this test is to determine if the PCM has detected any fault conditions that would cause a hard start or no start condition. there is a restriction between the fuel pump and the fuel tank. Connect the test adapter to gauge 0-762 mm Hg (0-30 in Hg) vacuum.6. 18 de Junio de 2012 01:01:53 a. install a new fuel pump. Measure restriction at wide open throttle (WOT) (maximum engine speed out of gear with the brakes set and the wheels blocked). LLC. Diagnostic trouble codes (DTCs) set during this test are current faults. Possible Causes: Fuel line restriction Fuel pressure regulator valve Fuel filters Fuel pump Tools Required: Fuel Pump Adapter 310-111 or equivalent Vacuum Gauge (part of Pressure Adapter Kit 014-00761 or equivalent) 7.

Perform the necessary vehicle preparation and a visual inspection. it must be turned off to perform the self-test. first clear continuous DTCs (be sure to record all DTCs and Freeze Frame information before clearing). Perform a KOEO On Demand Self-Test. Follow the operating instructions from the diagnostic menu. Retrieve Continuous DTCs DTCs retrieved during this test are historical faults. a hard fault has occurred. Key on. .6. RETRIEVE CONTINUOUS DTCS Purpose: The purpose of this test is to determine if the PCM has detected any historical or intermittent fault conditions that would cause a hard start/no start symptom.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . The condition that caused a continuous DTC may no longer exist. Page 17 © 2005 Mitchell Repair Information Company. Connect the scan tool. If the DTC is set again. Record the DTCs and Freeze Frame information and refer to the appropriate pinpoint test. Refer to the scan tool operating manual for instructions. Rerun KOEO On-Demand Self Test. Wait 4 seconds for the transmission control module (TCM). Possible Causes: The most likely PCM detectable faults that will cause a no start or hard start condition are: CMP sensor inactive fault CKP sensor inactive fault IPR output circuit check fault FICM ENABLE circuit fault Tools Required: Scan tool 8. Turn off all accessories. Refer to QUICK TEST OPERATION . PCM and the FICM to initialize. LLC.m. If the vehicle is equipped with an auxiliary powertrain control module (APCM). engine off. 18 de Junio de 2012 01:01:53 a.0L Diesel NOTE: To ensure that the DTC is a hard fault. Diagnostic Trouble Codes (DTCs) Recommended Procedure: SERTECA Lunes.

Injector Trouble Codes 6. Refer to the scan tool operating manual for instructions. . If the vehicle is equipped with an APCM.0L Engine. NOTE: DTCs can be historical if not cleared from a previous test. Follow operating instructions from the menu. KOEO INJECTOR ELECTRICAL SELF-TEST (CLICK TEST) Purpose: NOTE: If unable to perform KOEO Injector Electrical Self-Test (Click Test). All injectors will momentarily click.6. then each injector will click in sequence 1 through 8. Key on. Continuous DTCs must be cleared after a repair. The purpose of this test is to determine if the injector solenoids and valves are functioning by clicking all injectors together and then each injector in numerical sequence (1 through 8). Cylinder and Fuel Injector Location SERTECA Lunes. Page 18 © 2005 Mitchell Repair Information Company. Injector DTCs will be displayed after the self-test is completed.0L Diesel Connect the scan tool. it must be turned off to perform self tests. Tools Required: Scan tool 9. Refer to QUICK TEST OPERATION .m. LLC. KOEO Injector Electrical Self-Test (Click Test) Use the scan tool.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Record the continuous DTCs and Freeze Frame information and perform the appropriate pinpoint test for continuous DTC diagnostics. Turn off all accessories. NOTE: Sequence repeats three times. Perform the necessary vehicle preparation and a visual inspection. disconnect the FICM connector and check injector for shorts or opens. engine off. 18 de Junio de 2012 01:01:53 a.

6. Page 19 © 2005 Mitchell Repair Information Company. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . .0L Diesel SERTECA Lunes.m. 18 de Junio de 2012 01:01:53 a.

If a fault is detected.6. Recommended Procedure: This test determines if the injector circuits and solenoids are electrically operating without fault. it must be turned off to perform self tests. 10: Identifying Firing Order Courtesy of FORD MOTOR CO. a DTC will be output on the data link at the end of the test when requested by a scan tool. Scan Tool . LLC. If vehicle is equipped with an APCM. then each injector will click for approximately 1 second in numerical order (1 through 8). SERTECA Lunes. Select the parameters indicated from the scan tool parameter list and monitor while cranking the engine. engine off. CHECK VPWR DURING CRANKING Purpose: The purpose of this test is to verify PCM power during cranking. Refer to the scan tool operating manual for instructions. Key on.m. Possible Causes: Open or shorted injector circuit Injector connector Injector solenoid FICM power or ground circuit FICM Tools Required: Scan tool 10A. Only a hard fault DTC will be displayed. 18 de Junio de 2012 01:01:53 a. Turn off accessories. Connect the scan tool.Data List Monitoring Scan tool may reset below 9. Perform the necessary vehicle preparation and a visual inspection.5 volts. Refer to QUICK TEST OPERATION .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Perform the KOEO Injector Electrical Self-Test (Click Test). Page 20 © 2005 Mitchell Repair Information Company. . Record the DTCs and refer to the appropriate pinpoint test. All injectors will first click together for approximately 2 seconds. Follow the operating instructions from the diagnostic menu.0L Diesel Fig.

Scan Tool .5 volts may cause the scan tool to reset. CHECK FICM POWER DURING CRANKING Purpose: The purpose of this test is to verify FICM power during cranking. Recommended Procedure: Connect the scan tool. Possible Causes: Battery cables Low battery voltage Charging system problem Power circuit and ground faults to the PCM PCM relay GO to PINPOINT TEST A: VEHICLE BATTERY to diagnose a voltage concern.6. check the battery.5 volts. You may need to use an outside power source for the scan tool.Data List Monitoring SERTECA Lunes. If excessive crank time is a concern. Tools Required: Scan tool 10B AND 10C.0L Diesel NOTE: The 8 volt specification represents the minimum battery voltage required for engine starting. LLC. If the scan tool resets during a self-test or while PID monitoring.m. Parameter B+ () Specification 8 volts minimum Measurement NOTE: () If a low voltage condition is present. verify battery voltage is greater than 9. Access and monitor the B+ PID while cranking the engine. . engine off. NOTE: Battery voltage below 9.5 volts. Page 21 © 2005 Mitchell Repair Information Company. Greater than average crank times will be encountered if the battery voltage is less than 9. it may be necessary to install a battery charger to maintain correct system voltage.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . charging system or power and ground circuits to the PCM. Key on. 18 de Junio de 2012 01:01:53 a.

5 volts.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Select the parameters indicated from the scan tool parameter list and monitor while cranking the engine. Possible Causes: Low or no battery voltage to the FICM High resistance or an open FICM power circuit FICM power relay GO to PINPOINT TEST AS: LOSS OF COMMUNICATION WITH THE FICM for FICMVPWR diagnosis. Key on. NOTE: You may need to use an outside power source for the scan tool. Parameter FICMLPWR () Specification 8 volts minimum Measurement 8 volts minimum FICMVPWR () () No or low voltage indicated could be caused by a 12-way connector issue or logic power fuse. CHECK THE RPM SIGNAL WHILE CRANKING Purpose: The purpose of this test is to verify the CMP and CKP sensors and circuits are functioning. Access and monitor the FICMLPWR and FICMVPWR PIDS while cranking the engine. 18 de Junio de 2012 01:01:53 a. engine off. Tools Required: Scan tool 10D.0L Diesel Scan tool may reset below 9. GO to PINPOINT TEST S .5 volts. Recommended Procedure: Connect the scan tool. .Data List Monitoring Scan tool may reset below 9. () No or low voltage indicated could be caused by a 12-way connector issues. Page 22 © 2005 Mitchell Repair Information Company. LLC. Scan Tool . SERTECA Lunes.6. Select the parameters indicated from the scan tool parameter list and monitor while cranking engine.m.

LLC. MONITOR THE ICP WHILE CRANKING Purpose: The purpose of this test is to determine if the injection control system can supply enough injection control pressure to sustain starting. SERTECA Lunes. Tools Required: Scan tool 10E. .0L Diesel NOTE: You may need to use an outside power source for the scan tool. Possible Causes: Weak battery or starter Circuitry CKP sensor CMP sensor GO to PINPOINT TEST D: CRANKSHAFT POSITION (CKP) SENSOR for CKP sensor diagnosis. Parameter RPM () Specification 100 RPM minimum Measurement () Low RPM may be caused by starting or charging system concerns. Recommended Procedure: Connect the scan tool. RPM and VPWR signals correct usually indicates a loss of the CMP or CKP synchronization signal. No FICM synchronization while cranking the engine with the ICP.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Key on. refer to the appropriate pinpoint test for diagnosis. GO to PINPOINT TEST V: CAMSHAFT POSITION (CMP) SENSOR for CMP sensor diagnosis. Select the parameters indicated from the scan tool parameter list and monitor while cranking engine. Access and monitor the RPM PID while cranking the engine.m.Data List Monitoring Scan tool may reset below 9. Refer to CONTROL SYSTEM DIAGNOSTIC SHEET REFERENCE for normal operating values. AND 10F. Scan Tool .5 volts. 18 de Junio de 2012 01:01:53 a. No RPM indicated while cranking may be a CMP or CKP fault.6. Page 23 © 2005 Mitchell Repair Information Company. engine off.

