7.3L (IDI Turbo) Diesel Engine Diagnostics Guide sspranitine encom garters Sennen ree — a Sent teeee ae Customer Concems (reas taencent)nei ton Lt concam ethan sek, 208 Evtatng Noma twat Sch’ toner come TESTS Page 1 of 4 ‘DRLESS SPECIFIED ALL TEST ARE TO BE RUN WITH TRANS- oe See ae cece MISSION I NEUTRAL (PARQ AND REAR WHEEL OFF THE GROUND eat PVC | Fra Tone | peor toe No svenues + Fw amen OF and bet per G0 wt + Fw deton Okan bien pnt Goto aston dao paces (oo Carano aces Sp Mana Vre ndtoCA en sat tr + Fon dncon NOT OX Rgace srs vr anny, oat 68. [Le-cneck Fon Fu. cowramnaTioN. ara are nd vuln sage nach com ec Demmi on, uy cba caren we smocamelbanian eerie bons ae Gciace a abwse, INSTRUMENT OED ar Cova + Trveriaten win OoT, + eration wed pon ee oe mo sao st. come, ae! Grwok CI FUEL SUPPLY SYSTEM — Seo lisvafion ~ Reverse Side [4, TURBOCHARGER BOOST — Soo lustaion ~ Roverse Sido A SHEEKTUR ATW OUTLET PESTON ab Bee erore i: ener aman and connect 0.15 PS! Gauge bos tt port on My a 3000 RPM wh acon tambo: Rea a anne INSTRUMENT | GUDELME DATA | 1st ONEOE BOOER S = war meet anemone ata over tal et 1680- 2100) APL. +[0-15 P51 Gu Fr Fue | a Tat | Fo Tr] Rew Ta ‘bee Pt edna, 5651 Agr | 0751 NMA + wa arian rd ger, ezlratrm12001 2800 RP pre ees gene, -CO1 ws 7. ‘cose PSI cng premio - 1078. INSTRUMENT “GUDELNE onTA | iw cnecx [angcrecx] | [rue surpty puwe ouTLET PRESSURERecord ve" Baw) 75°51 Gauge "P51 BOOST NMA fe | ime oooenae ‘NOTE: IF BOOGTIS WITaN IMTS, PERRORMANCS 15 ACCEPTABLE Maar at 675 RPM i consti of. + Woeetis iow ot mat insTauvent_[ GuOEUNE oats | ie CHEER ROGER + 'S, WASTEGATE ACTUATOR CONDITION — Seo lusiation — Reverse Side |*| 0-15P5i cam Fane | ar Tan | re Tr Rew Tank ‘Connect 020 PS! Gauge nd hare pare oak. Ap preseuoactar lo enaso1sAdapee|_ 2.075 uns, sitar pro Amie ed ss bogie mov a 12.5 781 Ful acu + menue mies pido, ice ers pet 7A ‘rt ssl era 2022 PI. Oberve prose gauge for 30 sca ter + peau ew e107, PSI sb eae No Geren pene 7 Set Po tet 7A tas bu INSTRUMENT ‘GUDELAE OXTA TaCreCX | mecrece] | [e.~RveL PumP CAPACITY - Record Vue in 30 se: Baow '020Ps1 | ADROO TRAVEL START AT ISH, os 675 FM accra taro ‘one [ep pco rus Teaves AT2022 Pat nstmuvent_[ queune pata | ve CHECK BB SRESK & "NO DECAY OF APPLIED PRESSURE ‘ont or Fran] Ror Tar | Ft Tv |e Ta + acre aro move, ence rod tom wae aed Cok west ‘contrac ard | aunt oF + Pw] {ores of vera 200 139 secowos reenact none woe osteoma + Nemo tt move fo mate pce Pag cy + Pure Okun Vere NOT OK = Go 07. * Von OX an Peni NOT ORs at uy doe Wt 7A. CHECK FOR FUEL GUALITY ~ Soe usvaion ~Ravorse Sab + Pama nd Vn HO OK 00070. (coe a ‘rt an wore rh ofS PVC on ce he beh on a a an 300 FEM wn acess tured INSTRUMENT | GUDELNE DATA | 1a CHECK RO CEOK « *[To-somema. | Less Tan | Fert Tan] Row Ta | Fron Te] rT ‘cncun vert Fa engi 9909 Pr? mtn and sear er ht ana for ‘able ol eng at 000 RPM Ful