FCS-14570-REF Updated January, 2006 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 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 As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a 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 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 and belts To prevent serious burns, avoid contact with hot metal • • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, 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 your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2006 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division March, 2006 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time Complete servicing my vehicle in a Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns I bring to your attention timely and professional manner Expectation “Fix It Right The First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST – Self Study – FordStar Broadcasts – Ford Multimedia Training (FMT) – Instructor Led New Model – Self Study – FordStar Broadcasts – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS INTRODUCTION Engine Performance Curriculum Goals Intro Planned Training Pathway Intro Engine Performance Curriculum Overview Intro How to Complete the Curriculum Intro Course Description Intro Course Length Intro Target Audience Intro Course Prerequisites Intro Course Structure Intro Course Objectives Intro PC-Assisted Activities Intro Evaluation Strategy Intro Day One Flowchart Intro Day Two Flowchart Intro Day Three Flowchart Intro 10 Day Four Flowchart Intro 12 MECHANICAL CONCERNS Student Objective Transmission Concerns Base Engine Concerns Air Conditioning 1-1 1-2 1-2 1-2 MODE DATA Student Objective 2-1 Mode Data 2-2 ALTERNATIVE FUEL DIAGNOSIS, ESM EGR, ELECTRONIC THROTTLE CONTROL Student Objective 3-1 Service Area Precautions 3-3 Diagnosing Engine Performance Concerns on Alt Fuel Vehicles 3-5 Alternative Fuel Systems 3-7 ESM EGR / Electronic Throttle Control 3a-1 ESM EGR Overview 3a-2 Electronic Throttle Control Overview 3a-3 DAY ONE WORKSHEETS Worksheet – Hands-on (Rough Idle) Worksheet – WDS Recorded Session Worksheet – Hands-on (Hesitation) Worksheet – WDS Recorded Session WS1-2 WS1-5 WS1-6 WS1-8 DTC-DRIVEN DIAGNOSIS Student Objectives 4-1 Introduction 4-2 Advanced Engine Performance January,2006 TOC-1 TABLE OF CONTENTS SYMPTOM-DRIVEN DIAGNOSIS Student Objectives 5-1 System Relationships 5-3 DAY TWO WORKSHEETS Worksheet – Hands-on (Engine Miss) WS2-2 Worksheet 2A – PC-Assist (Crank/No Start) WS2-4 Worksheet 2B – PC-Assist (Rough Running Engine) WS2-6 Worksheet – Hands-on (No Start) WS2-8 Worksheet – PC-Assist (Crank/No Start) WS2-10 INTERMITTENT DIAGNOSIS Student Objectives 6-1 PID Selection 6-7 DAY THREE WORKSHEETS Worksheet – Hands-on (Intermittent Buck/Jerk) Worksheet – PC-Assist (Intermittent Rough Idle) Worksheet – Hands-on (Intermittent Rough Idle) Worksheet 4A – WDS Recorded Session (Data Analysis) Worksheet 4B – WDS Recorded Session (Data Analysis) TOC-2 January,2006 WS3-2 WS3-4 WS3-6 WS3-8 WS3-9 Advanced Engine Performance INTRODUCTION Planned Training Pathway Ford Motor Company has identified the skills and knowledge necessary to meet the Engine Performance Curriculum goals The Planned Training Pathway is a sequence of courses that are designed to provide students with these skills and knowledge Engine Performance Curriculum Overview The Engine Performance Curriculum consists of all of the following types of courses: Web-based – These courses are self-paced The technician is responsible for learning the material on his/her own time The courses are posted on the Internet and technicians are given the appropriate access codes Classroom – The classroom courses allow for application of the skills and knowledge learned in the prerequisite courses through hands-on, real-world scenarios Advanced Engine Performance January,2006 Intro INTRODUCTION How to Complete the Curriculum To successfully complete the Engine Performance Curriculum, the student must take the following sequence of courses: Ignition Theory and Operation – Course Code 31S01W0 Fuel and Air Theory and Operation – Course Code 31S02W0 Exhaust/Emission Theory and Operation – Course Code 31S03W0 Fuel, Air, Ignition and Emission Relationships – Course Code 31S04W0 OBD II Monitors – Course Code 31S05W0 Engine Performance Theory and Operation – Course Code 31S07T0 Driveability Diagnostic Process – Course Code 31S06W0 Driveability Diagnostic Routines – Course Code 31S08W0 Engine Performance Diagnosis and Testing – Course Code 31S10T0 Diagnosis and Testing of OBD II Vehicles – Course Code 31S09M0 31S12W0 Advanced Engine Performance – Diagnosis and Testing – Course Code 31S15T0 Intro January,2006 Advanced Engine Performance INTRODUCTION Course Description This course is designed to provide the technician with hands-on application of advanced diagnosis and testing skills related to driveability concerns The course specifically addresses critical thinking skills needed for the application of the advanced engine performance diagnosis and testing concepts Although the technicians work together in groups, each technician is responsible for completing their own worksheets The course includes instructor lecture, instructor-led group discussion, student activities, and student hands-on workstations Course Length This is a four-day, hands-on classroom course Course Structure The Advanced Engine Performance Diagnosis and Testing classroom course includes the following: • Instructor-led Discussion – The students are asked to complete review questions that address content previously covered in the curriculum Instructor-led group discussions focus on critical thinking skills and specific concepts that are critical to advanced diagnosis and testing • Instructor Lecture – The instructor presents information related to advanced diagnosis and testing • Student Activities – The student activities are designed to reinforce concepts presented during the instructor lecture • Workstations – The instructor presents the concepts that are critical to successfully completing the workstations Technicians participate in six on-vehicle exercises, interpret data from four WDS recordings, and four PC-assisted activities during the workstation portion of the course • Worksheets – All activities and workstations have an accompanying worksheet designed to complement the hands-on activities and are identified by number and by name • Evaluation – At the end of the four-day course, the instructor asks the technicians to complete a final written test, a final hands-on workstation, an interpretation of a WDS recording, and a course evaluation Advanced Engine Performance January,2006 Intro INTRODUCTION Course Objectives Upon completion of the Advanced Engine Performance Diagnosis and Testing classroom course, the technician will be able to: Use critical thinking skills to evaluate and diagnose DTC-driven, symptom-driven, and intermittent concerns a Use critical thinking skills to evaluate and diagnose DTC-driven concerns i Discuss the critical thinking that must take place when following pinpoint tests to diagnose faulty circuits or components ii Discuss causes that could set a component or condition generated DTC iii Discuss how to address multiple DTCs b Use critical thinking skills to evaluate and diagnose symptom-driven concerns i Discuss grouping symptoms/concerns ii Discuss viewing PIDs to determine condition iii Discuss comparing values with diagnostic reference values from PC/ED iv Discuss checking possible causes of abnormal values c Use critical thinking skills to evaluate and diagnose intermittent concerns i Explain how to use pinpoint test Z, including: • PID selection • Reference values • Recreating the symptom • Capturing and interpreting data Identify if a concern is fuel related when diagnosing alternative fuel vehicles a Discuss service area precautions b Discuss how to diagnose engine performance concerns on alternative fuel vehicles c Discuss Bi-fuel Liquefied Petroleum Gas (LPG), Bi-fuel Compressed Natural Gas (CNG), and Dedicated CNG operation d Discuss changes to base vehicle operation strategies Perform simulated hands on diagnosis to resolve intermittent, DTC-driven, and symptom-driven concerns a Perform simulated hands-on diagnosis of the following concerns: i Villager - Crank / No Start ii Villager - Rough Running Engine iii Ranger - Crank / No Start iv Town Car – Intermittent Rough Idle Perform hands-on diagnosis to resolve intermittent, symptom-driven, and DTC-driven concerns a Perform hands on diagnosis of the following concerns: i Rough Idle ii Hesitation iii No start iv Engine Miss v Intermittent Buck / Jerk vi Intermittent Rough Idle Intro January,2006 