Early Build) Air Pressure Check (F-Super Duty/Excursion .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 24 © 2005 Mitchell Repair Information Company. ICP pressure should increase above 3. () Voltage reading below specification indicates low ICP during crank. If the IPR duty cycle is greater than 14%.5 MPa (500 psi) minimum Measurement 0. IPR duty cycle defaults to 14% [2. Recommended Procedure: Connect the scan tool. engine off.80 volts minimum ICP VOLTS () () A minimum of 3. Key on. injector O-rings. Recommended Procedure: (F-Super Duty/Excursion . 18 de Junio de 2012 01:01:53 a. .Early Build) NOTE: An air leak on the high pressure oil pump shaft lip seal is normal while performing this procedure.0L Diesel Parameter ICP () Specification 3. NOTE: A CKP signal is required before the IPR is commanded above 14%. system leakage.6. faulty IPR or high pressure pump could cause low pressure.5 MPa (500 psi) is required before the injectors are enabled. the injectors will not be enabled by the PCM because of insufficient rail pressure. This is not an indication of a high pressure oil leak and the high pressure pump should not be replaced for this condition.1 MPa (300 psi)] without a CKP signal.5 MPa (500 psi) provided that the IPR valve is not stuck open.5 mPa (500 psi). No or low oil in the system. SERTECA Lunes. If the ICP does not meet the minimum specification of 3. Access and monitor the ICP and IPR PIDS while cranking the engine.m. the high pressure pump is building pressure and there is not an injection control pressure leak between the high pressure pump and the injectors. LLC. Possible Causes: Low base engine oil pressure Injection control pressure system leak IPR failure Faulty high pressure pump Injector O-ring leaking Purpose: Isolate the cause of low injection control pressure.

check the high pressure oil system for leaks. 18 de Junio de 2012 01:01:53 a. With the IPR commanded closed. If no change is heard.Early Build) Fig. the IPR valve is not functioning as commanded.0L Diesel Verify base engine oil pressure. With air pressure applied. Check the operation of the IPR valve. use the scan tool to increase the IPR valve duty cycle. install a new IPR valve and retest. SERTECA Lunes. Apply regulated shop-air pressure to the high pressure oil rail using the adapter from the Oil High Pressure Leakage Test Adapter Set 303-766. With KOEO.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . If no DTCs are present. an air leak will result from the IPR valve's normally open state. 11: Identifying High Pressure Oil System Components (F-Super Duty/Excursion .m. LLC. .Early Build) Courtesy of FORD MOTOR CO. Refer to the appropriate ENGINE article for additional information.6. The IPR valve should close and block the air leak. Page 25 © 2005 Mitchell Repair Information Company. A leak may exist in the following areas: High Pressure Oil System (F-Super Duty/Excursion . GO to PINPOINT TEST R: INJECTION PRESSURE REGULATOR (IPR) for IPR circuit DTCs. Remove one of the valve covers from the engine.

Early Build) Remove the RH valve cover. Crank the engine and monitor the ICP PID. refer to the appropriate ENGINE article. Standpipe from high pressure hose to tappet gallery (O-ring at the bottom may be cut/torn or missing).6. Remove the high pressure hose from the right oil manifold using Quick Disconnect Tool 303-755. connect a digital multimeter between signal return and ICP signal wires on the adapter cable. Branch tube from high pressure pump to stand pipe in tappet gallery. CAUTION: The engine may start. Right Cylinder Head Check (F-Super Duty/Excursion . If the ICP/EBC Adapter Cable D94T50-A is connected to the ICP sensor. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . . and cover the fitting on the oil manifold. Crank the engine and monitor the signal. O-ring around discharge tube that fits inside high pressure pump cover. O-ring in-between discharge tube and high pressure pump. Page 26 © 2005 Mitchell Repair Information Company. Disconnected high pressure hoses under the valve covers. CAUTION: Oil is under high pressure. under either valve cover. For additional information. High pressure inlet O-ring.0L Diesel Cracked/broken check valve and fitting in high pressure oil rail. 18 de Junio de 2012 01:01:53 a. F-Super Duty/Excursion . the injection control pressure leak has been isolated to the right cylinder head.Early Build SERTECA Lunes.m. Install the plug from the Oil High Pressure Leakage Test Adapter Set 303-756 into the high pressure hose to block it off. If the engine starts or if injection control pressure is now within specification. The digital multimeter should read 1 to 4 volts.

Left Cylinder Head Check (F-Super Duty/Excursion . and cover the fitting on the oil manifold. then reinstall the high pressure hose to the right oil manifold. Remove the cap and plug. 12: Installing High Pressure Pump Test Adapter Into High Pressure Hose (Right Cylinder Head . Crank the engine and monitor the signal.0L Diesel Fig. LLC.FSuper Duty/Excursion . Install 303-756 into the high pressure hose. SERTECA Lunes. connect a digital multimeter between the signal return and ICP signal wires of the adapter cable. If the ICP/EBC Adapter Cable D94T-50-A is connected to the ICP sensor.Early Build) Courtesy of FORD MOTOR CO. refer to the appropriate ENGINE article. Page 27 © 2005 Mitchell Repair Information Company. Crank the engine and monitor the ICP PID.Early Build) Remove the LH valve cover. For additional information.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Remove the high pressure hose from the left oil manifold using Quick Disconnect Tool 303-755. . CAUTION: The engine may start. The digital multimeter should read 1 to 4 volts.m.6. 18 de Junio de 2012 01:01:53 a.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

If the engine starts or if injection control pressure is now within specification, the injection control pressure leak has been isolated to the left cylinder head.
F-Super Duty/Excursion - Early Build

Fig. 13: Installing High Pressure Pump Test Adapter Into High Pressure Hose (Left Cylinder Head -FSuper Duty/Excursion - Early Build) Courtesy of FORD MOTOR CO.
IPR and High Pressure Pump Test (F-Super Duty/Excursion - Early Build)

If injection control pressure is still low after ruling out both cylinder heads as the source of injection control pressure leakage, perform the following steps to isolate the cause. Remove the high pressure hose from the right
SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 28 © 2005 Mitchell Repair Information Company, LLC.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

oil manifold and cover the fitting. Install the plug from the Oil High Pressure Leakage Test Adapter Set 303756 into the high pressure hose to block it off. With the high pressure pump effectively deadheaded, crank the engine and monitor the ICP PID. If a low pressure condition still exists, the problem is most likely with the high pressure pump or the high pressure pump drive gear.

Fig. 14: Testing IPR And High Pressure Pump
SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 29 © 2005 Mitchell Repair Information Company, LLC.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

Courtesy of FORD MOTOR CO.
Recommended Procedure (E-Series or F-Super Duty/Excursion - Late Build)
Air Pressure Check (E-Series or F-Super Duty/Excursion - Late Build)

NOTE:

An air leak on the high pressure oil pump shaft lip seal is normal while performing this procedure. This is not an indication of a high pressure oil leak and the high pressure oil pump should not be replaced for this condition.

Verify base engine oil pressure. Refer to the appropriate ENGINE article for additional information. Remove the left valve cover from the engine. Refer to the appropriate ENGINE article for additional information. Apply regulated shop-air pressure to the high pressure oil rail using the adapter from the Test Adapter Set 303-766. With air pressure applied, an air leak will result from the IPR valve's normally open state. With KOEO, use the scan tool to increase the IPR valve duty cycle. The IPR valve should close and block the air leak. If no change is heard, the IPR valve is not functioning as commanded. GO to PINPOINT TEST R: INJECTION PRESSURE REGULATOR (IPR) for IPR circuit DTCs. If no DTCs are present, install a new IPR valve and retest. With the IPR commanded closed, check the high pressure oil system for leaks. A stethoscope may be used to help identify a leak. A leak may exist in the following areas:
High Pressure Oil System (E-Series or F-Super Duty/Excursion - Late Build)

SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 30 © 2005 Mitchell Repair Information Company, LLC.

2004 Ford Cab & Chassis F350 Super Duty
2004 ENGINE PERFORMANCE Diagnostic Subroutines - 6.0L Diesel

Fig. 15: Identifying High Pressure Oil System Components (E-Series Or F-Super Duty/Excursion - Late Build) Courtesy of FORD MOTOR CO. Standpipe from high pressure hose to tappet gallery (O-rings may be cut/torn or missing). O-ring between discharge tube and high pressure pump. O-ring around discharge tube that fits inside high pressure pump cover. High pressure inlet O-ring. Branch tube and O-ring from high pressure pump to stand pipe in tappet gallery. O-ring on the top of the injector where the high pressure rail seats into the injector.
Left Cylinder Head Check (E-Series or F-Super Duty/Excursion - Late Build)

CAUTION: The engine may start.

CAUTION: Oil is under high pressure.
SERTECA Lunes, 18 de Junio de 2012 01:01:53 a.m. Page 31 © 2005 Mitchell Repair Information Company, LLC.

Refer to the appropriate ENGINE article for additional information. . Page 32 © 2005 Mitchell Repair Information Company. LLC.Left Cylinder Head Courtesy of FORD MOTOR CO. Fig. Remove the existing pipe plug.0L Diesel Remove the LH valve cover.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .6. 16: Removing Pipe Plug . SERTECA Lunes. 18 de Junio de 2012 01:01:53 a.m.

0L Diesel Fig. LLC. Right Cylinder Head Check (E-Series or F-Super Duty/Excursion .Left Cylinder Head Courtesy of FORD MOTOR CO.6. Refer to the appropriate ENGINE article for additional information. SERTECA Lunes. If the engine starts or if injection control pressure is now within specification. Access and monitor the ICP PID while cranking the engine. the injection control pressure leak has been isolated to the left cylinder head. CAUTION: Oil is under high pressure. 18 de Junio de 2012 01:01:53 a. Install the Oil High Pressure Leakage Test Adapter 303-1071/2 (solid block-off tool). 17: Installing Oil High Pressure Leakage Test Adapter .Late Build) CAUTION: The engine may start.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . remove the test adapter (303-1071/2). Page 33 © 2005 Mitchell Repair Information Company. If the pressure is not within specification.m. . reinstall the original pipe plug and perform the right cylinder head check. Remove the RH valve cover.

m. . Page 34 © 2005 Mitchell Repair Information Company. 18 de Junio de 2012 01:01:54 a.0L Diesel Fig. Remove the ICP sensor from the high pressure rail.6.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Remove the existing pipe plug.Right Cylinder Head Courtesy of FORD MOTOR CO. 18: Removing Pipe Plug & ICP Sensor . LLC. SERTECA Lunes.

