Series Super Duty Features Description ° Service FeaturesUe ie ae ‘This publication is intended to provide technicians and service personnel with the latest technical advancements incorporated in the 7.3 DIT Diesel Engine. The information contained in this publication will supplement information contained in available service literature IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as, the personal safety of the individual doing the work, This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as, in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. The following list contains some general WARNINGS that you should follow when you work ona vehicle. © Always wear safety glasses for eye protection. © Use safety stands whenever a procedure requires you to be under the vehicle. © Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. * Never perform any service to the engine with the air cleaner removed and the engine running unless a turbocharger compressor inlet shield is installed. © Set the parking brake when working on the vehicle. if you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation, * Operate the engine only in a well- ventilated area to avoid the danger of carbon monoxide. '* Keep yourself and your clothing away from moving parts when the engine is running, especially the fan, belts, and the turbocharger compressor. ‘+ To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbocharger pipes, exhaust manifold, tail pipe, catalytic converter and muffler. '* Do not smoke while working on the vehicle. © To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. ‘* Keep hands and other objects clear of the radiator fan blades.7.3L DIT Direct Injection Turbocharged Diesel EngineTABLE OF CONTENTS ENGINE SPECIFICATIONS . New Features .. Engine Serial Number Emission Label : Horsepower Comparison . .. Torque Comparison PHYSICAL ID AIR CHARGING SYSTEM . Turbo Id 13 ‘Wastegate Control 15 TURBO REMOVAL AND INSTALLATION fr FUEL CHARGING SYSTEM ........ Injectors... es. Fuel Fiter and Supply High Pressure il System NEW AND REVISED SENSORS SPECIAL TORQUE DATA... 7.3L DIT ANTHOLOGY ... Fuel filter service DIAGNOSTIC GUIDES AND FORMS ........ GLOSSARY . INDEX 2 cigmiiewns st 9-501 5 er |!ENGINE SPECIFICATIONS New Features Engine Serial Number + There is now an engine serial number on the valve cover as opposed tothe oi reserve. “As ith previous Power Stroke engines, the engine serial number is til stamped into the crankease atthe rear ol coler pad + The vehicle production date break for most ‘of the material covered in the front section of this book is Jan. 88, unless otherwise stated in text. Electronically Controlled Wastegated Turbo All Split Shot Injectors Snap to Connect ICP Oil Lines Redesigned Fuel System | Snap to Connect ICP Oil Lin: | Redesigned Fuel Supply System | All Split Shot Injectors (Carryover from | 1997 Model Year) Chassis Power Train Changes Chassis Mounted Electric Fuel Pump ZF 6 Speed Manual Transmission (F-Series only) Low Gear Added for Heavy Loads Differential Ratios Availabl *F’ Series: 3.73, 4.10, 4.30, 4.88 Econoline: 3.55, 4.10, 4.63 Single 35 gallon Fuel Tank (F-Series only) Ls eae el 4ENGINE SPECIFICATIONS Bauer $090 noo wontis A250 aan cas Peer date eed cere je sion Label Seberouturion + The emission label is located on the right er valve cover and identifies the engine model, vasa nano z ‘gross horsepower, and fuel delivery rate. aso 200 180 Horsi wer Comparison 1999 °F’ Series i 5 100 Fak Horsepower i 8% more han previous rmadle and ocoure © 2700 RPM versus 8000 Pa % ° 1500 2000 2500 000 sso « ¥ qs fee sinter thhorspavorevone, peak aco torque is higher at 500 lb/ft, between 1600 | and 2200 RPM Ths a 15% notease over 1899" Seen eae Beery a nd Frvisus “Series ‘0 ams] om «SD gine RPMCrankshait Engine Serial Engine Serial #576010 and ebove +#576009 and below + For improved strength and ease in ‘machining, the crankshaft no longer has lightening holes drilled into tre connecting rod pins. + The counterweights are larger to counteract, ‘the extra weight in the connecting rod pin. ‘+ The engine serial number break for this ‘change is 576010, Note: The “larger” crankshafts may only be used in crankcases with serial numbers higher than 571930. Counterweight has & larger radius Crankease * The lower section of the crankcase has been modified to allow larger crankshaft ‘counterweights fo clear the crankcase, + The serial number break for this change is: ae 571930. Deen + This change occurred on the crankcase prior to the crankshatt. Note: This crankcase may be used with ‘lther crankshafts described above. ‘Mechanical lift pump eccentric eliminated Camshaft + The 1939 model year engine incorporates fa chassis mounted electric fuel pump. ‘= Duo to tho use of an electric fuel pump the eccentric lobe on the camshaft has been eliminated.0185" Rings + The intermediate ring wich has been Increased to increase ring tension in the bore. *+ The intermediate ring has a larger chamfer ‘on its inside face and increased width to distinguish i rom the prior second ring. Note: The intermediate ring must not be used on earlier pistons. 5 ti. Pre.Jen, 98 Post fn 98 0.435" Slightly deeper . intermediate 402 ‘in geaavs ee : ‘+ The new piston has a deeper intermediate. 