Advanced Engine Performance INTERMITTENT DIAGNOSIS DAY THREE Intermittent Diagnosis Z12 KOEO INPUT TEST PROCEDURE FOR PCM SENSORS WARNING: WHEN PERFORMING ANY OF THE TEST STEPS, ALWAYS BE AWARE OF HANDS, CLOTHING OR TOOLS NEAR COOLING FANS, OR HOT SURFACES • Using circuits chosen from the Intermittent Test Chart, select only the recommended PIDs and/or Signals to monitor with the scan tool If a PID is not available for the circuit, use a digital multimeter • Proceed to the area of the suspect wiring or component fault • Key on, engine off • If the input is a switch-type component, turn on manually • Monitor the PID or digital multimeter values while tapping on component • Monitor while wiggling sensor harness wire from component to PCM • Look for abrupt changes in values Compare the actual values to the KOEO Typical Diagnostic Reference Values in Section Reference Values Are values fluctuating in and out of range? Yes REPAIR as necessary VERIFY repair No GO to Z13 Test Result: _ 6-16 January,2006 Advanced Engine Performance DAY THREE INTERMITTENT DIAGNOSIS Intermittent Diagnosis Z13 KOER INPUT TEST PROCEDURE FOR PCM SENSORS WARNING: WHEN PERFORMING ANY OF THE TEST STEPS, ALWAYS BE AWARE OF HANDS, CLOTHING OR TOOLS NEAR COOLING FANS, ENGINE DRIVE BELTS OR HOT SURFACES • Key on, engine running • Continue to monitor PIDs or circuits as in Step Z12 • Proceed to the area of the suspect wiring or component fault • If the input is a switch-type component, turn on manually • Monitor the PID or digital multimeter values while tapping on component • Monitor while wiggling sensor harness wire from component to PCM • Look for abrupt changes in values Compare the actual values to the HOT IDLE Typical Diagnostic Reference Values in Section 6, Reference Values Are any values fluctuating in and out of range? Yes REPAIR as necessary VERIFY repair No GO to Z14 Test Result: _ _ Advanced Engine Performance January,2006 6-17 INTERMITTENT DIAGNOSIS DAY THREE Intermittent Diagnosis Z16 KOEO OUTPUT TEST PROCEDURE FOR PCM ACTUATORS WARNING: WHEN PERFORMING ANY OF THE TEST STEPS, ALWAYS BE AWARE OF HANDS, CLOTHING OR TOOLS NEAR COOLING FANS OR HOT SURFACES Note: PIDs selected from the Intermittent Test Chart will display commanded values only Digital multimeter measurements will display actual values • Using circuits chosen from the Intermittent Test Chart, select the recommended PIDs and/or Signals to monitor using the scan tool Also, use a digital multimeter to compare circuit values with the scan tool PID values If PIDs are not available for a particular circuit, look for a digital multimeter fluctuation to occur when doing any of the following tests Note: Output Test Mode may not control some outputs, such as injectors and ignition coils To test these output types, GO to Z17 Caution must be used for the next steps Cooling fans or fuel pump may turn on • Key on, engine off • With the scan tool, turn all outputs on using Output Test Mode (refer to scan tool instruction manual) • Proceed to the area of the suspect wiring or component fault • Monitor the PID and digital multimeter values while tapping on component • Monitor while wiggling actuator harness wire from component to PCM • Look for abrupt changes or PID to digital multimeter value mismatches Also, compare the actual values to the KOEO Typical Diagnostic Reference Values in Section 6, Reference Values Is there a mismatch or are any values fluctuating in and out of range on the Reference Value Charts? Yes REPAIR as necessary VERIFY repair No GO to Z17 Test Result: _ 6-18 January,2006 Advanced Engine Performance DAY THREE INTERMITTENT DIAGNOSIS Intermittent Diagnosis Z17 KOER OUTPUT TEST PROCEDURE FOR PCM ACTUATORS WARNING: WHEN PERFORMING ANY OF THE TEST STEPS, ALWAYS BE AWARE OF HANDS, CLOTHING OR TOOLS NEAR COOLING FANS, ENGINE DRIVE BELTS OR HOT SURFACES • Key on, engine running • Proceed to the area of the suspect wiring or component fault • Monitor PIDs with the scan tool (if PIDs are available) using the PID monitor function Compare the digital multimeter values with scan tool or look for a fluctuation in idle while tapping on the component • If a coil for a coil on plug application has been tapped and is suspect, with key off, it may be helpful to remove the coil and measure continuity from the spark plug terminal to the signal terminal while tapping