If the injection control pressure is now within specifications. Connect the ICP/EBC Adapter Cable 418-D003 to the wiring harness and the ICP sensor.0L Diesel Fig. If the engine starts or if injection control pressure is now within specifications. IPR And High Pressure Pump Test (E-Series or F-Super Duty/Excursion .Right Cylinder Head Courtesy of FORD MOTOR CO. If a low pressure condition still exists.Late Build) If injection control pressure is still low after ruling out both cylinder heads as the source of injection control pressure leakage. Reinstall the left cylinder head Oil High Pressure Leakage Test Adapter 303-1071/2 (solid block-off tool). perform the IPR and high pressure pump test. SERTECA Lunes. the injection control pressure leak has been isolated to the right cylinder head.6. 18 de Junio de 2012 01:01:54 a. perform the following to isolate the cause. Access and monitor the ICP PID while cranking the engine. . LLC. Page 35 © 2005 Mitchell Repair Information Company.m. If the pressure is not within specifications.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . crank the engine and monitor the ICP PID. inspect all components carrying high pressure oil on both engine banks. 19: Installing Oil High Pressure Leakage Test Adapter . the problem is most likely with the high pressure pump or the high pressure drive gear. Install the Oil High Pressure Leakage Test Adapter 303-1071/1. With the high pressure pump effectively deadheaded. Install the ICP sensor into the Oil High Pressure Leakage Test Adapter 303-1071/1 (open-ended block-off tool).

branch tube. 18 de Junio de 2012 01:01:54 a. No fuel command signal when the ICP. injection control pressure is above 3.Data List Monitoring Scan tool may reset below 9. this test should identify the leak. LLC. Tools Required: ICP/EBC Adapter Cable 418-D003 (D94T-50 -A) or equivalent Oil High Pressure Leakage Test Adapter Set 303-756 or equivalent Oil High Pressure Leakage Test Adapter Set 303-1071 or equivalent Multimeter 105-00050 or equivalent Quick Disconnect Tool 303-755 10G. . Scan Tool . engine off. A 5 MUE s to 2 ms fuel pulse width (FUEL PW) will be sent to the FICM if the system voltage is greater than 8 volts during cranking. A 0 ms fuel pulse width (a no fueling pulse) will be sent by the PCM when a sync pulse has not been received from the CMP sensor and if insufficient injection control pressure is present. If the concern is related to a leaking standpipe.5 MPa (500 psi) and is in sync.0L Diesel The leak could also be in the discharge tube. Perform the air pressure check if this procedure has not already been completed.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . engine cranking speed is above 100 RPM. Possible Causes: SERTECA Lunes. Recommended Procedure: Connect the scan tool. Access and monitor the FUEL PW PID while cranking the engine.5 volts. Page 36 © 2005 Mitchell Repair Information Company. Parameter PW () Specification 5 MUE S to 2 mS Measurement FUEL () Pulse width defaults to 0 with no CMP or CKP signal.m. CHECK FUEL PULSE WIDTH WHILE CRANKING Purpose: The purpose of this test is to verify the fuel delivery signal is correct. RPM and VPWR signals are correct usually indicates a loss of the CMP signal. branch tube or discharge tube. Select the parameters indicated from the scan tool parameter list and monitor while cranking engine. or stand pipes.6. Key on. GO to PINPOINT TEST V: CAMSHAFT POSITION (CMP) SENSOR . Note that low fuel pressure or no glow plug operation could still be the cause of the No Start or Hard Start condition.

Refer to CONTROL SYSTEM DIAGNOSTIC SHEET REFERENCE for normal operating values.m.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . engine off. Possible Causes: PCM FICM CKP synchronization signal CMP synchronization signal Tools Required: SERTECA Lunes.Data List Monitoring Scan tool may reset below 9. No FICM synchronization while cranking the engine with the ICP. RPM and VPWR signals correct usually indicates a loss of the CMP or CKP synchronization signal. CHECK FICM SYNCHRONIZATION WHILE CRANKING Purpose: The purpose of this test is to verify the PCM and FICM synchronization. Key on. LLC. Parameter () FICMSYNC () No synchronization could be caused by a CMP or CKP fault. Recommended Procedure: Spec. YES/NO Measurement Connect the scan tool. Scan Tool .6. Select the parameters indicated from the scan tool parameter list and monitor while cranking the engine.5 volts. Access and monitor the FICMSYNC PID while cranking the engine.0L Diesel PCM FICM CKP signal CMP signal Tools Required: Scan tool 10H. refer to the appropriate pinpoint test for diagnosis. 18 de Junio de 2012 01:01:54 a. Page 37 © 2005 Mitchell Repair Information Company. .

2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 38 © 2005 Mitchell Repair Information Company.0L Diesel Scan tool 11. NOTE: The Wait To Start indicator "ON" time (1 -10 seconds) is independent from glow plug "ON" time. Glow Plug System Operation Glow Plug Control Module (GPCM) Operation Glow plug ON time is dependent on oil temperature and altitude. Measure the resistance between the glow plug bus bar connector. Turn the key to the ON position and measure the glow plug voltage ("ON" time).6. harness side. Measure the resistance between the GPCM connector. LLC. GO to PINPOINT TEST AF: GLOW PLUG SYSTEM . Access and monitor the GPCTM and EOT PIDS to verify sufficient glow plug "ON" time. Glow Plug to Ground (0.1 to 2 Glow Plug Connector to GPCM ohms) Connector (less than 5 ohms) Glow Plug Number 1 3 5 7 2 4 6 SERTECA Lunes. GLOW PLUG SYSTEM OPERATION Purpose: The purpose of this test is to verify the glow plug system operation. harness side and the glow plug bus bar connector.m. 18 de Junio de 2012 01:01:54 a. If GPCM DTCs are present. On Time 1 to 120 seconds Specification B+ Measurement Glow Plug Resistance Disconnect the glow plug bus bar connector. Access and retrieve the KOEO and continuous DTCs. The GPCM does not operate if the oil temperature is above 55° C (131°F). component side and battery ground. Connect the scan tool. The GPCM will command the glow plugs on for 1 to 120 seconds. . Verify B+ voltage is supplied to the GPCM. Disconnect the GPCM.

Fig. Incorrect measurements will result if all glow plug connectors are not disconnected.6. For fault detection.m. 20: Glow Plug Circuit Diagram Courtesy of FORD MOTOR CO. .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 39 © 2005 Mitchell Repair Information Company. 18 de Junio de 2012 01:01:54 a. LLC. Possible Causes: GPCM power circuits Glow plugs Glow plug bus bar SERTECA Lunes. the self-test requires a fault present at the time of testing. The PCM will activate the GPCM which monitors the glow plugs. The pedal may be used to increase the engine speed to increase voltage if needed. The self-test is performed on-demand with the engine running and the A/C off.0L Diesel 8 Recommended Procedure: NOTE: NOTE: Check for poor connections or loose fitting pins. The glow plug monitor self-test is a KOER functional test of the glow plug system.

Page 40 © 2005 Mitchell Repair Information Company.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . LLC.EARLY BUILD (BUILT BEFORE 9/2003) SERTECA Lunes. 18 de Junio de 2012 01:01:54 a. .6.m.0L Diesel GPCM Circuitry Tools Required: Multimeter 105-00050 or equivalent Scan tool PERFORMANCE DIAGNOSTIC PROCEDURES F-SUPER DUTY/EXCURSION .

21: Performance Diagnostic Procedures F-Super Duty/Excursion .m.0L Diesel Fig.6. 18 de Junio de 2012 01:01:54 a.Early Build Courtesy of FORD MOTOR CO. Page 41 © 2005 Mitchell Repair Information Company. E-SERIES OR F-SUPER DUTY/EXCURSION . . LLC.LATE BUILD (BUILT AFTER 9/2003) SERTECA Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .

18 de Junio de 2012 01:01:54 a.0L Diesel Fig.6. Page 42 © 2005 Mitchell Repair Information Company. 1. 22: Performance Diagnostic Procedures E-Series Or F-Super Duty/Excursion .Late Build Courtesy of FORD MOTOR CO.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . LLC. .m. VISUAL ENGINE/CHASSIS INSPECTION SERTECA Lunes.

including the fuel tank.0L Diesel Purpose: The purpose of this test is to check the general condition of the engine and chassis. Visual Engine/Chassis Inspection Verify that there are no fluid or pressure leaks.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Inspect the MAP hose. Check the coolant level. and verify the connectors are properly secured. Inspect wiring for correct routing. Inspect the intercooler hoses for leaks. Fuel Oil Coolant Electrical Hoses Leaks Method Visual Recommended Procedure: Check Inspect for a hole in the MAP sensor hose or a pinched hose. fuel filter housing and fuel lines. Inspect the fuel system.6. LLC. Inspect all wire connections for damage. Possible Causes: Loose or leaking fuel lines Kinked or blocked fuel lines Fuel or oil leaks Coolant leaks could indicate engine problems Pinched or open MAP sensor hose Pinched or open intercooler hose Improper connections Tools Required: Inspection light 2. fuel pump. SERTECA Lunes. and verify no rubbing or chafing has occurred. SUFFICIENT CLEAN FUEL Purpose: The purpose of this test is to verify the fuel quality. intercooler hoses and intake for leaks. Inspect for coolant leaks at the radiator and coolant hoses. bends or leakage. for kinks. Page 43 © 2005 Mitchell Repair Information Company. Inspect all sensors.m. . 18 de Junio de 2012 01:01:54 a.

Method Visual Recommended Procedure: Check Open the drain valve on the fuel control module and fill a clear container until it is half full. LLC. It also should be free of water and contaminants. If the indicator is illuminated. 18 de Junio de 2012 01:01:54 a. the fuel is probably contaminated with water. Dyed red or blue fuel indicates off-highway fuel. Inspect the fuel in the container.0L Diesel Sufficient Clean Fuel Check for illumination of the WATER IN FUEL indicator. Page 44 © 2005 Mitchell Repair Information Company. A cetane rating between 40 and 50 is recommended for optimum performance.6. Flow out of the drain should be a steady stream. If that is the case.m. Some sediment and water may be present in the fuel sample if the fuel filter has not been serviced for a prolonged period of time and/or if the sediment and water have not been drained recently. a second sample may be required to determine fuel quality. It should be clear. not cloudy. . Close the drain valve. Insufficient flow could indicate fuel supply or fuel system problems. Observe the WATER IN FUEL indicator.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . F-Super Duty/Excursion SERTECA Lunes. Drain a fuel sample from the fuel control module.

18 de Junio de 2012 01:01:54 a.0L Diesel Fig.m. 23: Identifying Fuel Control Module Drain Valve . Page 45 © 2005 Mitchell Repair Information Company.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . LLC.F-Super Duty/Excursion Courtesy of FORD MOTOR CO.6. . E-Series SERTECA Lunes.

0L Diesel Fig. 24: Identifying Fuel Control Module Drain Valve . 18 de Junio de 2012 01:01:54 a. .6.E-Series Courtesy of FORD MOTOR CO. LLC.m.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 46 © 2005 Mitchell Repair Information Company. Possible Causes: SERTECA Lunes.