3 ting grove to accommete the nen incosseditrnedate ring with, | Note: Pistons and rings cannot be | intermixed due to increased and narrow intermediate ring widths. ‘Under Valve Cover harness (UVC) Cover Gasket and UVC + To reduce the number of electrical ‘connections and improve reliably, the valve cover gasket now uses a single 9 pin ‘connector (versus two 6 pin), for injectors and glow plugs. *+ This new one piece design UVC is stil removable, and uses larger wires and terminals for the glow plug circuit+ Similar to the UVC harness, the engine harness also has two 9 pin connectors, Incorporating larger wires and terminals for the giow plugs. § pin valve caver connector ee E Valve Cover Gaske! Breakout Te + Because of the new 9 pin connector, ‘essential tool #418-F221 has been roleased {or testing glow plug and injector crculis, *+ The four White pins are for glow plugs. * The Black pin Is common for the four injectors. Essential tool #419-F221 * Red, Green, Blue, and Yellow pins are injector ground, Pre Jan. ‘98 “F* Series Drivers side up pipe * To improve joint serviceability, the exhaust up pipes are now common for both “E” and “F* Series. * On previous engines the exhaust up pipes ‘were model specific. The previous "F” series drivers side exhaust up pipe is shown. an 98 Drivers side up pipe, smunon for "E’ and "F" Series, Cox a) 8Exhaust Manifolds *+ The driver side "=" Series exhaust manifold has changed to allow the use of a common exhaust up pipe. Pre Jan. ‘98 st Back Pressure ther Package + With the 1999 model year “F* Series, 2 “Cold Weather option delete” package is available. I the cold weather package has been deleted, a naw procedure for ‘checking exhaust back pressure is Renny described below, cen ee ‘To check exhaust back pressure on a Vehicle that is not equipped with an exhaust back pressure sensor, you wil have to make your own cooling coils. ‘The coils are to cool exhaust gases belore they reach the pressure gauge to avoid damage to the gauge. The coil should be made out of copper tubing obtained locally. ‘Attor making coll, attach tubing to the ‘exhaust manifold by removing the plug in front of the right exhaust manifold where the exhaust back pressure sensor tube EEL ‘would normally be located, Use gauge bar tool number 014-00761 or equivalent to read pressure; on vehicles equipped with EPB this can be read using the NOS tool CAUTION: TURBO WILL BE HOT. Do not touch during or immediately after test. Route tubing away from parts that can be damaged by heat and keep away from accessory drives and fan. enero Ceo eaN Se eect) Pe aTurbine Inlet i “i ao - (pally Bee circraeocovel nie : eee, oat ~ a Peer) Engine of! ill location Oi Fill Location and Dipstick ‘+ The engine oil il location has been ‘extended to rake it easier to change or ‘add oil to the engine + The dipstick is now common for both “E* ‘and "F” series. This makes it easier to check the oll level on ">" serios. 2 Pre Test *+ Place crankcase pressure adapter on oil fl extension to check pressure. * Crankcase pressure should not be more than 4 Inches of water using the Magnahelic gauge. Note: Be sure to block off crankcase ventilation system (breather tube) before performing test. Dipstick tubeWater P: 7» + Water pump seals are dynamic seals, During engine cranking, seopage past the ‘seal occurs, ‘+ A reservoir has been added to the housing {0 allow the small amounts of seepage past the seal to accumulate and evaporate. ‘+ This oliminatos the staining seen on prior water pumps. EE Post Jan. ‘98 “F” Series thermostat housing The: t Housing, + To provide clearance for charge alr cooler piping and improve serviceability during ‘normal service operations, the "F” Series thermostat housing is shorter, has @ thicker flange and a new seal, Pre Jan, ‘98 Post jan. ‘98 Ww 4 *+ The water pump pulley diameter has been decreased 7 Pump Pulley * If service is required, be sure to use the proper pulley to obtain proper pump speed ‘and avoid cooling system concerns. ME wEngine Mounts ~ ‘F’ Series + With the new Super Duty “F” Series ‘chassis, the driver side engine mount is ‘made from cast iron instead of stamped. steel. F Series F Series Left engine mount Loft engine mount Air Cle ‘+ The air cleaner for the 1999 model year *F" serias has been totally redesigned to lise a lat rectangular filter element, ++ The air fier housing continues to Incorporate a fiter minder restriction gauge fo monitor air iter condition, ‘Single Mass Flywheel | Assingle mass flywheel replaces the previously ulized dual mass flywheel for ‘manual transmission applications |+ The flywheel can be identified by the _absence of bots that would normally ‘connect the inertia member from the clutch “surface. Note:The single mass flywheel ean only be used with the ZF 6 speed manual transmission. 12 No bots in i this location Single mass flywheelAIR CHARGING SYSTEM Turbo Charger “F’ Series ‘+ "F Series turbochargers are wastegated in Conjunction with charge air cooling. Wastegate with EBP + °F” Series may be ordered without EBR. Wastegate without EBP * AIl“E" Series turbochargers are equipped with EBP and no wastegate. E’ Series All with EBP — Non-Wastegated ‘Turbo mounting bolt + In the front view shown, the EBP ragulator ‘and new top dawn turbo to pedestal ‘mounting bolts are depicted. + The wastegate regulates maximum speed of the turbocharger by allowing excess: ‘exhaust gases to bypass tho turbine housing and be directed into the exhaust ‘stream to atmosphere, + From the rear view, EBP and wastegate actuators are shown. In addition, note the locator dowel hole for positioning the turbine inlet. + As previously stated, the turbocharger ‘assembly is now attached to the pedestal ‘with two bolts from the top. This is for in chassis removal and installation of turbo ‘assembly which is explained in detail starting on page 17. ET 13AIR CHARGING SYSTEM Turbo mounting bolt Turbo “F* Series with Wastegate and without EBP + Front view shown with EBP regulator Temoved from turbo pedestal, No EBPregulator ‘Turke “F" Series with Waste; and without EBP + Rear view shown without EBP actuator assembly, + The turbine inet, not shown, utlizes an alignment dowel for positioning on the ‘turbine housing, Location for dowel Na EBPactuator ‘Turbo “E’ Series without Wastegate and with EBP ‘+ Front view shown with EBP regulator ‘moved to front of podestal and top down, ‘mounting bolts. * Because the "E” Series does not utlize charge cooling, wastegated turbochargers ‘are not incorporated in the Econoline engines. ii 14AIR CHARGING SYSTEM ‘Turbo mounting bolts Location for dowel Turhe “E’ Sei Wastegate and with ERP Exhaust back * Rear view shown pressure actuator CAC Housing and Wastegate Contral Note: The inside of this housing will be damp with oil mist carry over from the closed crankcase ventilation system. + Oils not an indicator ofa turbocharger concern, To wastegate ectuator ee Wastagate solenoid / aoe * With the electronically controtod wastegate, a pressure differential between the induction system and the intake is used to regulate boost pressure, via a duty cycle controlled (PCM) solenoid. To manifold pressure a ST 15AIR CHARGING SYSTEM je Actuator Operation + The wastegate actuator is a spring loaded diaphragm acted on by manifold pressure ‘and controlled by the wastegate control (Seg htt MAP WGC Solenoid + The wastegate control solenoid, duty cycle controlled by the POM, is allowed to bleed pressure via @ hose connected to the ait Intake system for precise conto. “+ Spring pressure closos the wastegate, INLET Note: A tampered or disabled wastegate will result in decreased performance and potential turbocharger damag Open<—> Clos Actuator + To test the wastegate actuator, apply regulated air pressure to the actuator, starting at zero and slowly increasing pressure while observing actuator rod movement. * The actuator should start to move at 5 psi. + The actuator should hold § psi for 80 seconds. Apply pressure Apply Air Cooled Charge Air Cooled jake to CAC Housing Hoses "+ The CAC intake air hose has offset diameter inlet and outlet, ths is due to the ifference in the CAC housing and intake cover. eeltar aT: Note: Hoses are of special material and - should not be substituted during service. UIE RY 616 ea 16URBO REMOVAL AND INSTALLATION + If turbo noise is reported, frst check to insure all sound insulating material isin its proper location, if not, install all insulation in proper locations, + If all insulation material is in the proper locations, check for whee! to housing contact at the turbine or ‘compressor, if there are signs of contact then replace the turbo. + I'the insulation is present and no wheel to housing contact is present, the sound may be normal Sound Insulating Material for Engine No! ‘= When diagnosing engine noise complains, ‘such as turbo whine, you must frst check to see that all sound insulating material is in place as shown in accompanying photos. ‘+ The materia is in the fender and mounted between the fender and the A-piller and is sed to isolate the engine compartment fom the vehicle's interior. ‘+ Thore should not be any holes or gaps between the A-piller and the fender. Sound insulating material shown from, 7eee oad cac ae + First remove the two nuts holding the Power Stroke cover in place *+ Then, loosen the four clamps that are holding the charge alr cooler pipes to the charge air cooler housing. Important: When reinstalling clamps, tighten to 71 tbffin (8 Nm), to insure joint Integrity, performance, and internal engine protection. CAC Connecti Note: After removing the charge air pipes it is normal to see oil inside the flexible hose area. CAUTION: When the intake system is ‘open, care must be used to avoid any foreign objects from entering the engine or charge air cooler system. ees EAC Connections + Next foosen the two clamps on both lowor ‘charge air cooler pipe connections at the charge alr cooler, and move charge air ‘c00Ier pipes out of the way to access the turbo.ee al Sore rce rere it Cece Cena Eee cls ae fomp. wining > eee Lee An Deere ss eee + Remove all wiring and hosas going to the ‘charge air cooler housing. * Loosen hose clamps holding charge air cooler housing to turbo and intake covers. Air Induction Hose + Loosen the two clamps holding the air intake hose to the turbo, ‘+ Remove the air intake hose. Exhaust Pipe ‘+ Next loosen v-band clamp holding exhaust pipe to turbo. ‘+ Move exhaust pipe out ofthe way for turbo removal + When reinstalling clamp, tighten to 50 Ibtfin (5.6 Nm), 13Exhaust Inlet Adaptor * Loosen the v-band clamp holaing the ‘exhaust inlet adapter to turbine * When reinstaling c'amp, tighten to 100 bff (11.8 Nm). Turbocharger Assembly Note: In-chassis removal and installation Of turbo requires leaving the pedestal attached to the engine, + Remove the two bolts holding the turbo to the mounting pedestal, + When relnstaling bolts, tighton to 36 Ibe/t (Nm), Po eee *+ To install turbo, reverse above steps. Pe rereemns Peet 20FUEL CHARGING SYSTEM Injectors Cp tae yg ¢ O-Ring Pack Split Shot Operation ‘Spit shot injectors provide improved exhaust emissions and quieter engine operation, particulary atic, by tailoring the injection: ‘uel, without a decrease in performance, ‘Spit shot injectors (prime) have been used in California engines since the 1996 model year Fill Stage nd all 1997 Econolines. Now they are in all Step #1 Power Strokes, FUEL SUPPLY PRESSURE [i INJECTION PRESSURE hail Step #2 White the lower land of the plunger covers the upper port in the barrel, plunger movement increases pressure, unseals the sch ra ts Sue ets OER riser cl Stove $16 0105 EOT eoTabeibow HOER ii Atos OER kin eis ei rae aos