the coil A large fluctuation in resistance will indicate an intermittent open Otherwise, monitor while wiggling actuator harness wire from component to PCM • Look for abrupt changes in idle or PID to digital multimeter value mismatches or fluctuation Also, compare the actual values to the HOT IDLE Typical Diagnostic Reference Values in Section 6, Reference Values Is there an idle fluctuation, a digital multimeter value mismatch, or fluctuation? Yes REPAIR as necessary VERIFY repair No GO to Z18 Test Result: _ Advanced Engine Performance January,2006 6-19 INTERMITTENT DIAGNOSIS DAY THREE NOTES 6-20 January,2006 Advanced Engine Performance DAY THREE WORKSHEETS DAY THREE WORKSTATIONS Worksheet – INTERMITTENT BUCK / JERK This workstation is a hands-on activity that requires you to diagnose an intermittent buck/jerk You are asked to locate the cause of the fault and identify all of the diagnostic steps taken to resolve the concern Worksheet – INTERMITTENT ROUGH IDLE This workstation is a PC-assisted activity that requires you to diagnose an intermittent rough idle on a 2003 Town Car You are required to toggle between the computer images, WDS desktop mode, and the Ford electronic PC/ED and identify all of the diagnostic steps taken to resolve the concern Worksheet – INTERMITTENT ROUGH IDLE This workstation is a hands-on activity that requires you to diagnose the cause of an intermittent rough idle and identify all of the diagnostic steps taken to resolve the concern Worksheet – DATA ANALYSIS (WDS RECORDINGS) This workstation requires you to analyze data from two WDS recordings They are required to determine if a fault occurred, type of fault, and conditions under which the fault occurred Advanced Engine Performance January,2006 WS3-1 WORKSHEETS DAY THREE WORKSHEET Vehicle: DIRECTIONS: Your instructor has provided you with a repair order that states the concern of the vehicle at this workstation Verify the concern, perform tests and diagnose the concern What is the symptom? Based on the symptom, what system(s) could be at fault? Based on the symptom, what component (s) could be at fault? The table below lists the steps that have already been performed for you DIAGNOSTIC STEP Perform Visual Inspection Verify Concern QT1 - Perform Quick Test OASIS and TSBs • Retrieve DTCs Z1 Perform PCM Reset to Clear FMEM Z2 Select PIDs Related to the Symptom RESULT No obvious fault Vehicle has an intermittent buck/jerk condition Inspect related electrical connectors and fuses, vacuum lines, air intake system, fuel quality, cooling system All systems look OK No warranty history and no applicable TSBs No DTCs Concern is intermittent Is the PCM Reset complete? YES – GO TO Z3 Answer the questions below What chart number should be used to diagnose this concern? Fill in the table with the PIDs that should be recorded for this concern WS3-2 January,2006 Advanced Engine Performance DAY THREE WORKSHEETS WORKSHEET Intermittent Buck / Jerk The table below lists the steps that should be performed after selecting PIDs Z4 Decision to Verify Symptom Does symptom need to be verified? YES – GO TO Z5 Z5 Collect Data Has all data been recorded? YES – GO TO Z6 Z6 Recreate Symptom Answer the questions below Use the VDR to record the PIDs from question #5 Compare the PID values to the Typical Diagnostic Reference Values in the PC/ED to determine if any are out of limits Did the concern occur? YES NO If you answered NO notify your instructor Review the recording Cross off any PIDs in question that could not cause the concern Which PIDs, if any, were out of specifications? What was the cause of the customer concern? How does this failure cause the concern? The MAF sensor is intermittently under-reporting airflow The PCM sees this as an immediate reduction in airflow and reduces FUELPW1 and 2, causing the buck/jerk condition LOAD changes due to MAF 10 How does the PCM try to compensate for this failure? Both upstream O2 sensors indicate a lean condition so SHRTFT1 & start adding fuel 11 How could checking the DPFEGR, LONGFT1 and 2, and VPWR PIDs help in diagnosing this concern? A stuck EGR could cause a buck/jerk condition on acceleration, where maximum power is needed LONGFT can help determine if the concern affects one bank or two and if it is a long term concern A problem with a VPWR circuit could cause multiple malfunctions 12 Were you able