CHECK ENGINE OIL LEVEL Purpose: The purpose of this test is to verify oil quality and determine if there is sufficient oil to operate the injectors.m.6. If the oil level is overfull. .95L (1 -quart) 3. If there is no oil or very little oil in the crankcase. Miles/hours on oil. Inspect oil for color. 2 fuel) Pickup tube screen in tank could be clogged Cloudy fuel indicates that the fuel may not be a suitable grade for cold temperatures.approximately 0. A milky white oil indicates possible coolant contamination which will have an ethylene glycol odor. 18 de Junio de 2012 01:01:54 a. If the engine SERTECA Lunes.0L Diesel No fuel in tank Fuel supply line could be broken or crimped Fuel could be jelled (most likely in cold weather with No.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . WARNING: SMOKING OR OPEN FLAME OF ANY TYPE MUST NOT BE PRESENT WHEN WORKING NEAR FUEL OR FUEL VAPOR. Oil contaminated with diesel fuel will have a diesel fuel odor and will increase the engine oil level. the injectors will not operate. coolant). LLC. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Tools Required: Clear container . Check Engine Oil Level Check for contaminants (fuel. Page 47 © 2005 Mitchell Repair Information Company. it is possible the engine was incorrectly serviced or fuel is diluting the oil and filling the crankcase. Excessive water or contaminants may indicate that the tank and fuel system may need to be flushed and cleaned. correct level. Method Visual Recommended Procedure: Check Check for correct oil level using the dipstick with the vehicle on level ground. Correct grade/viscosity.

18 de Junio de 2012 01:01:54 a. access OSC and command the fuel pump ON. Remove the valve cover at the suspect cylinder head and inspect the injector area for leaks.oil cooler. . Possible Causes: Oil level low . Install the plug in the outlet port. LLC.oil leak. Diagnostic Trouble Codes SERTECA Lunes. Isolate either cylinder head by removing the corresponding fuel line from the fuel filter housing. Depending on the severity of the leak. Using the scan tool.1 MPa (0-160 psi) Bar 014-00761 or equivalent at the test port to confirm constant fuel pressure. fuel dilution from injector O-rings Oil contamination with coolant . Page 48 © 2005 Mitchell Repair Information Company. incorrect servicing Oil level high . oil consumption.0L Diesel oil level is above "Max" due to diesel fuel dilution. 10W-30 oil is recommended for cold ambient temperatures. PERFORM KOEO ON-DEMAND SELF-TEST Purpose: The purpose of this test is to determine if the PCM has detected any fault conditions that would cause a performance problem. Refer to the lube oil chart in the ENGINE SYSTEM .incorrect servicing. Single weight or 15W-40 oil is not recommended for cold ambient temperatures. Oil that has had extended drain intervals will have increased viscosity (become thicker) and will make engine cranking more difficult and starting less reliable at temperatures below freezing. Watch for fuel to drain out of the oil pan drain hole. drain the oil and the fuel filter housing.GENERAL INFORMATION article or Owner Literature for the correct oil selection for temperature conditions. it may take some time before a leak is noticeable. the oil will appear thin and watery. head gasket. Remove the fuel pressure test port plug from the secondary filter housing. porosity Tools Required: Adapter 303-765 or equivalent Gauge 0-1. If the oil level is overfilled.6.m.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Install Fuel Pressure Adapter (303-765) and Gauge 0 -1. Check service records for correct oil type and viscosity for the vehicle operating temperature.1 MPa (0-160 psi) Bar (part of Pressure Adapter Kit 014-00761 or equivalent) Scan tool 4. Perform KOEO On-Demand Test Use the scan tool. DTCs set during this test are current faults.

Turn off all accessories. Connect the scan tool. LLC. Tools Required: Scan tool 5. DTCs retrieved during this test are historical faults. Follow the operating instructions from the diagnostic menu. The condition that caused a continuous DTC may no longer exist. Refer to QUICK TEST OPERATION .0L Diesel Recommended Procedure: NOTE: To ensure that the DTC is a hard fault. first clear Continuous DTCs (be sure to record all DTCs and Freeze Frame information before clearing). Refer to the scan tool operating manual for instructions. a hard fault has occurred. Turn off all accessories. Refer to QUICK TEST OPERATION . Key on. Refer to the scan tool operating manual for instructions. it must be turned off to perform the self-test. it must be turned off to perform self-tests.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . 18 de Junio de 2012 01:01:54 a.6.m. If the vehicle is equipped with an APCM. Diagnostic Trouble Codes (DTCs) Recommended Procedure: Connect the scan tool. Perform a KOEO On Demand Self-Test. Record the DTCs and Freeze Frame information and refer to the appropriate pinpoint test. Perform the necessary vehicle preparation and a visual inspection. RETRIEVE CONTINUOUS DTCS Purpose: The purpose of this test is to determine if the PCM has detected any historical or intermittent fault conditions that would cause a performance problem. Perform the necessary vehicle preparation and a visual inspection. SERTECA Lunes. powertrain control module (PCM) and the fuel injector control module (FICM) to initialize. Retrieve Continuous DTCs Use the scan tool. . engine off. Wait 4 seconds for the transmission control module (TCM). If the DTC is set again. Page 49 © 2005 Mitchell Repair Information Company. If the vehicle is equipped with an auxiliary powertrain control module (APCM). Rerun KOEO On-Demand Self Test.

disconnect the FICM connector and check injectors for shorts or opens. KOEO Injector Electrical Self-Test (Click Test) Use the scan tool.6.m.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . 18 de Junio de 2012 01:01:54 a. KOEO INJECTOR ELECTRICAL SELF-TEST (CLICK TEST) Purpose: NOTE: If unable to perform KOEO Injector Electrical Self-Test (Click Test). Tools Required: Scan tool 6. All injectors will momentarily click. Record the continuous DTCs and Freeze Frame information from the PCM and TCM and refer to the appropriate pinpoint test for continuous DTC diagnostics. Page 50 © 2005 Mitchell Repair Information Company. Follow operating instructions from the menu. Injector Trouble Codes 6. . Injector DTCs will be transmitted after the self-test is completed.0L Engine. then each injector will click in sequence 1 through 8. NOTE: NOTE: Sequence repeats three times.0L Diesel Key on. LLC. The purpose of this test is to determine if the injector solenoids and valves are functioning by clicking all injectors together and then each injector in numerical sequence (1 through 8). Cylinder and Fuel Injector Location SERTECA Lunes. Continuous DTCs must be cleared after a repair is made. engine off. DTCs can be historical if not cleared from a previous test.

2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 51 © 2005 Mitchell Repair Information Company.6. 18 de Junio de 2012 01:01:54 a.0L Diesel SERTECA Lunes. LLC. .m.

2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . then each injector will click for approximately 1 second in numerical order (1 through 8). 18 de Junio de 2012 01:01:54 a. Follow the operating instructions from the menu. Refer to QUICK TEST OPERATION . Measure the vacuum on clean side of air inlet system at WOT with Magnehelic(R) gauge. . If a fault is detected. Key on. a DTC will be output on the data link at the end of the test when requested by a scan tool. Intake Restriction Check air filter restriction gauge/indicator. If vehicle is equipped with an APCM. Page 52 © 2005 Mitchell Repair Information Company. Refer to the scan tool operating manual for instructions.0L Diesel Fig. Perform the necessary vehicle preparation and a visual inspection. engine off. Possible Causes: Open or shorted injector circuit Injector connector Injector solenoid FICM power or ground circuit FICM Tools Required: Scan tool 7.6. Turn off accessories. a considerable amount of black or blue smoke may be produced. Connect the scan tool. SERTECA Lunes. Record the DTCs and perform the appropriate pinpoint test.m. Only a hard fault DTC will be displayed. Recommended Procedure: This test determines if the injector circuits and solenoids are electrically operating without fault. it must be turned off to perform self-tests. INTAKE RESTRICTION Purpose: This purpose of this test is verify an air intake or exhaust restriction is not contributing to a low power condition. LLC. 25: Identifying Firing Order Courtesy of FORD MOTOR CO. All injectors will first click together for approximately 2 seconds. Perform the KOEO Injector Electrical Self-Test (Click Test). If the engine does have a high air intake restriction.

F-Super Duty/Excursion SERTECA Lunes. 18 de Junio de 2012 01:01:54 a. . Inspect for any indication of water intrusion into air cleaner/filter.6. If necessary.7 -46. Inspect the air cleaner housing and filter for proper installation.0L Diesel Instrument Magnehelic/Filter Restriction Gauge Recommended Procedure: Specification 3. LLC. Page 53 © 2005 Mitchell Repair Information Company.m.7 mm Hg (2-25 H2 O) Measurement Inspect the air cleaner inlet and ducting to ensure that it is not blocked or collapsed. use Pressure Adapter Kit 014-00761 or equivalent to install a Magnehelic(R) gauge on the port on the air cleaner and measure restriction at high idle.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .

F-Super Duty/Excursion Courtesy of FORD MOTOR CO.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 54 © 2005 Mitchell Repair Information Company. LLC.m. 18 de Junio de 2012 01:01:54 a. 26: Identifying Air Filter Restriction Gauge . E-Series SERTECA Lunes.6. .0L Diesel Fig.

.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .0L Diesel Fig.m. Page 55 © 2005 Mitchell Repair Information Company. Magnehelic(R) Gauge SERTECA Lunes.E-Series Courtesy of FORD MOTOR CO. 18 de Junio de 2012 01:01:54 a. LLC.6. 27: Identifying Air Filter Restriction Gauge .