Tht ime o_o TAs ction ta a6 asus teem “varie racy Sensi aang ou sical dom 1a 220" API ie seine Sana Tice cg a es PO 2s" @2y" APE nn sh age ny a Tae A 12) rat Tox Comer Ci Sl a ae MAF ea ce sca ise ees MAP ra Sn aad a (ies eese ar ale se ee A Rese ert Taneata (Fur — ora 12 cee tes Aes aR TAB rade eae Lon ares a sie shi or ost ED Cnet 81 -COT ‘nae tg ea OST Powe ie a ea pe mer Stan Ps POM spe us cet hi es Low seston ota it IE rf, ge wal none sd Tae [sa oes pcr canta = Oot ol rei coins COT st Pont eine ab tn co ma 15126 POWON eat ch iideifeaon Ie sc Ha el ge, most ao torte ear Note tort a EM mode eno a Mares st urd bis e109 Pew Oa ‘Oy eset In ck be sna LOR) CO cet not rd iy a 38 au sro ES cA EM nods eos ln Med ena ress 196A ge sa ci 48 Ett ls cerranded er sed no, le 3 oe ig COT lier bono wn ge een sh til be commanded of cl, Oper aad DM ae Lew ae sta et FE nts eg ll on avers hr ene 14a Ice stat age Usa ri sna Chl hr ase xara PO 44272 PCED ner 4 oT ne ton ua OST a fee stn cts em 185 ae Pa se ree ie Fl PR eas eng PR hg rT tow ta Fe nots, eg wil BAB Pee Gare aC “a tn a OST Pe eine ab co pa 29007 ‘wl ert tc LEM moss, ng wl on 4G sa PEED Gna -O5F alana ao Posen ai ir ar Tne son grt ce ve deen a anor Here oat rare ao tail aso en ag it ston at deme isi crmet or vies, hea wend Line sot eee 47 Et nods ee anon Miwred cmt ah Beast Ciena #7 CCT Diner rt ong aa Pose ode ska a i sat Hie cd ng ‘Seid wey OM ae Lie st rd 08 Bich neas eee Mo brs tr eins ceo Ls A Eubhinece sri wanor Murad crm rane seat ae KOE fe KOER A. 3 Chinen 007 Caine antag rego owe nar a a a eae TT ies No CUP asec scl Saeed a i ana 7 ott ae gn Becta tee Dac — ma ng ohpa a am 98 PBA pry ba aging Satoh et ER Oper sel, St POM r,sPOWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE ‘cece _Cede_tndee_Deseripton mers causes ma ue ches Gas bar MP Saran Sa CAP Sarco ol Go so DOW EN cesta 10M El sty COC — HOE Oper own he, nao ra a 9) GPG asc ‘Glow Pugh OCS EO Openigede ieee anthers Sid 66 test poMa—FUCS et el demand commend sgl: O66 uc TOED onde i ey Be S16 GP GP a ou ct lee Poa OEO ‘png ce are open lcd 355 1a) POUR eB cet iertoain erent O05 ck “HOE ded a ay ML 1s SBP EP cat od ara Dales ac esse des rund erates snr of POM 1} POM PCAOM den snmunston anor Cane an EF (anc Foe ites EF FCS wi sn S540 A Tener tat Sid os eR EPR soak te a amc OSE a aes PO 3608 ro resi sg 78 ER EBP proce Abia Oi Dated Gr Durand MOEA. Hain ohare lof) EPR Bene ack Tedinmas ie Pied serene ay i a ef oy Sah Ba sorte or COT a oe aa en aed aw a LAS EPC st open cat ete ons a ra ‘ye ong dion oa ToS Wotan, Crab Da, al POM aes Este lace soe ora ‘ane goa dion 07 meat Tigh Se tas, an ie or POWs Set ON at sod ‘Se KER (Gam ai ca mipean)— Gpanorabon wan Soc s roMatun om oe ri tna ie PCED Spee OFF pres [Sea ADER_ [Soul ae npn] ea sh da ie OER 133 PCED Spe Gt RESUME wl sed ‘Soot OER ode stoi a £52 7a8 168, TOS et ou ot ant (8 PCED sulcrt SET ret Sia KOE Ga tee nl pend Gas slo ib clo an Se ‘i658? PCED Sere COAST [Sina OER eas seus een) te al ood wih cea al (65) 185TH Tareneson Oust Gon KOEO — Standard Test + Tumall accessories of *+ Sot STAR tastor to Fast Code position “+ Latch STAR tet button on (ground STH) + Tum key to ON position + Unlatching the STAR tester during “ast” code transmission wit lear all codes inthe POM (They wil be stored in the STAR tester for viewing) KOEO Key On Engine Off — Buzz Test + Tum all accessories ott ‘+ Latch STAR test button on (ground ST), + Tum kay 0 ON positon + ‘Alter “iast” code transmission depress and reloase brake to abort slow codes + Depress and release accelerator pedal to stat test *+ Codes willbe cisplayed at end of est (Test can be repeated by depressing and releasing accelerator eda twice) ‘Note: The engine will run rough during the KOER ‘Standard and Cylinder Contribution Tests! KOER Key On Engine Running —Standard Test + Tum all accessories off Engine of temerature mast be up to @ minimum of 176°F (0°C) “+ ‘Set Star tester to Fast Code postion, latch Star test button on (ound ST), start engine ‘+ ter Coc 50 is transmitted, depress and release the following switches: “Accelerator Pedal (must dopress and release fist) “Cruise Contra! On, Off, Resume, SevAccel, Coast ~Emorgoney Brake and Cluich Pedal Brake Pedal (must depress and release last) — Stab rmiy to ‘activate brake pressure switch [tthe end ofthe such test the PCM wil perform the ICP and EBP step tests “+ Depressing and releasing the brake pedel alter the last test wil stop the CCT test and allow the PCM to transmit codes KOER Cylinder Contribution Test ‘+ This test wil un automaticaly ater @ KOER test ‘+ Codes 51 thru 58 wil be transmitted to ingloato the eylinder under ‘+ Pass ofall codes will bo transmitted at ond of teat *+ This test can be accessed cirecty by starting a KOER test ‘depressing and releasing the accelerator pedal once and the brake pedal two times (Ignore resutantshitch codes)saopeyeauuoeg uo paen 0H 6 steps sunoog oor) 18 = Sojapse cee SIDS & “aoe Crs panoip ng 70 ‘OND wid WOTETST FORE WO RAST AAO HI tig aI) — | — AFA “Tk Sr SO a BOE S| AUC aHOzer Fai * = PAS FZEAST TSPRGL EL REST EU Aare 70 70 +E mare 70 ss ¥-10 REL 7a OER 00, = W POGORS WA) 10S —| RE. UOT 78 0 TRIOS dA PanEIRY Wun wrowENee| —|~AT e-OET HLOELSS Ticks 0ose-060 08105 UOUsog WEIsUES |Z aeZ-OET eH AZ BWP BUT apse oNONTAS | — Aa ea oo rR 7 TIPE TS PIE me © W RST a MOREL ane i a Wi WN TORE WA 79, RET to wwBr=n21 vo NOM=No ‘a “a “a +a HOLE RETO, = AO POS Ret me i ‘siuowuiog emo | emimor | uo Aan 20799 94K) RAID 9661. — Sen|eA INO urd jeseiq TELPower Stroke 1995/1996 ER pie 1 ‘ous for | concion Geecgton ts Probabe rr Bas raed ——[ pata OSE ed ede POH af 108 BaP ciltigh