to use Freeze Frame data? No Advanced Engine Performance January,2006 WS3-3 WORKSHEETS DAY THREE WORKSHEET Intermittent Rough Idle (PC-Assist: Town Car) Customer’s Concern: The customer brings in a 2003 Town Car with an intermittent rough idle concern Directions: Diagnose the cause of the customer’s complaint and identify all of the diagnostic steps you took and the results of those steps in the table below Use WDS recording DAY3 Town Car 4.6L WKST2 DIAGNOSTIC STEP RESULT PINPOINT TEST STEPS RESULT WS3-4 January,2006 Advanced Engine Performance DAY THREE WORKSHEETS WORKSHEET Intermittent Rough Idle (PC-Assist: Town Car) Compare the PID values from the WDS recording to the Typical Diagnostic Reference Values in the PC/ED to determine if any are out of limits Use WDS recording DAY3 Town Car 4.6L WKST2 What component(s) or circuit(s) failed? The vapor management valve circuit How does this failure cause the concern? The unexpected purge of the stored vapors at idle causes a rich air/fuel mixture How does the PCM try to compensate for this failure? The PCM closes the IAC (decreasing air flow), FUELPW1 & are reduced Why might you check conditions related to the MAF sensor? If the BARO PID is malfunctioning, the air/fuel mixture will be incorrect for the altitude Which PIDs would you select based on the symptom? (Rough Idle – Category #11) CKP, CMP, DPFEGR, EGRVR, EVAPCV, EVAPPDC, (EVAPVMA – not listed), FP, FP M, FPM, FRP, FRP V, FSVM, FUELPW1/2, FUELSYS, HTR11/12/21/22, IAC, LONGFT1/2, MAF, MAF V, MISF, O2S11/12/21/22, RPM, SHRTFT1/2, TP, TP V, VPWR, VCT Name three reasons the path to symptom verification is recommended (1) Vehicle is in for repeat repair – (2) No DTC is present – (3) Customer has difficulty describing the symptom Which PIDs, if any, were out of specifications? FUELPW1/2: 1.7ms @ approximately +2 second mark (3.3ms – 3.5ms); RPM: Initially increased to approximately 1100rpm; IAC: drops to approximately 27% (29% - 36%); O2S11 and O2S21 indicate rich (not switching); (EVAPVMA PID is not listed) Advanced Engine Performance January,2006 WS3-5 WORKSHEETS DAY THREE WORKSHEET Vehicle: Intermittent Rough Idle DIRECTIONS: Your instructor has provided you with a repair order that states the concern of the vehicle at this workstation Verify the concern, perform tests and diagnose the concern What is the symptom? Based on the symptom, what system(s) could be at fault? Based on the symptom, what component (s) could be at fault? The table below lists the steps that have already been performed for you DIAGNOSTIC STEP Perform Visual Inspection Verify Concern QT1 - Perform Quick Test OASIS and TSBs • Retrieve DTCs Z1 Perform PCM Reset to Clear FMEM Z2 Select PIDs Related to the Symptom RESULT No obvious fault Vehicle has an intermittent rough idle condition Inspect related electrical connectors and fuses, vacuum lines, air intake system, fuel quality, cooling system All systems look OK No warranty history and no applicable TSBs No DTCs Concern is intermittent Is the PCM Reset complete? YES – GO TO Z3 Answer the questions below What chart number should be used to diagnose this concern? Fill in the table with the PIDs that should be recorded for this concern WS3-6 January,2006 Advanced Engine Performance DAY THREE WORKSHEETS WORKSHEET Intermittent Rough Idle The table below lists the steps that should be performed after selecting PIDs Z4 Decision to Verify Symptom Does symptom need to be verified? YES – GO TO Z5 Z5 Collect Data Has all data been recorded? YES – GO TO Z6 Z6 Recreate Symptom Answer the questions below Use the VDR to record the PIDs from question #5 Compare the PID values to the Typical Diagnostic Reference Values in the PC/ED to determine if any are out of limits Did the concern occur? YES NO If you answered NO notify your instructor Review the recording Cross off any PIDs in question that could not cause the concern Which PIDs, if any, were out of specifications? What was the cause of the customer concern? How does this failure cause the concern? 10 How does the PCM try to compensate for this failure? 