18 de Junio de 2012 01:01:54 a. EGR POSITION Purpose: The purpose of this test is to check the EGR valve closed.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Page 56 © 2005 Mitchell Repair Information Company. . LLC. plastic bags or other foreign material may restrict airflow at the air inlet Misrouted air cleaner ducting On engines recently repaired.6. rags or cap plugs may have been inadvertently left in an air inlet pipe Tools Required: Magnehelic(R) gauge (part of Pressure Adapter Kit 014-00761 or equivalent) 8. open. and travel positions.m. Possible Causes: Snow. EGR Position SERTECA Lunes. 28: Identifying Magnehelic(R) Gauge Courtesy of FORD MOTOR CO.0L Diesel Fig.

m. Monitor the EGR valve position sensor PID to calculate travel. Recommended Procedure: Connect the diagnostic tool. install a new EGR valve and retest the system.2 volts 100% (Open) 3.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .800 RPM with the vehicle in PARK/NEUTRAL.3 . SERTECA Lunes. engine off. If the valve travel and travel voltage are below specification. Possible Causes: EGR control circuit EGR valve PCM Tools Required: Scan tool 9. Subtract the closed EGR valve position voltage from the open EGR valve position voltage.4 . 18 de Junio de 2012 01:01:54 a.6.0L Diesel Key on. Instrument Diagnostic Tool Specification 0% (Closed) 0. engine off.4. LLC. Access the EGR valve position sensor PID and record the closed EGR valve position voltage. Record the EGR valve open position voltage. Exhaust Restriction Visually inspect the exhaust system for damage. Monitor the EP PID with scan tool and the engine temperature greater than 70°C (158°F) at 3. Key on. Use the diagnostic tool to command the output state control (OSC) for the EGR valve.7 volts Travel greater than 2. Page 57 © 2005 Mitchell Repair Information Company. Access OSC and open the EGR valve 100%.71 volts Actual ____ Closed ____ Open ____ Travel Correct concern causing out of specification values before continuing.1. . EXHAUST RESTRICTION Purpose: The purpose of this test is to determine if an exhaust system restriction is causing a performance problem.

Road test the vehicle with the engine at full load condition. .800 RPM (E-Series or F-Super Duty/ Excursion . Electric Fuel Pump Pressure Measure the fuel system pressure at the engine filter housing test port. ELECTRIC FUEL PUMP INLET RESTRICTION .m. Record the EP PID value. Possible Causes: Collapsed tail pipe Clogged tail pipe Clogged catalytic converter Damaged muffler Turbocharger Tools Required: Scan tool 10A.800 RPM (F-Super Duty/ Excursion Early Build) 244 kPa (35 psi) MAX @ 3. SERTECA Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .800 RPM. Access and monitor the EP and RPM PIDS.Early Build) or 244 kPa (35 psi) (E -Series or F-Super Duty/Excursion . go to 10B.0L Diesel Parameter EP Specification 234 kPa (34 psi) MAX @ 3. Run engine at 3. Page 58 © 2005 Mitchell Repair Information Company. 18 de Junio de 2012 01:01:54 a.Late Build) Measurement Recommended Procedure: Connect the scan tool. Instrument 0-1. ELECTRIC FUEL PUMP PRESSURE Purpose: The purpose of this test is to verify the fuel system pressure.Late Build) indicates a restricted exhaust condition.6. A low RPM or an EP PID greater than 234 kPa (34 psi) (F-Super Duty/Excursion .1 MPa (0-160 psi) gauge Specification 310-379 kPa (45 -55 psi) minimum Measurement If pressure fails low. LLC.

Road test the vehicle at a full load condition.m. Remove the plug from the front of the engine fuel filter housing. go to 10B.0L Diesel If fuel pressure is above specification. ELECTRIC FUEL PUMP INLET RESTRICTION . If no restriction is present.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Install Adapter 303-765 and Gauge 01.6. If no restriction is present. check the fuel return lines for a restriction. Page 59 © 2005 Mitchell Repair Information Company. 18 de Junio de 2012 01:01:54 a. install a new fuel pressure regulator valve. If pressure fails low. If fuel pressure is above specification. . SERTECA Lunes. Recommended Procedure: Verify there is fuel in the tank. check fuel return lines for restriction. LLC. install a new fuel pressure regulator valve.1 MPa (0-160 psi) Bar 014-00761 or equivalent.

18 de Junio de 2012 01:01:54 a. LLC. 29: Locating Fuel Pressure Regulator Valve Courtesy of FORD MOTOR CO.6.0L Diesel Fig. Page 60 © 2005 Mitchell Repair Information Company. Possible Causes: Fuel return line restriction Fuel pressure regulator valve Tools Required: Adapter 303-765 or equivalent Gauge 0-1. 30: Exploded View Of Fuel Pressure Regulator Valve Courtesy of FORD MOTOR CO. Fig.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .1 MPa (0-160 psi) Bar (part of Pressure Adapter Kit 014-00761 or equivalent) 10B.m. . Electric Fuel Pump Inlet Restriction SERTECA Lunes. ELECTRIC FUEL PUMP INLET RESTRICTION Purpose: The purpose of this test is to isolate the cause of low fuel pressure.

Run at the engine at WOT for 2 minutes. Fuel Aeration Test Install a clear hose on the fuel return line at the fuel control module.m. Check . Instrument (0 -30 in Hg) Vacuum gauge Recommended Procedure: Specification 6 in Hg MAX Measurement Remove the fuel line to the inlet side of the fuel pump. Method Visual SERTECA Lunes. 18 de Junio de 2012 01:01:54 a. Measure restriction at WOT (maximum engine speed out of gear with the brakes set and the wheels blocked). . LLC. there is a restriction between the fuel pump and the fuel tank. inspect the fuel regulator valve. If restriction is less than 152 mm Hg (6 in Hg). Refer to the appropriate FUEL TANK AND LINES article. Install Fuel Pump Adapter 310-111 or equivalent between the fuel inlet line and the electric fuel pump. install a new fuel pump. If the filters are OK.0L Diesel Measure restriction at fuel pump inlet. inspect both fuel filters. Possible Causes: Fuel line restriction Fuel pressure regulator valve Fuel filters Fuel pump Tools Required: Fuel Pump Adapter 310-111 or equivalent Vacuum Gauge (part of Pressure Adapter Kit 014-00761 or equivalent) 10C: FUEL AERATION TEST Purpose To determine if the fuel is aerated and causing a poor idle condition. If the regulator and filters are OK. If restriction is greater than 152 mm Hg (6 in Hg). Return fuel should be free of bubbles.6. Connect test adapter to a 0-762 mm Hg (0-30 in Hg) vacuum gauge. Page 61 © 2005 Mitchell Repair Information Company.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .

m. SERTECA Lunes. .6. If the fuel has air in it. PERFORM KOER ON-DEMAND SELF TEST Purpose: The purpose of this test is to determine if the PCM has detected any fault conditions that would cause a performance problem while the engine is running.0L Diesel 1. the fuel will appear clear/transparent. Diesel fuel may not flow out through the attached hose after only one key cycle. Remove the fuel return line at the fuel control module. Perform KOER On-Demand Self Test NOTE: Before performing the KOER On-Demand Self-Test make sure the high pressure oil passages are free of air. 2. The self-test will verify the ICP. LLC. If a predetermined threshold is not reached. foamy or non-transparent. To remove the air. drive the vehicle (with deceleration and acceleration cycles) at highway speeds for 32 km (20 miles). then off. 4. If air is present in the return fuel. Return fuel should be free of bubbles. The KOER self-test will perform step tests on the injection control pressure system and the exhaust back pressure system.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . The fuel pump will cycle on. 3. This test can be performed at any engine temperature. Possible Causes: NOTE: Air can enter the fuel system at any point where there is suction in the fuel system. Attach a 1/4-inch diameter hose (clear) to the fuel control module and place the other end of the hose into Rotunda Tool 034-00005 or equivalent. Fuel pickup in the fuel tank Fuel supply line entering the fuel module from the fuel tank Fuel return line entering the fuel module from the engine Tools Required: Rotunda Tool 034-00005 or equivalent 11. Step tests are PCM controlled tests where the PCM commands a specific exhaust back pressure or injection control pressure and then measures the result. 18 de Junio de 2012 01:01:54 a. Run at WOT for 2 minutes. inspect the fuel system for leaks. Turn the ignition on. the fuel returning to the tank will appear white. 6. 7. Start the engine. If no or very little air is present in the fuel. a DTC will be generated. A recent repair to the system may allow air to enter the oil passages. 5. EGR and VGT systems performance. Repeat the key cycle until fuel flows from the attached hose. Page 62 © 2005 Mitchell Repair Information Company.

. Tools Required: Scan tool 12A.Early Build) 4. it must be turned off to perform the self-test.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Turn off all accessories. If the vehicle is equipped with an APCM.3 MPa (580-725 psi +/45 psi) (E-Series or F-Super Duty/ Excursion .5 MPa +/.0L Diesel KOER DTC Recommended Procedure: NOTE: Engine will run rough during this test.Late Build) Take reading before disconnecting ICP sensor.0 . disconnect the ICP sensor. engine running.m. Parameter ICP Specification @ 670 RPM 4.5.0. Refer to the scan tool operating manual for instructions.3 MPa (650800 psi +/. Follow the operating instructions from the diagnostic menu. Key on. Perform the necessary vehicle preparation and visual inspection. Measurement If engine RPM is unstable. Low Idle Stability (ICP Pressure) Check at low idle and EOT above 70°C (158° F) Monitor the ICP and RPM PIDS with the scan tool. Perform a KOER On Demand Self-Test.6. Page 63 © 2005 Mitchell Repair Information Company.5.0. Connect the scan tool.45 psi) (F-Super Duty/ Excursion . SERTECA Lunes.0 MPa +/. LLC. Record the DTCs and refer to the appropriate pinpoint test. Refer to QUICK TEST OPERATION . LOW IDLE STABILITY (ICP PRESSURE) Purpose: The purpose of this test is to determine if idle stability or low power is caused by a stuck or dirty IPR or faulty ICP signal.5 . 18 de Junio de 2012 01:01:54 a.

0 MPa (725 psi) when disconnected. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . If RPM smooths out.m. disconnect the ICP sensor. Specification @ 670 RPM 30% MAX Measurement . INJECTION PRESSURE REGULATOR TEST . the ICP sensor or circuit is suspect. 18 de Junio de 2012 01:01:54 a. Parameter IPR Recommended Procedure: SERTECA Lunes. INJECTION PRESSURE REGULATOR TEST . Connect the scan tool. INJECTION PRESSURE REGULATOR TEST Purpose: The purpose of this test is to determine if idle stability or low power is caused by a stuck or dirty IPR. engine running. Access and monitor the ICP and RPM PIDS. Possible Causes: Debris stuck in the IPR ICP sensor Circuitry Tools Required: Scan tool 12B. Page 64 © 2005 Mitchell Repair Information Company. the problem is most likely in the ICP sensor circuit. If low idle speed stabilizes with the ICP sensor disconnected. If RPM is still unstable.6. Operate the engine at low idle speed.0L Diesel ICP will default to 5. Recommended Procedure: NOTE: The engine must be at operating temperature. If RPM does not stabilize. GO to PINPOINT TEST Q: INJECTION CONTROL PRESSURE (ICP) SENSOR . If engine does not stabilize. Key on. reconnect the ICP sensor and go to 12B. Low Idle Stability (ICP Pressure) Check at low idle and EOT above 70° C (158° F) Monitor the IPR PID with the scan tool. reconnect the sensor and GO to 12B.