ad ere ct win 2 rt. ‘Comet ow ren om Merton ha lum sta econ SEE REVERSE GIDE FOR TEST HAROWARE ISTALLATION > ENGINE MUST BE AT NORMAL OPERATING TEMPERATURE |¢ 27s check SHOULD BE PERFORMED ONLY AS INDICATED AND TO VERIFY CORRECTIVE ACTION Page tt FPS-2026010147.31 (IDI Turbo) Diesel Engine Diagnostics Guide a cantons & == = carte cnees eit = Seon 7.3 IDI TURBO} THE DIAGNOSTIC PROCEDURE. po Meson, I comencs) [Customer Concerns (ree tt onants)n tito. ace cha ache, 8s “voting Nome Estat Ske, pt ower cae. ft conown thar rr ToS haze Fores paommare evan. rer TSO No: 0.128, TESTS Page 2 of 4 ————__+ | "CHECK FUEL RETURN LINE PRESSURE — Soo lustation ~ Reverse Side | 13. CHECK INJECTION LINES AND INJECTION NOZZLES ‘Chackprensr at incon ol ange adept ae cami om hae. = Soe Mustain ~ Reverso Side NOTE: Fate eve tA mut be oor NOTE: PERFORM ONLY IF ENGINE IS MISSING OR RUNNING ROUGHLY. haan 9009 RPL wi conse red Record" bow. ‘Check eyeen nae ori an ecsone Pamove nese ni ie opening presse NT_[GUDELNE DATA, 1ST HED BRO GHERK « ‘sp lntage on ech naz. No er unto sou b pore 7 jomige | LESS THAN | Front Tark | faurTunk | Peer: [ near | | CAUTION: Keep ance and cer paso bay away fromthe spaying roe. The bc ana sees adage |_ 20751 dechure aves tence wh uit foc pneu hs an caee savas '3, AIR INTAKE RESTRICTION — Soe llustraton ~ Reverse Side ‘nur. Te nazi p shou be suounced by « wneparnt cate eb “+ Manus 3000 APA wt ccs eed of. Raord "Va below, ‘A. Connaet ara rari tute la a en nora mmo eta 0 mee eet a er recon pe (er Me). Operate engi 3000 AP ne reteon ‘una dct a. Pup tee omy anc recor peat ress each maar. ove Mr mia anal 14-0765 ath magnate page an et ‘toro fe rete epenirg(ctargng Ric) and Pacortn Bor) Elon. (8 nmin tat omni tty an toa cont yao arg nt. Open eto TReTROMENT (Supa oma [rw creer ma ood maaan prams or 5 sean t 200 PS! beow nore openeg presue recored Faerie orveac7eTvecia | BETWEEN? Aor sac ners Na pcan be wat 5 seconde ta pt ent ot a AND 2°20, INSTRUMENT [GUIDELNE DATA «itr ringor nein pcr cay, race 016.0000 TERGNE CAUBRATION _ S807ROO “abo 907 tae er amar ae pcan | CODE GH NOZZLE BODY @ RECORD nes tan 7 hapector nan ae, NerieTerer [mann oremmcrressure| usoesi | vate BELOW = Hosen alr, Goon 10 NOZAE ya 3 4 5 6 7 "10. = LOW IDLE (RPM) — Seo lhvstalion ~ Raverse Side DOr Preenre PS “+ Ato anamin ive pon. - cord "Va" blow (toy estage (OC NOT OR + Manual varaninsin nade potion Rest "Vat boon. Train nt to spatenon, pace nits mesniy. NOTE: WARRANTY CLAIMS INSTRUMENT ‘GUDELNE DATA | tw CHECK] es HECK] ©] FOR REPLACEMENT OF THE NOZZLE(S) WILL NOT BE ACCEPTED UNLESS ‘7e-a200 Oya Trang | SEE EMISSIONS LABEL ‘THE COMPLETED ENGINE PERFORMANCE CHART (VALUES RECORDED) 1S ts 078-0001 age SUBMITTED WITH THE RETURNED PARTIS). “TT: INJECTION PUMP TIMING ~ Soe lustraton — Reverse Side ‘ach ba dao ta prose santa on fa Nock nara for Sa (4 for Sas) and