11 Were you able to use Freeze Frame data? No Advanced Engine Performance January,2006 WS3-7 WORKSHEETS DAY THREE WORKSHEET 4A Data Analysis (WDS “DRIVE” Recording) Select “Previous Sessions,” select the Held Session "DRIVE – Town Car 4.6L – 07/02 – MIKE,” open Toolbox and select DataLogger, select Recordings Group “DRV_1,” Recording: 1, Description: NORMAL DRIVE Compare the PID values from the recording to the Typical Diagnostic Reference Values in the PC/ED to determine if any are out of limits Does this WDS recording indicate an obvious fault? No If yes, which PIDs indicate a concern? No obvious fault indicated Why did EGR start to increase, then fall back to zero at approximately 12 seconds into the recording? The PCM senses the vehicle moving off idle and starts EGR flow When it detects a hard acceleration, it returns EGR duty cycle to 0% Why is EGRVR at 0%, IAC is over 75%, and the FUELPWs are around 16ms at the 15-second mark? EGR flow (inert gas) is stopped to allow a more combustible mixture in the combustion chamber, IAC increases in anticipation of next movement of throttle and to allow for dashpot effect if the throttle should close rapidly, and FUELPW1 and FUELPW2 increase to add more fuel to the increased air, which provides more power Is the IAC PID value within specifications at idle (0 – 10 seconds)? No If not, what could be the cause? The AC or defroster could be ON (or other accessories), PSPS, etc Why is EGR increased under cruise conditions? Cruise places a low load demand on the engine Exhaust gases can be introduced without hurting engine performance What the O2 sensors indicate at the 20-second mark? A rich condition What condition(s) cause the O2 sensors to indicate this? After acceleration, the PCM places the fuel system in “OL – Drive” which causes a rich air/fuel mixture The rich air/fuel mixture cools the catalyst WS3-8 January,2006 Advanced Engine Performance DAY THREE WORKSHEETS WORKSHEET 4B Hesitation / Stumble Data Analysis (WDS “DAY_3 Focus 2.0L” Recording) Customer’s Concern: Customer in Detroit (approximately 0’ - 500'above sea level) with a 2003 Focus (2.0L 4V MT) has a severe hesitation / stumble on acceleration Select “Previous Sessions,” select the Held Session “DAY_3 Focus 2.0L,” open Toolbox and select DataLogger, select Recording Group “WS_4B,” Description: “DAY3_WORKSHEET4B.” Compare the PID values from the recording to the Typical Diagnostic Reference Values in the PC/ED to determine if any are out of limits Freeze-frame data: PID VALUE FUELSYS OL LFT1 0% SPARKADV 31° PID LOAD FRP TP VALUE 57.3% 57.3 psi 24.7% PID ECT RPM 02S11 VALUE 206.6°F 2110 0.32V Does the freeze-frame data indicate an obvious fault? Yes PID SFT1 VS 02S12 VALUE 0% 4.4 mph 1V PID IAT MAF VALUE -40°F 0g/s If yes, which PIDs indicate a concern? MAF: 0g/s; IAT -40°F At the 10-second mark, which PIDs are out of limits? BARO: 154.3Hz (157Hz – 158Hz Detroit, MI), RPM: 2953 (1630 – 1820 @ 30mph), IAC: 42.19% (34 - 50% @ 30mph), MAF: 0V (0.6 - 0.9V), OS211: 1V (Switching), SHRTFT1: 15.57% (-10 to +10%), SPARKADV: 14.5° (28 - 35°° @ 30mph) At the 40-second mark, which PIDs are out of limits? BARO: 150.5Hz (157Hz – 158Hz Detroit, MI), RPM: 1922 (1450 – 1630rpm), IAC: 65.63% (34 – 50%), MAF: 0V (1 – 1.6V), SPARKADV: 38° (28 35°°) At the 80-second mark, which PIDs are out of limits? BARO: 149.7Hz (157Hz – 158Hz Detroit, MI), RPM: 3146, IAC: 66.8%, MAF: 0V, SHRTFT1: 21.31% What value should the BARO PID display for this location (Detroit)? Approximately 157Hz – 158Hz Why would the BARO PID value be inaccurate in this WDS recording? The MAF sensor is malfunctioning (not reporting air flow) With this failure, what other value(s) is probably incorrect? LOAD Why? Load is a calculated value determined by the amount of air entering each cylinder during the intake stroke compared to the cylinder displacement Since there is a MAF malfunction, the LOAD value is incorrect Advanced Engine Performance January,2006 WS3-9 WORKSHEETS DAY THREE NOTES WS3-10 January,2006 Advanced Engine Performance ... OBD II Vehicles – Course Code 31S09M0 31S12W0 Advanced Engine Performance – Diagnosis and Testing – Course Code 31S15T0 Intro January ,2006 Advanced Engine Performance INTRODUCTION Course Description... Start (PC-Assist) Advanced Engine Performance Team Worksheet • Engine Miss (Hands-on) Worksheet • Engine Miss (Hands-on) Team Worksheet • No Start • Rough Engine (PC-Assist) January ,2006 Team Worksheet... result in a surge or idle concern 1-2 January ,2006 Advanced Engine Performance DAY ONE MECHANICAL CONCERNS NOTES Advanced Engine Performance January ,2006 1-3 DAY ONE MODE DATA Student Objective