GO to PINPOINT TEST KA: TURBO CHARGER SYSTEM Page 65 © 2005 Mitchell Repair Information Company. Possible Causes: Debris stuck in the IPR Injection control system leak Tools Required: Scan tool 13. Operate the engine at low idle speed. If the IPR duty cycle is greater than the MAX specification. and MAP hose for signs of damage or leaks.6. Monitor the EGR duty cycle. Control the VGT duty cycle to 0% and 85% with the diagnostic tool. Boost Pressure Test Carefully inspect the intercooler tubes/connections. and VGT duty cycle PIDS with the diagnostic tool. BOOST PRESSURE TEST Purpose: The purpose of this test is to determine if the engine can develop sufficient boost to obtain specific power. turbocharger connections.0L Diesel NOTE: The engine must be at operating temperature.200 RPM and EGR duty cycle to 0% with the diagnostic tool. .200 RPM.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Lunes. Access and monitor the IPR and RPM PIDS. MGP. RPM. Control the engine speed to 1.m. Carry out the boost pressure test at 1. LLC.87 psi) minimum at 85% VGT duty cycle Measurement Recommended Procedure: NOTE: SERTECA If the test fails. Parameter MGP MGP Specification 3 kPa (0. 18 de Junio de 2012 01:01:54 a. If the IPR duty cycle is less than the MAX specification. go to the next step. Connect the scan tool. engine running. Key on. go to Test 10e of the Hard Start/No Start Diagnostics and check for an injection control system leak.44 psi) maximum at 0% VGT duty cycle 6 kPa (0.

Make sure the MAP sensor is hooked up for this test. Crankcase Pressure Test . Route the hose so that it is not crimped and does not come in contact with any hot surface. and VGTDC PIDS.m.0L Diesel PERFORMANCE . EGR_DC. Possible Causes: MAP hose pinched or open Leaking intake. Access and monitor the MGP. Page 66 © 2005 Mitchell Repair Information Company. go to the next step.6.F-Super Duty/Excursion SERTECA Lunes.200 RPM and EGRDC PID to 0%. Control the RPM_DSD PID to 1. 18 de Junio de 2012 01:01:54 a. Crankcase pressure is a measure of how well the cylinders are sealing. Decrease the VGTDC PID to 0% and record the MGP PID value. If the MGP PID values are not within specifications. hoses or fittings Leaking exhaust system Turbocharger Base engine Intercooler hoses leaking Intercooler EGR sticking Tools Required Scan tool 14. Alternate Procedure: Install a T (manufactured locally out of common fittings) into the MAP sensor line that comes from the intake manifold. If the MGP PID values are within specifications.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . GO to PINPOINT TEST KA: TURBO CHARGER SYSTEM PERFORMANCE . LLC. Connect a T to a 0-30 psi gauge that is temporarily installed in the cab. CRANKCASE PRESSURE TEST Purpose: The purpose of this test is to measure the crankcase pressure. Key on. RPM. engine running. . Increase the VGTDC PID to 85% and record the MGP PID value. Decrease the VGTDC PID to 0% and record the MGP PID value.

.0L Crankcase Pressure Tester p/n 303-758.6. Less than 15 mm Hg (8 H2 O) Measurement If greater than 15 mm Hg (8 H2 O). refer to the base engine the appropriate ENGINE article.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . with engine at 70° C (158° F) minimum.m. F-Super Duty/Excursion SERTECA Lunes. Instrument 0-112 mm Hg (0 to 60 H2 O) Magnehelic(R) gauge Specification. LLC. Block the breather tube on the left valve cover.000 RPM. Page 67 © 2005 Mitchell Repair Information Company. Measure with no load at 3. 18 de Junio de 2012 01:01:54 a.0L Diesel Measure the pressure at the oil fill tube with 6.

18 de Junio de 2012 01:01:54 a. LLC.6. . Page 68 © 2005 Mitchell Repair Information Company.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .m.0L Diesel SERTECA Lunes.

0L Crankcase Pressure Tester p/n 303-758. . Block the outlet at the valve cover with the cap provided in Pressure Test Adapter Kit 014-00761 or equivalent. Make sure the Magnehelic(R) gauge has been zeroed. Make sure the engine is at operating temperature. Page 69 © 2005 Mitchell Repair Information Company.6. E-Series SERTECA Lunes. Screw the Crankcase Pressure Test Adapter 303-758 in the oil fill cap hole. Block the breather tube on the left valve cover. Hold for 30 seconds minimum and take a stabilized reading. 31: Testing Crankcase Pressure Courtesy of FORD MOTOR CO. Instrument 0-112 mm Hg (0 to 60 H2 O) Magnehelic(R) gauge Specification. Crankcase Pressure Test . refer to the base engine the appropriate ENGINE article. A cold engine will give higher readings.0L Diesel Fig. Do not block the hole at the top of the restrictor tool. Less than 15 mm Hg (8 H2 O) Measurement If greater than 15 mm Hg (8 H2 O). Install a protective screen over the turbocharger inlet.F-Super Duty/Excursion: NOTE: Do not plug hole on Crankcase Pressure Test Adapter 303-758.m. 18 de Junio de 2012 01:01:54 a.000 RPM. Remove the ducting to the turbocharger inlet pipe and remove the inlet pipe and elbow that connects to the breather box. Measure with no load at 3. LLC. with engine at 70°C (158° F) minimum. Plumb to the Magnehelic(R) gauge in the gauge block. Recommended Procedure . Start the engine and operate at 3.E-Series Measure the pressure at the oil fill tube with 6.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .000 RPM.

Recommended Procedure . 32: Testing Crankcase Pressure E-Series Courtesy of FORD MOTOR CO. LLC. . 18 de Junio de 2012 01:01:54 a.6. Page 70 © 2005 Mitchell Repair Information Company.0L Diesel Fig.E-Series: SERTECA Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .m.

A cold engine will give higher readings. Make sure the Magnehelic(R) gauge has been zeroed. Remove the ducting to the turbocharger inlet pipe.6. Start the engine and operate at 3. OIL AERATION TEST Purpose: The purpose of this test is to determine if the engine lube oil is aerated and causing poor idle quality.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Oil Aeration Test SERTECA Lunes.m. Make sure the engine is at operating temperature. . LLC. Remove the air cleaner assembly. Block the outlet at the valve cover with the cap provided in Pressure Test Adapter Kit 014-00761 or equivalent. For additional information. Remove the inlet pipe and elbow that connects to the breather box. Hold for 30 seconds minimum and take a stabilized reading. Start by connecting one end of the hose to the knurled surface of Crankcase Pressure Test Adapter 303-758 and the opposite end of the hose to the oil fill tube and secure with screw clamps. Install a protective screen over the turbocharger inlet.0L Diesel NOTE: Do not plug hole on Crankcase Pressure Test Adapter 303-758. CAUTION: Excessive screw clamp torque may damage the oil fill tube. Possible Causes: Broken or worn compression rings Polished cylinder bores Leaking or bent valves Inspect the air induction system. Install the Crankcase Pressure Test Adapter 303-758 to the oil fill tube using an appropriate diameter hose and secure with screw clamps. Plumb to the Magnehelic(R) gauge in the gauge block.000 RPM. If the air induction system allows dirt to enter the cylinders. Page 71 © 2005 Mitchell Repair Information Company. Tools Required: Crankcase Pressure Test Adapter 303-758 or equivalent Magnehelic(R) gauge (part of Pressure Test Kit 014-00761) Protective screen Hose Screw clamps 15. Do not block the hole at the top of the restrictor tool. 18 de Junio de 2012 01:01:54 a. Refer to the appropriate ENGINE article . it will quickly "dust" the engine causing high crankcase pressure.

Tools Required: Clear container . Obtain an oil sample with the engine at idle. 5.m. Remove the EOT sensor. Install the High Pressure Pump Test Adapter 303-765 or equivalent and Gauge 0-1. Recommended Procedure: NOTE: The engine must be at operating temperature.approximately 0. © 2005 Mitchell Repair Information Company.000 RPM and maintain for 1 minute. 4. .the anti-foam additives in the oil may be depleted from severe use or extended intervals.0L Diesel Run engine at 3000 RPM for 1 minute.1 MPa (0 -160 psi) Bar 014-00761 or equivalent. pick-up tube leak.6. Incorrect type or grade of oil. Inspect the sample for presence of air bubbles. For additional information. It may be necessary to operate the vehicle aggressively for 24-32 kilometers (15 -20 miles) to remove excess air. 2. Method Visual Check Excessive oil aeration can be caused by depleted oil additives. 1. Possible Causes: Extended oil drain intervals .95L (1 -quart) Gauge 0-1. or upper pan seal leak. Return the engine speed to idle. 3. Take an oil sample from the engine oil temperature (EOT) sensor port at idle. Increase the engine speed to 3. 18 de Junio de 2012 01:01:54 a. front cover seal leak. refer to the FUEL CHARGING & CONTROLS . LLC.1 MPa (0 -160 psi) Bar 014-00761 or equivalent High Pressure Pump Test Adapter 303-765 or equivalent DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS Pinpoint Test Step GO to Direction Continuous GO to 4-Digit KOEO P0046 SERTECA Description KOER Turbo/Super Charger Boost Control Solenoid Page 72 Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . Air may be present due to recent engine repair on injection control pressure system.