coed te arc ring mate Ol 20° eel n eet. Dacre ot stat echanen eld connecter em he alan ial, Maan 2000 PM th ng ‘perng opens an rect dani ring Box (A Aol tay vag aed 77d. CRANKCASE PRESSURE ~ Soo Ilustraion — Ravorse Sido Maas presse sl pe Loosen crankcase coprasen rr CR) va, et clon caroard betwen COR vat nt sal ng. Rattan COR andra peck sete bn tee. Remove canoer upen cette of at + Mauer 29000 RPM wit acetal red ot Recor "Ve bl ‘evi aaa 2200 APM ae od $n Bor (3 Record" ow meTRUMENT | GUDELNE DATA sa.cnecx | DCEO & Ce RRR | GoCEMEDNA [imoee ae Gead |-ewaerte] — wana Pressire Ne 22 BTOC pasoeon7s | OF IN. OF WATER 27-00209 rai Trg 200M 601 Aaa ‘aac an 7-002 Aaapec |B) GHEGK WITH POWER {ro aovance souEnoi| + Ravana Tring Cho @) do (ie) move marae tan Tig Sie A = NO} ao pan 1.9 nce rom (A), placa jection pure. 72. CHECK INJECTION PUMP TRANSPER PRESSURE ~ Soe Mustaon —— NOTE: PERFORM ONLY 1ST TIMNG CHECK (STEP 11) WAS NOT WITHIN SPEC. WARNING: THE COMPRESSOR INLET SAFETY GUARD MUST BE INSTALLED WHEN ENGINE IS RUNNING WITHOUT AIR CLEANER ATTACHED. * suasre 019000 RPM wir acensoes ted of. cor "Vit bow. [-_xsreseenr (GUDELNE OATH | we CHECK el HECK] | + | tasr-000-40-100 PS Game 90-10 P31 sr 5860 Adape 0 200 PH, pes wet wean fare an aowal ene cana \F THE PERFORMANCE CONCERN STILL EXSTS AFTER COMPLETION OF THE ENGINE PERFORMANCE CHART REPLAGE THE INJECTION PUMP, NOTE: WARRANTY CLAMS FOR| "THE INJECTION PUMP WAL NOT BE ACCEPTED UNLESS ALL TAMPER RESISTANT SEALS Ane NEAT 0 COPA EAE FONORCE COAT LES NOTE: WARRANTY CLAIMS FOR THE ILJECTION PUMP WILL NOT BE ACCEPTED UNLESS ALL TAMPER RESISTANT SEALS ARE INTACT AND THE COMPLETED [ENGINE PERFORMANCE CHART (VALUES RECORDED) 1S SUBMITTED WITH THE RETURNED PART. ‘SHOP MANUAL -"ENGINE/EMISSIONS DIAGNOSIS" -VOLUME H [SEE REVERSE SIDE FOR TEST HARDWARE INSTALLATION ~ ENGINE MUST BE AT NORMAL OPERATING TEMPERATURE ‘¢_znd CHECK SHOULD BE PERFORMED ONLY AS INDICATED AND TO VERIFY CORRECTIVE ACTION. "THIS GUIDE SHOULD BE USED IN CONJUNCTION WITH THE CARTTRUCK Page 204 FPS. 20069104 ‘TB-4954-A,B® 7.31 (iD! Turbo) Diesel Engine Diagnostic Guide SETUP ILLUSTRATION OF ROTUNDA® 0714-00761 connect cucan PRESSURE TEST KIT AND TEST FITTINGS PVC TEST HOSE AT ‘conTINUOUS INJECTION PUMP FUEL, ‘TRANSFER PRESSURE TEST 12, CRANKCASE PRESSURE TEST 14 + LOOSEN CDR FASTENERS sINSERT CLEAN CARDBOARD ‘BETWEEN COR VALVE AND ‘SEAL RING ‘*RETIGHTEN CDR FASTENERS USE GUARD WHEN cx GQ SSUee rae ouccns Tear tg ‘SUPPLY PUMP OUTLET PRESSURE & CAPACITY TEST 7B&C RESTRICTION AT SUPPLY ‘TURBOCHARGER BOOST PUMP INLET TEST 4 a Page dof 4 FPS 20269101-A TB-4955-A€ZP 7.3L (1D! Turbo) Diesel Engine Diagnostic Guide ‘Too Fs! PRESSURE GAUGE ease TS 5 FY Stern FUEL RETURN OILONLY ‘TEST INJECTION NOZZLES TEST 13 o7e-00201 UNE PRESSURE ADAPTER. DYNAMIC TIMING MARK LOCATION TEST 11 ENGINE TIMING SPECIFICATION TEST 11 Page sot FPS 20269101-A