tou | Oat 00K eed oY Sane a, POM tia fe ii alin toa Defic 10 ‘Suni eu ese ane FC | Inet eo: cel oh Dette 180 ie bed ats, POM. hoa ST tae Beeb onl sera cet on ea oy HiT ‘coed a iu ate iesitdtcat erence ral i a iad eden PCM ho BT 196 fOT | cOY Sensor acon 5 MY) oii KOER CCT es Sa eo, ekg Demos r oho (6 Boas KEE CCTs a erg tres Hemost [eng enor eli me Noes fetiow da ‘and cl el emer PO [ise“for — I tarsal ssc oe eesti fete tl aed sre PCM. stew BY oa Tell esto 0 cu rakes ‘Set _FOER ‘Shetege cee cpa, POM. ez Trl sn cel ete V5 sas ce nani ae Fes dl aca 0135 LA? | se beet ator rat prea ied WAP sr bro a soso 236 HAP | Te oe anor A crt i ns? LAP | us hse ener Aston ut ee Hered MAP ar Sento PCM (SAN) Ootn ser sen, POM BEAN P| Te bos ter A ck Ne al ‘Uses Hired MAP Nek, ul stte i ines: inet ve red ers i a ore hrs gir ma Ist eet Cae FE rede ea iL ot Momed cnn or hese 2b ner sspears Bu co cnn asta CCT Pov cderie Yan o Naar nee Ines cet aes FE rd un ot ree ser iste A xe EE none ge wot ied ene ornare der ert z ene ing OCT ea a or on Sa Z neste ene cit EM tig Ln on Hames ono os Inet eyi nn = Cae FE ned eno wi on 4 Revit eomce er hanes ins abn Bo olsen ar CCT i le a or Son (bt et oat = Cee Fue neds eg wil on Hare seria an Inject se eh ase EN red wl ot Mamie cea hese ere de crores al cso sng Sang GET et Dover ie ran o NBSSr ERE SN an Inet ston Cv FE nod ego win a Heres str ound are ist cst = Ca ENE nods pe win ot Mae conn ons ner entero al Cl onsen eg OC eae a orien a a ic le = is etn toons wb 28 re stra oun oa Ist et ih = ide FG nes ego il ot Seed emma or bese 7" ins neta Bo olen ang GT we cri te rr a zs Inject oeibe Canter EEN recs ng won eer aer a0 necro 5M sig non Maeda om een butonnaares Sih ia ug OCT Pavers ais tan or NBG SSA se Instr set Cnr FEW note. ge wi on 4 aris serio ain Incr se non = ch MEM ts, ene wl ond asin sone haaes ra fst onal ak Cnet cet Stes OO a Pisa i oc cao a 40 fue | canteen sets ox msecion | Ne CUP ener e tenrnfe oe sens au hr owe Da fu ta set seen seemed] ard ae eee ea Sout fu> | cans gectin sees Friant [ears canter CM ain ca Hares gran este, Lc Sa eso to | Sew pus ceutmatncon er ae KOED on dererdint sold penne es POM BL dale ct a Corn i KOED oranda sre ra psn, ls rate | eeu ist anton Noster rr mes Bat ers pn Sa Dirt Foe —| re ee ser cra peters | Cons a koran ee Diese | evn pee srr eon eat Dents epee Openireoed set bases aes PO Ea 173 FoP | nat pee soe ethene r es est hed Babee er PCH 6 EeR | nse pree snl ae pr NOE er seman EPR. EDP nd EPA a ae us ae ah [se ce tsar Commas r ty ered 00 ssc sr ain certo ine er POU, PSOM ow are ad > —| fs tana natn. os ROE oa ies aoa eat dow ae > [Sean sta ow sy laos sonora oan on Lee, car aye rr PB 0669 Foe | oprerstane ah ate tenga coon 2074 Hits clase mea ie te ss_Foe | se Gr sl natin OER ofc Cece ef dette tt seh ae, POM su ser pot | cuss Rese saat mtuncion au fl oo al een eer 8 PoeD Sets OER ss el (Ce sel ess et ree ie saad BA a wD LR tf ai OER ss esl (Cen st ese et reser ‘er oan eoupged wh on t at eh eh OER awh ce ofc ne reset ae Fao | neta tenes | Seber acamater PO pe deci Be BO arte bP. eh oc ek OER swe hte OER ah z “yes | nn aoa eset nine ne [Bhar rune asl [Fatee fs [ns ge src ot ah “Cetra 5 si a aS sama a fEt_—_| tne cng ser OED NOES. en Crue Stor ound aed eres, POM ors Jet | tare ene seria ae EOE, and Crue aa Based eo POP ta1 foo | Tosser - = Fy selec POM. cosr ie 7s Bst | ase & rat WOEO sr Onin ia, tyson OM. ars bee st ackeas NEO ar Covi su, uly slr FM are “sh ont Cerin iat a rome 25 stern Coren 7POWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE Conners ronal conse gh cow sacha ‘oer wi pete ‘She cel honed oa od Tih ow aa epanayT ‘iwi a wi a ape ‘Sparc psn eT TCP wots OER et ‘ote ROER COT an nr daa ie 57ATR ACOT=AA ROOT=T WW ACO We [ATTEN OAR RC OT=O ATTN MOE WH i RE [po = a ng soe areas es WTI ON = RWW = BND Ty aT IOS tismenmeimetion Ho wBn=/2h ‘uo wre sey i reun0 sea 10 id sweuwoo | genta | amt u6m piney 0 how wo fy | 09 84m (Atuo e1usoj1e9) ose-a/0Sz-d UPe (eIULOHIED PU eIEIS Bp) BUJjOUDD| TY — L661 SOnIeA INO Uld [98810 TELPower Stroke 1997 Econoline (ALL) F-250/F-350 (California only) E53 | fede" | conaon osergton communis Probable Cau ator [BAR Baar sre ete DO ned st Ro PO ne [mano | sarees eocrcheatheh rt | Dalal 105 tre SY, ed ssa, ize" | Ae [Acts pil sno ratiow pst el an a htt en os | ae esl tbl engine | Erg al ony ha Bate et, POM, st 0197 or bore srs cat No coldest ioe de feat, adn, POM ist ot [ie of ne srr cet an foal Nol stir de at sre, PM, eT V5 | Tete sok ernst nafetin Svoch ist KOE. vlog St sui es cosa, POM [ann] Tree abive MEET pes exer ze | ub | et ct cons Acta pfemarss | Uses ras MAP al isbn 97a coal ees ets gard tee [Aue | tus tsa age ined MAP a Noe est | tne ction =r FE pole, ene vane arenes gtd ass ni Gv FE rote, rane lan on 4 Mase sie hia Th eye sonra ye ae te ST sige a ar i fe [IN| ner ht UE ri, erare il 004 Hrs det and [aeons —T oxic a on ins Por ade abate ln Sa ze? | Wi net at w= Cn UE dee nono fists ser ae zen ect cat i= EH node soe son Movtd errs erharais Td | sora w= Cds BEA ne non Harare ound eet [mu —| ine ost Onder eH note nse anon rr — Nl Cfnser ore a ine net tts dura CS Powe ce, ate tn 9 er lo a 7s | hese aston EH nase ere hon as sor gn’ 7 [aT tee cst gh Cyn LEM ade. rr sate sree ras se of ott aera sata Pose ede va tn fe Golem Sa wer ns —| tet ee REM oi wl on ised ener 12m nu | rte crews nent cba srg COT i Powe at in os a ra ier elon Ce RE a, ie won Haass ot go yor as ig ae FUE ore wl en Ma I a ede oleae un ST Bowe ine vate tin no pon, Sa [ests [-nd [rece tet heh vice ue aun Med cred res [ats 1 ce 8 ergs a inst cored ng Ck over onde skabc pl ca ‘cud | cub | Const