GO to E2 . (1) P0196 P0197 P0198 P0219 P0230 P0231 P0232 P0236 P0237 P0238 P0261 P0262 P0263 P0264 P0265 P0266 P0267 SERTECA Engine Oil Temperature Sensor Circuit Range/Performance Engine Oil Temperature Sensor Circuit Low Input Engine Oil Temperature Sensor Circuit High Input Engine Overspeed Condition Fuel Pump Primary Circuit Fuel Pump Secondary Circuit Low Fuel Pump Secondary Circuit High Turbo/Super Charger Boost Sensor A Circuit Range/Performance Turbo/Super Charger Boost Sensor A Circuit Low Turbo/Super Charger Boost Sensor A Circuit High Cylinder #1 Injector Circuit Low Cylinder #1 Injector Circuit High Cylinder #1 Contribution/Balance Cylinder #2 Injector Circuit Low Cylinder #2 Injector Circuit High Cylinder #2 Contribution/Balance Cylinder #3 Injector Circuit Low GO to M2 . GO to M10 .m. GO to L7 . GO to H6 .0L Diesel Circuit Range/Performance P0069 MAP/BARO Correlation P0096 P0097 P0098 P0101 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0148 Intake Air Temperature Sensor 2 Circuit Range/Performance Intake Air Temperature Sensor 2 Circuit Low Input Intake Air Temperature Sensor 2 Circuit High Input Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/BARO Sensor Low Input Manifold Absolute Pressure/BARO Sensor High Input Intake Air Temperature Circuit Low Input Intake Air Temperature Circuit High Input Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature High Input Fueling Error PINPOINT TEST AK . GO to F2 . GO to J8 . GO to P1 . GO to F4 . GO to E10 . GO to P1 . GO to G8 . Lunes. 18 de Junio de 2012 01:01:54 a. GO to PINPOINT TEST AT . GO to K2 . GO to L9 . GO to P1 . GO to G2 . .6. GO to P1 . Page 73 © 2005 Mitchell Repair Information Company. GO to PINPOINT TEST AU . GO to M6 . GO to K4 . GO to P1 . GO to P1 . GO to H2 . GO to J2 . GO to G6 . LLC. GO to E6 . GO to L2 .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . GO to P1 .

GO to P1 . LLC. GO to P1 .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . . GO to P7 . GO to P1 . GO to P1 . 18 de Junio de 2012 01:01:54 a.6. GO to P1 . GO to P7 .0L Diesel P0268 P0269 P0270 P0271 P0272 P0273 P0274 P0275 P0276 P0277 P0278 P0279 P0280 P0281 P0282 P0283 P0284 P0297 P0298 P0299 Cylinder #3 Injector Circuit High Cylinder #3 Contribution/Balance Cylinder #4 Injector Circuit Low Cylinder #4 Injector Circuit High Cylinder #4 Contribution/Balance Cylinder #5 Injector Circuit Low Cylinder #5 Injector Circuit High Cylinder #5 Contribution/Balance Cylinder #6 Injector Circuit Low Cylinder #6 Injector Circuit High Cylinder #6 Contribution/Balance Cylinder #7 Injector Circuit Low Cylinder #7 Injector Circuit High Cylinder #7 Contribution/Balance Cylinder #8 Injector Circuit Low Cylinder #8 Injector Circuit High Cylinder #8 Contribution/Balance Vehicle Overspeed Condition Engine Oil Overtemperature Condition Turbo/SuperCharger Under Boost GO to P1 . GO to P1 . GO to P1 . GO to P7 . Page 74 © 2005 Mitchell Repair Information Company. GO to P7 . GO to P1 . GO to PINPOINT TEST D . GO to P7 . GO to P1 . GO to P7 . GO to P1 . GO to P7 .m. (1) P0300 Random Misfire Detected P0301 P0302 P0303 P0304 P0305 P0306 P0307 P0308 P0335 Cylinder #1 Misfire Detected Cylinder #2 Misfire Detected Cylinder #3 Misfire Detected Cylinder #4 Misfire Detected Cylinder #5 Misfire Detected Cylinder #6 Misfire Detected Cylinder #7 Misfire Detected Cylinder #8 Misfire Detected Crankshaft Position Sensor A Circuit P0336 Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or single sensor) P0340 GO to L19 . GO to P1 . GO to PINPOINT TEST V SERTECA Lunes. GO to PINPOINT TEST KA . GO to P1 . GO to PINPOINT TEST D . GO to P1 . GO to P7 . GO to PINPOINT TEST AR . GO to P1 . GO to P1 . GO to P1 .

GO to PINPOINT TEST AX . (2) (2) P0408 Exhaust Gas Recirculation Sensor B Circuit High P0460 P0461 P0470 P0471 P0472 P0473 P0478 Fuel Level Sensor Circuit Fuel Level Sensor Circuit Range/Performance Exhaust Pressure Sensor Exhaust Pressure Sensor Range/Performance Exhaust Pressure Sensor Low Input Exhaust Pressure Sensor High Input Exhaust Pressure Control Valve High Input P0480 Fan 1 Control Circuit P0487 EGR Throttle Position Control Circuit P0488 EGR Throttle Position Range/Performance GO to X2 . GO to W9 . GO to PINPOINT Lunes.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .0L Diesel P0341 Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or single sensor) Glow Plug/Heater Indicator Circuit Exhaust Gas Recirculation Flow Insufficient Detected Exhaust Gas Recirculation Flow Excessive Detected Exhaust Gas Recirculation Control Circuit Exhaust Gas Recirculation Control Circuit Range/Performance Exhaust Gas Recirculation Sensor A Circuit Low Exhaust Gas Recirculation Sensor A Circuit High Exhaust Gas Recirculation Sensor B Circuit Low GO to PINPOINT TEST V (2) P0381 P0401 P0402 P0403 P0404 P0405 P0406 P0407 GO to W2 . GO to W10 . GO to PINPOINT TEST KA . 18 de Junio de 2012 01:01:55 a. .m. GO to W14 . Page 75 © 2005 Mitchell Repair Information Company. GO to X15 . LLC. GO to W4 . GO to X6 . GO to PINPOINT TEST AX . (3) P0500 P0528 Vehicle Speed Sensor A Fan Speed Sensor Circuit No Signal P0560 SERTECA System Voltage GO to PINPOINT TEST AH . GO to PINPOINT TEST AX .6. GO to W2 . GO to PINPOINT TEST AH . GO to X10 . GO to PINPOINT TEST AX .

(2) (6) P0649 P0657 P0670 P0671 SERTECA Cruise Control Lamp Control Circuit Actuator Supply Voltage A Circuit Open Glow Plug Module Control Circuit Cylinder 1 Glow Plug Circuit PINPOINT TEST AF PINPOINT TEST AF Lunes. GO to PINPOINT TEST Y . GO to PINPOINT TEST Y . GO to PINPOINT TEST Z . LLC.6. GO to PINPOINT TEST Y . GO to PINPOINT TEST A .0L Diesel P0562 System Voltage Low P0563 System Voltage High P0565 Cruise Control ON Signal P0566 Cruise Control OFF Signal P0567 Cruise Control RESUME Signal P0568 Cruise Control SET Signal P0569 Cruise Control COAST Signal P0603 Powertrain Control Module Keep Alive Memory (KAM) Error Powertrain Control Module Read Only Memory (ROM) Error ECM/PCM Processor Fuel Injector Control Module Performance P0605 TEST A . . (5) (5) P0620 P0623 P0645 Generator 1 Control Circuit Generator Lamp Control Circuit A/C Clutch Relay Control Circuit GO to PINPOINT TEST AV .m. GO to PINPOINT TEST Y . (4) P0606 P0611 GO to PINPOINT TEST S . GO to PINPOINT TEST AA . 18 de Junio de 2012 01:01:55 a. Page 76 © 2005 Mitchell Repair Information Company.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . GO to PINPOINT TEST A . GO to PINPOINT TEST Y .

(2) (5) (5) P1139 P1148 P1149 P1184 P1260 P1284 P1334 GO to L13 . LLC. GO to PINPOINT TEST C . GO to PINPOINT Lunes. (7) (8) P1335 SERTECA GO to PINPOINT TEST AX . Page 77 © 2005 Mitchell Repair Information Company. (1) P1001 P1102 KOER Not Able To Complete. KOER Aborted Mass Air Flow Sensor In Range But Lower Than Expected Water in Fuel Indicator Circuit Generator 2 Control Circuit Generator 2 Control Circuit High Engine Oil Temperature Sensor Out Of Self Test Range Theft Detected.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .6.m. GO to PINPOINT TEST AC . . Vehicle Immobilized Aborted KOER -Injector Control Pressure Regulator EGR Throttle Position Sensor Minimum Stop Performance EGR Position Sensor Minimum Stop Performance GO to PINPOINT TEST J .0L Diesel P0672 P0673 P0674 P0675 P0676 P0677 P0678 P0683 P0700 P0703 Cylinder 2 Glow Plug Circuit Cylinder 3 Glow Plug Circuit Cylinder 4 Glow Plug Circuit Cylinder 5 Glow Plug Circuit Cylinder 6 Glow Plug Circuit Cylinder 7 Glow Plug Circuit Cylinder 8 Glow Plug Circuit Glow Plug Control Module to PCM Communication Circuit Transmission Control System (MIL Request) Brake Switch B Input Circuit PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF PINPOINT TEST AF (6) P0704 Clutch Switch Input Circuit P1000 OBD Systems Readiness Test Not Complete GO to PINPOINT TEST AY . 18 de Junio de 2012 01:01:55 a.

GO to AG2 .6.Accelerator Pedal Movement Parking Brake Switch Circuit P1531 P1536 GO to PINPOINT TEST AE . GO to PINPOINT TEST AL . 18 de Junio de 2012 01:01:55 a. GO to AG8 . GO to S2 . GO to AG8 . GO to AG13 .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . GO to AG8 . Page 78 © 2005 Mitchell Repair Information Company. (3) P1501 P1502 Vehicle Speed Sensor Out Of Self-Test Range Invalid Test . .0L Diesel P1378 P1379 P1408 P1464 FICM Supply Voltage Circuit Low FICM Supply Voltage Circuit High Exhaust Gas Recirculation Flow Out Of Self-Test Range A/C Demand Out Of Self-Test Range TEST W . GO to AG2 . GO to S7 . GO to PINPOINT TEST I . (11) (11) P1725 P1726 P2122 P2123 P2127 P2128 P2132 P2133 P2138 SERTECA GO to AG2 .m. (9) GO to PINPOINT TEST AM . Lunes. LLC. Repeat the selftest. (10) (10) P1635 P1639 P1703 Tire/Axle Out Of Acceptable Range Vehicle ID Block Corrupted. Not Programmed Brake Switch Out Of Self -Test Range P1705 Transmission Range Circuit Not Indicating Park/Neutral During Self-Test Insufficient Engine Speed Increase During Self Test Insufficient Engine Speed Decrease During SelfTest Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input Throttle/Pedal Position Sensor/Switch E Circuit Low Input Throttle/Pedal Position Sensor/Switch E Circuit High Input Throttle/Pedal Position Sensor/Switch F Circuit Low Input Throttle/Pedal Position Sensor/Switch F Circuit High Input Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation GO to PINPOINT TEST AI .Auxiliary Power Control Module Functioning Invalid Test .