otto ona ct nan SP ere el ood al ca gears i, cl St TCT ain sur pera ciel ms es arses reg, sing ta esr ase [cue | Const onion ener ct ier | Tras nnbor ol OP Tani ca [Heres tea remanence | 1660] Grin rast relation Cains a 7 ser pen leg FCM | get | ws ent ret sek Covi nd KOEO oda et ae st. eee SM Pier, cok cua > | hs ps smn tel ow at Dist toca eee Opener ea ese [ese | brour pass nc hah at estes Bn renee ee Gres crossed ora, PO ou | een | Sour om cx abe nits nit fatoar Spr seine SPSL Estos pom canta hgh Eres bak Se. te ti ok te ated ide oreo aunt ormneae [sero cios POM PSOMionisnatiie | sacs aa Blow KOE ondenender COT tet aa st | herana rs lu i nas cae ae a Ls evel. ene on POM ts Steam tee Bah bo ont easter 200 one ea igh se olga sl POM ae 9. On sre mena ill 006s pen (Openers eat uth ie PEM art s2 sil msn EF eh et Coe et see oe ‘State oan KOER ach st, Gis Resa srl eco OES she (Code et ea ue Se ses maknton OES Code st oe rsa ‘rs cee and OPA ade wb stn yah ‘es Cast sara mansion Oa et Coe fie tae ston vee no enue ee ei ovr Carb Mess Kal etarar | Noho ul ul bg elt oan Pa ‘aie Foes Goto Mihie NOM eens it 2 ge nr EO sr Pau i ov mast Segre a ners POM Sa veh 8 chest ration OER ari ‘Gpentert rat sch, POW die ae i si i ct makin TER ath at ch ie EN eh nt Tre ange see cesta Seis econ dg TS gn la [oe [rns [tere nae serena, | carn ae Stet rund aia TAS a [Lorum[ tas | tane anasosecisut tian np | ante | Gees sason TAS con in seaataes | [lone [arr [rs tictonn ons ioe ro entra Ses goand,Saed seen, POM 71a [rer | ere tp saa cli SEOKDER, on Cerra ae ad sme, PC sh ora iouesconte aud stewrrrenes | Cannon Fas POM, carver deseo. za | roe | Ce sean cch en ti OED sre Co nut san POM ra [081 | Sit sera Arar OED are Crees ic i alas PL [se Shales marc HOED are Cosost roa oreo | wa [Pa a no Coes is Sah i, BE rss [Wa | sober Cont ci uy sono ely uPPOWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE gn oon shor ont 8 Hah ow a pon ern * (0500 st tennationoeur tr 2d corsecutve out inde wi a rae ide wi a i rape Boa HOER CCT anon aan a fesion ot REO onder et Tianemilrhadtenp bo gh ow er HOED aT OER For F-250/F-350 (49 state) and F-Super Duty (ALL) refer to Diagnostic Guide #FCS-70230208 ‘par oa open pa ATOM sy, ly oa, FE Fos.7a2s0207 61tome sunosona yon) 18 > unaid Fem WERT IOVERET_TUS TRT ION THD Ne NO UO WENT = 10 OWE Bl MOS TO. = AO" lO. = REF WOT Mae Ss Ssasiasselaslaaaaaaaaaacialal a a 2 HQ WBN =NZ 4 YO WEN=A0_ +8 +8 +a +a 10 1 TOSET ESM pas isi a ae oa is oe i swouuoa | goutt> [sven | emnor | voto | noson | veo eam] #nano suen [eis (e}us0129 pur ayes Gy) Aing Jedns-4 Tv pur (Ajuo a1eys By) OSE-4/0S7-4 £66} — SenIEA INO Uld [98910 TELPower Stroke 1997 fe acter ay ALL 588 [ Fee | conetion ‘Soom Probable Causes aig | oero | pinecone sree oaarraa [Sana ice oe a PT us| Sto | Saseeteorar eet fei osreb sD ie [ot [ht er ee ct mse i | aston eet las [APT tas se cer i i Fs Ta ee sa hte nee rie a8 gee todas | Execalwam sah ax XOES CCT htt r ar eot | eee oltre sent focsan ri esc ecg aas PO 2 [ ee ltr geste [Neel e a bes wr, POM Sa ST Saleh tHE ‘Stinnett se ge AOU Tt sl ioc fet dee oY TE foiedee uci Ts At eerorsaca | Use ch eed elas Te se enmerA sto esas MA tigate alee “htc baste Acastnan oa ase MAP era ith sr inact ston: Cader Ee, ane LER nee tote ae te aA fs oie gee Mite nec ae Gio srncntaires a isn cig utc fone seo nace scl Sa inbr alloCoie fu con area Hersh ard tee ssn Garr Tu coe ete ano ed ats Gin titres Cc tte at OT a Soe os so PaaS ieee eta ae Une eon aha hs aa Ineo ad asa ae Luna eed eer faa ti.) eat dase anc ar Ge “ee seater sana stot oad “i etc A regen ite ec a oe sets BA tno ca at noc ste van cer gi, Sa inet fueron cara inn at tere hr nas ne nts a ces us Co ove fn eo Sc inser Flere eaten tecaste ae eth uta ea an tee var oi rs a aut gS? ints cana oa Sa ace toe: Gc? EY i ise et une reas ese eoesrs inde tc Eo cea tin ceri, So esr ee Ge eve cee ress gard vse cere ae Bows, ve van er nla ra posh sao ata god cis ener cet paste sea gt ret ula. cng re ene a z " nes ie en, op (Gs ces matin reused lead osha Sled POM 7 Gow suse cut nan C SG 6 oe, es PL 0 aout ees soa ot nani Neonat ed sree op (ose es oes oon a ‘sees aa Gee re cesses ees PE ma [eats ee err tel Bans sa eres i heres Ease ee, PM. sre Esha es orl alin ‘ete bas res OED Sndenand a [openizirsl sora pened ica PER 0s Enh fe ora pass Fn ohaenara et Fated EPA CBP, EP raat 00 | stan ton sole or REA a andes OT lesbos ea ene soa ew ere cn sek Low i chat ve rel PE se 20 vonm {System tan ah be erry soni“ High vole. rae er POM le sss | S008 | cris On rl malin OER ek de ee ‘Opa shor oro sn POM Glue lod uss | 6068 | cue Of ara aint DER ah Ci feats ‘watt onen ng ROEM eich at or sine sera rah EF teh et Coot er osse_| 6008 | one Set agra ale KOE i Cae at ue pee ‘rut ete nd oles lb tn ary Crise Coss ea ston OE eee ode set oie a pee ‘eter verons ot equip css et ou | Povaran cona ele Kasse | Noone nts eet ean PW i, eu ae PO cut | Ponainin Conte Mase ROM ral POM i erst FC rs ‘73 | 600 | Sle wh ci OER seh ‘pena et ath, POU do ae rot | ore {oc mcs rout ic ania OER auth ‘ih uve OER ef oe_| Tas —[ re ih ont ince ted ua, POM, ia [Ter | re een ee io KOEO HOEK. and Goo ‘Stab orn, as es, PO 715 [Terre snp exer lh eu HOED AER, " OU, babed soe, PAL, sh aa 7s rs OED a fe ey oe Pa ED at sr, eld POM [Cast [ea rears rin oO rea IPA aia ied uk & ea OAT a [ee [ep ata ede es (rst ode a KOEO er dean et Sa Sho pen ag ow ln aeraPOWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE igh kw a chav AB Tighe i epan ey yew il pele ‘i wih a an pee Doors KOER CCT et For Econoline (ALL) and F-250/F-350 (California only) refer to Diagnostic Guide #FCS-70230207 ‘Sec store ec ea EA ‘Soca pen wes eT NT Fos.roza020eF-Series POM Connector ‘Cab Mounted Components os ‘GD PTO Enable, “Kevewn® ae Dialaier Ooo a” | eArrugnt @ __KEVDWR * | eae OO I wl ! Signal etn Ver OP Signal vi MAT Signal ‘CAMP Grou i Seeeees csaaeweem, aa Bane KEYPWR Connector 4, *Not used on ooneane ‘oeoboooo® ; | erecta engoonOots/ Be Keven + 4 ee Jar wooute [eat tere | ewe ano | | ~__revewn [ep KEYPWR GPL KEYPWR [sex © ~—eren brow. fet Bre KEYPWR, ‘Pace Guorstal!~__xevewa KEYPWA feoS = 0 Speed Conte! Saiches} 01, Onion ter F-Series ny Box To Terre) 67Power Stroke 1999 ee 008 Series SS es ae esas Sa ee — ee 55-2 eee (eae pares oar oo eee eee ee — ee eae a ee ee ee eee ee a eee, — ete eee ee ee ea ——— ole eee it eg te ae = = eae ee me ee aa a = a pe ae Se ee ae cae Bree [Het ouraar its ee Se neers oe faces eee a ee teers Ce ieee ee fees Tones Syne” courses ox ———[ eyes aot cotati co a How ender ate so nsslar problem, rau oe ieee ee ue eaestieea a Ea ie fey ations ak eect ining atten Coa Powe Gye ats ae ST GOH Heat ieee oer ie Seraias ore, See a Fete ee en eee! eee eee eH em es oe Se eet ees ae ereceseueamn ee a rH a score tronnancs GE Elna ot cont ung Sain ‘ower eying wave Wa 0 NSCS BoB : ue e— Tae See Tear Sire eee eee oe Festa tsk Bas eee iercee— ee = oo Stine er nanan — teers = =e See ff St ime ene a (Tiere atom pg creat marten Spa saabad Spanish, aed PCM Saas Se a SN Exhaust otess seis lu aerfaunancs ——T Continua Peed. ck ore tea a es aoe — eens Seniee oe a ‘ea exhaust procs coral ale pat nace io en desta era FS a oe te pierce eer eee SSS ee ete foe gees aaa eee | ee es | frien ote, ee See es — ee eg — eee oe a eee (Hen PRs | ierneaatatns a 2 ee eo onereaen alla cincli Se se ete | ‘re | TAS [ra range sera eet gO por ‘Cortes aE ai enreeeean eee en yr ped eee epg ——| sree ah TROESKGER-sne Continues Sra, Based sansa POM, enor Wo power et — tesa = Bone a ome = = Fie er Here aa oe Soa ee eeePOWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE eae | tas | Barron onmants ona ie) [ WA —[ Bac of O00 AL [ est Anetra aut Ff rs aR Ha telat oro Suey ee pee lars Migr Se oe dar ROT OE ‘Short cteut, tori ngt ed OM ih Sw Bae SpE WT ST TR A TS Se 5 TAT a fii sar or nd on ogee | Muted eooecirseFemess tht ground | a ‘Stored wots ts itis ‘nse oe an Wat Us Se Tier ser Ser aa er cern a aS ert goer ear go nae rear ete pa as ts ar Tes zee Sm a Ped Ss kaa a a See = Tes Siete ny wie Ol omar aE + ‘i Toros & KOED or Senana E Rae SP TES Soul oo Tae o aa aoa SES PEM encom ween Laan a ees BAR rng FOES ese tr rato gies BT as Tet — | tnavesi otenempeste Soman a Tara Wasson re, ea ra anes PEW | “900m su uation ors ern conv at {Piet i tration esa a51998 1/2 Econoline Hard Start | No Start Diagnostics [Fae Pa Se oper vn bw WF pre nepa I te ae 7 cence ee — 1 RG ne can ar ma = ‘See POIED manual, Section 4B for more detail on all of the above test steps. 701998 1/2 Econoline Performance Diagnostics (con —] | aa : aca oe ae ‘one rat ines ne it a Setanta en ‘na so ie Snake Lr ‘ee eee] ‘ae aa Be nce rs ates Eel beet T= re eet — pen pennonnnmam mere aee ers ioe ana aoe ——wer] * Hoosen = rt tt ore Re oe a Snes aT lieenmeeree te maa peace geet) | amacrine + Tira ann we = peaenie| cee ane teh a ot ‘S00 PGIED manual, Section 4B for more detail on all of the above test steps. 71999 F-Series Hard Start | No Start Diagnostics Se Ri Dieta a rn Soaeen gman Sacer 7 ieee =o f saa see Tt Pleas en te ‘See POIED manual, Section 48 for more detal on all f The above test stops. 721999 F-Series Performance Diagnostics su schon att anaaseain ena Tena ° ims nyse |" at a l oe) erm “earns an ‘tesa i ah ‘See POIED manual, Section 4B for more detail on all of the above test steps. 73APS Accelerator Position Sensor ‘A potentiometer style sensor that indicates the operators Pedal position, Actuator ‘A device which delivers motion in response to an electrical signal Analog A continuously variable vollage. BARO Baromotric Pressure Sens ‘An analog device which indicates atmospheric pressure \which allows the PCM to compensate for altitude. A BARO ‘sensor has three connections, signal return (gnd), BARO signal, and Vret. CAC Charge Air Cooling ‘A process of cooling the ait coming out ofthe turbo before it enters the engine. EMP Camshaft Position Sensor ‘A Hall effect sensor used to indicate engine speed and, ‘camshait position. Speed is indicated by the number of vanes counted per revolution. Camshaft postion Is indicated by a single narrow vane which indicates #1 cylinder position (oF 2 wide vane in dual sync application that indicates #6 oylinder. DVOM Digital Volt Ghm Meter ‘A meter that uses a digital display to indicate a measured value, Preferred for use on microprocessor systems because 2 DVOM has a very high internal impedance and will not load down the circuit being measured. EBP Exhaust Back Pressure Regulator AA pulse width modulated controlled butterfly valve mounted (on the exhaust side of the turbocharger used to create ‘exhaust back pressure to insure faster engine and cab warmup. P Exhaust Back Pressure Sensor A transducer style sensor used to indicate exhaust back pressure, EOT Engine Oil Temperature A thermistor type sensor which indicates engine temperature. GPR Glow FI " Relay which supplies power to the glow plugs. Mall Effect Sonsor ‘A Hall Effect sensor generates a cigjtl ono signal that indicates speed and also engine timing. The signal is created by a switching action caused by the passing of a vane thru a postve and negative voltage potential. When the vane is between this potential, a signal is crested. When the gap in between this potential is open, no signal is {onerated. The wider the vane the longer the