GO to Q2 . LLC. GO to PINPOINT TEST AW .Engine Off P2290 P2291 Injector Control Pressure Too Low Injector Control Pressure Too Low . GO to PINPOINT TEST AO .Engine Cranking FICMM Circuit . GO to PINPOINT TEST AO .m. GO to PINPOINT TEST AT . Page 79 © 2005 Mitchell Repair Information Company. GO to PINPOINT TEST AP . GO to AO9 . GO to AG13 .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . GO to PINPOINT TEST Q . GO to PINPOINT TEST KA . GO to PINPOINT TEST KA .Throttle/Fuel Inhibit Circuit P2552 P2614 Camshaft Position Output Circuit P2617 Crankshaft Position Output Circuit P2623 SERTECA Injector Control Pressure Regulator Circuit Lunes. GO to PINPOINT P2262 Turbo/Super Charger Boost Pressure Not Detected Mechanical Turbo/Super Charger System Performance P2263 P2269 Water in Fuel Condition P2284 Injector Control Pressure Sensor Circuit Range/Performance Injector Control Pressure Sensor Circuit Low Injector Control Pressure Sensor Circuit High Injector Control Pressure Sensor Circuit Intermittent Injector Control Pressure Too High P2285 P2286 P2287 P2288 P2289 Injector Control Pressure Too High . GO to PINPOINT TEST AQ . GO to PINPOINT TEST V GO to PINPOINT TEST D . GO to PINPOINT TEST O . 18 de Junio de 2012 01:01:55 a.0L Diesel P2139 P2140 P2199 Throttle/Pedal Position Sensor/Switch D/F Voltage Correlation Throttle/Pedal Position Sensor/Switch E/F Voltage Correlation Intake Air Temperature 1/2 Correlation GO to AG13 .6. . GO to Q6 .

Diagnose Further Interactive Reprogramming Code . SERTECA Lunes.Replace PCM module Interactive Reprogramming Code . Page 80 © 2005 Mitchell Repair Information Company. (13) (1) Rerun self-test. .Flash Erase Error.4-WHEEL .6.m.0L Diesel U0101 U0105 Lost Communication with TCM Lost Communication with FICM TEST R . For E-Series. the appropriate INSTRUMENT CLUSTER article for diagnostic procedures. Refer to the appropriate AUTOMATIC TRANSAXLE/TRANSMISSION article. Reflash the module. refer to Symptom Quick Test for further diagnostic information. GO to PINPOINT TEST AS .Block Programming Error. vehicle speed information is provided by the anti-lock brake system. LLC.Flash Erase Error Interactive Reprogramming Code . (12) (12) (7) (7) (7) (7) (7) (7) (7) (7) U0155 U0306 B1213 B1342 B1600 B1601 B1602 B1681 B2103 B2431 P1610 P1611 P1615 P1616 P1617 P1618 Lost Communication with Instrument Cluster Software Incompatibility with Fuel Injector Control Module Less than two keys programmed to the system ECU damaged (EEPROM in PCM not working.Block Programming Error Interactive Reprogramming Code . Refer to ANTI-LOCK CONTROL . Low Voltage Interactive Reprogramming Code . Replace PCM. replace PCM) PATS Ignition Key Transponder Signal Is Not Received PATS Received Incorrect Key-Code From Ignition Key Transponder PATS Received Invalid Format Of Key-Code From Ignition Key Transponder PATS Transceiver Module Signal Is Not Received Antenna Not Connected Transponder Programming Failed Interactive Reprogramming Code .2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . (2) Refer to (3) For F-Super Duty/Excursion.EXCURSION & F250-F550 SUPER DUTY PICKUP . Reflash the module. Reflash the module. Low Voltage Malfunction Indicator Reflash the module. Reflash the module. Reflash the module. 18 de Junio de 2012 01:01:55 a.

repeat the Glow Plug Monitor (11) If the Glow Self-Test. low fuel pressure.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . if there is no direction given for corrective action and rough idle is present. the appropriate ANTI-THEFT article for diagnostic procedures.0L DIESEL (13) Malfunction INJECTOR INTERRUPT FOR ENHANCED DIAGNOSTICS DIAGNOSE ROUGH IDLE ONLY This test will help diagnose weak cylinders/injectors by allowing the scan tool operator to interrupt injectors individually. High ICP after the high idle test (test 12 on the performance diagnostics sheet to indicate oil aeration). If DTC P1284 is retrieved again.6. use the enhanced diagnostic ability of the Injector Interrupt. . (5) Refer to (6) Refer to the appropriate AUTOMATIC TRANSAXLE/TRANSMISSION article for diagnostic procedures. and high crankcase pressure are just a few of the possibilities that can cause a rough idle. the appropriate GENERATORS & REGULATORS article for diagnostic procedures. install a new PCM. (7) Refer to (8) Carry out the KOEO self-test. PERFORMANCE DIAGNOSTIC PROCEDURES for further diagnostics. After completing the performance diagnostic sheet. Diagnose all other DTCs first. Clear the DTCs. LLC.6. (12) Refer to the appropriate MODULE COMMUNICATIONS NETWORK for diagnostic procedures. indicator lamp concerns. Page 81 © 2005 Mitchell Repair Information Company. refer to the PERFORMANCE DIAGNOSTIC PROCEDURES to diagnose the high pressure oil system.FLASH EEPROM Plug Monitor Self-Test aborts and this DTC is present. 18 de Junio de 2012 01:01:55 a.0L Diesel (4) Clear the DTCs. DIAGNOSE ROUGH IDLE (ONLY) SERTECA Lunes. (9) Refer to (10) Refer to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY . bad dual-mass flywheel. This is performed by using scan tools to interrupt injector output to the engine cylinder that corresponds to the number on the injector PID. Refer to SYMPTOM CHARTS . If the DTC is retrieved again.m. A performance diagnostic sheet should be completed before using this tool. Repeat the self-test. Repeat the KOER self test.

7 0. round the number up to the nearest tenth). cylinder No. cylinder No.0 mg 9.1 0.7 0.7 + 0. The test must be performed while rough idle is occurring. For example. 5 has an average MFDES of 10.8 mg () Average MFDES 10.7 Deviation 0.8 10. For example.8 10.7 10.2 10. Record the MFDES reading before interrupting any injectors.7 0. MFDES 10. 5 has a reading of 10.6 + 0.7 10. In order to get the cutoff number.6 . the equation would be: 10. Now.0 mg 10.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines .6 0. average all of the deviations.6 0. this will be the baseline for the rest of the test. Therefore.1 mg 10.the EOT is to be maintained within -15 °C (5 °F) during the test. we would add the following numbers: 0. derive the average for each of the MFDES readings by adding the high and low numbers together and dividing by two.1-10.6 = 4.3 +0.1 + 0.6 mg 10.4-11. Injector Off Baseline = 0 1 2 3 4 5 6 7 8 () Low cylinder contributor EOT = 176°F mg = milligrams Complete the enhanced diagnostic graph to illustrate the difference between cylinders and help identify weak cylinders/injectors.1 = 0.1.4 10.7-10. using only MFDES numbers that have appeared at lease two times during the recording.9 mg 10.5 mg () 10.6-10.0L Diesel Start the engine and monitor the EOT . 18 de Junio de 2012 01:01:55 a.2-10.6.8 -10.5-11.9 mg 10.3 0.6-10. The MFDES reading will not steady and will fluctuate rapidly.7 + 0. For example.7 (if needed. subtract his number from the average MFDES recorded for the baseline. as in the sample.6 +0. Therefore. Take a five second snapshot of the PID information and record the high and low MFDES readings on the Injector Interrupt Tool Enhanced diagnostics sheet. After recording a baseline. 0. To start this process.7-10. These numbers should be recorded on the Injector Interrupt Tool Enhanced diagnostic sheet.9 = 21.5-10.5-10.9.4 divided by 2 = 10. The enhanced diagnostic sheet is intended to be photocopied and then completed for each vehicle that is tested.9 mg 10.3.6. Divide the sum by eight and round to the SERTECA Lunes. interrupt each injector individually and repeat the above steps to obtain the high and low readings while each injector is interrupted.5 + 10.7 + 0. the equation would be: 10. as described in the paragraph above. A completed performance diagnostic sheet and enhanced diagnostic sheet must accompany any returned warranty parts and cores. The following example illustrates the use of a scan tool to monitor the MFDES.6 would be the deviation from the baseline. Page 82 © 2005 Mitchell Repair Information Company. Record this number on the enhanced diagnostic sheet for the appropriate cylinder.m.9 10.1 10. Perform these calculations for all cylinder readings. LLC.7 and if the baseline MFDES was 10.

Page 83 © 2005 Mitchell Repair Information Company. 0.m. LLC.2004 Ford Cab & Chassis F350 Super Duty 2004 ENGINE PERFORMANCE Diagnostic Subroutines . all DTCs should be cleared before returning the vehicle to the customer. Perform a relative compression test using a scan tool or check compression with a mechanical gauge on the weak cylinders and one or two of the strong contributing cylinders. After injector replacement. After all tests are run. If the compression readings are within 20% of each other.0L Diesel nearest tenth: 4. test drive the vehicle for at least 20 miles and confirm that the rough idle concern has been corrected. cylinders No. 33: Identifying Injector Interrupt Enhanced Diagnostics Sheet Courtesy of FORD MOTOR CO. By using this test. the test should be performed again. 4 and 6 have been identified as being weak.3 + 8 = 0.6. Compare the weak cylinder readings against the strong contributing cylinders to verify that the power cylinder is mechanically sound. SERTECA Lunes.5 would be the cutoff line for weak cylinders/injectors.5375 ~ 0. 18 de Junio de 2012 01:01:55 a. Therefore. If a rough idle persists. . Fig. do not retest.5. the power cylinders can be considered good.