duty cycle of the signal, the narrower the vane the shorter the duty cycle of the signal. A narrow van is used t indicate the postion of 4 oylinder and a wide vane ti indicate the position of ¥8. A Hall Etfect sensor has throe connections: ground, Vref, and signal IAT Intake Air Temperature Sensor AA thermistor style sensor used to indicate air temperature, ICP Injector Control Pressure ‘A transducer style sensor used to indicate gallery pressure, IPR Injection Control Regulater Controls injection il pressure. An electrical signal to a solenoid creates a magnetic field which applies a variable force on a poppet to control pressure, The quantity of fuel delivered to the combustion chamber is proportional to injection control pressure. IDM Injector Drive Module ‘An electronic unit which has the primary function of an <’lectronic distributor forthe injectors. It also is the power ‘supply for the injectors, It supplies 90v @ 7 amps to the Injectors. IVS Idle Validation Switch ‘An on/off switch sensor that indicates when the accelerator ppedel isin the idle position. impedance ‘A form of opposition to AC current flow measured in Ohms, ‘A sal-test operation that is performed with the ignition ‘switch in the ON position with the engine off. OER Key On Engine Running Test {A selt-test operation that is performed with the ignition switch in the ON position and the engine running. 75Cp ACR w it MAP Manifold Absolute Pressure AMAP sensor is a sensor that generates a digital frequency ‘that indicates manifold boost pressure or vacuum, The signal is created by switching action caused by manifold prossure ‘on a diaphragm connected to a capacitor circu in the sensor. The digital frequency increases as pressure increases, A MAP sensor has three connections: signal return (gnd), MAP signal, and Vref. MAT Manifold Air Temperature {A thermistor style sensor used to indicate air temperature after passing through the charge air cooler. Normally Clos Refers to a switch or a solenoid that is closed when no control or force is acting on i Normally Open Refers to @ switch or a solenoid that is open when no control or force is acting on it PEM Powertrain Control Module ‘The housing which contains the micro computer, Vrot regulator, input conditioners and output drivers. Potentiometer (Pot) Converts a mechanical motion to @ voltage value. Most often used to sense the position of a component. This sensor works as a variable voltage clvider. The wiper arm is mechanically connected to the component desired to be sensed. Potentiometers have three connections: Vref, signal out, and ground. Pulse Width ‘The length of time an actuator, such as an injector, remains energized. Split Shat Injector (Prima) ‘Spit shot injectors provide improved exhaust emissions and Quits engine oparation by taloring the injection of uel, without a decrease in performance, Thermistor Sensor used to determine temperature, A thermistor ‘changes i's resistance value in relation to temperature change. Increasing temperature results in decreasing resistance, decreasing temperature results in increasing resistance. The thermistor in conjunction with a current limiting resistor in the ECA forms a voltage divider that provides a voltage signal that indicates temperature. Since the top half of the voltage divider isthe current limiting resistor and is internal fo the ECA, a thermistor sensor only thas two connections, signal return and ground, 78 vBAT Battery voltage (see VPWR), vPWR Battery voltage (see VBAT). VSS Vehicle Speed Sensor Normally a magnetic pickup style sensor that is mounted on the talshatt of the of the transmission to indicate ground speed.A Air cleaner, 12 Air induction hose, 19 ‘Antitoam concentrate, 47 c Cam follower guide, 38 Camshaft, 6 (Charge alr cooler housing, 15-16 piping, 18-19 Circuit diagrams, 51, $5, 69, 63, 66-67 Crankcase, 6, 98 pressure, 10 Crankshat, 6, 45, wear sleeve, 45, Cylinder head gasket, 99 > Diagnostic forms, 70, Diagnostic guide, 60-61, 64-85 Dipstick, 10 E EOM pinouts, 60, 54, 58, 62 Emission label, 5 Engine harness, 8, 43 Engine mounts, 12 Engine serial number, 4 Engine torque, § Exhaust manifolds, @ Exhaust pipe, 19 Exhaust up pipes, 8 F Flexplate/Flywheel, 12, 48 Front cover, 39 Fuolfitor assembly fiter element, 25, heater, 24-26,36 pressure regulator, 24, 85 restriction sensor, 35, service, 25:26, 95-97 standpipe, 26 water drain, 24-25, 37 water sensor, 25, 96 Fuel inlot chock valve, 27 Fuel supply lines, 27, 41 Fuel system diagram, 28, 6 Glow plug relay, 43, H High pressure oil pump, 42 Horsepower, 5 1 Injector, 21-28, 41 torque, 48 conings, 23, split shot (prime), 21-22, 41 Injection control reguiator, 43 contings, 43, Intake cover, 16, 48 Intake hoses, 16, 47 ° Oil cooler header fiter bypass valve, 46 pressure regulator, 46 lf, 10 (Ol pan, 40, capacity, 48 gasket, 42 resealing, 47 Oil reservoir, 29, 40 P Pistons, 7 rings, 7 Pressure check at pump, 29 left head, 28 Tight head, 28 s Sensors ‘camshaft position (CMP), 32, 43, 45 engine coolant temperature (ECT), 43, ‘exhaust back pressure (EBP), 32, 43 Injection control pressure (ICP), 43 ‘manifold air temp (MAT), 81 ‘manifold absolute pressure (MAP), 31 ‘Snap to connect ICP lines, 29 77‘connections, 29 tools, 30 ‘Sound insulating material, 17, T Thermostat, 44 ‘Thermostat housing, 11 Torque data, 33, ‘Turbine inlet and clamo, 10, 20 Turbo, 13-15, 20 Removal, 17-20 u Under valve cover harness (UVC), 7, 43 v Valve cover gasket, 7 Valve cover gasket breakout tool, 8 w Waste gate actuator, 16 control, 15, Water pump, 11, 44 Water pump pully, 11 787.3 DIT Power Stroke Direct Injection Turbocharged Diesel Engine FSC 12922JA