Engine Performance Operation and Diagnosis 31 ­ Engine Performance FCS21046REF Student Guide FCS­21046­REF Course Code: 31S26T0 August, 2009 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 in­ dividual 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 in­ structed otherwise for a special service operation If you have a manual transmission, it should be in REVERSE (en­ gine OFF) or NEUTRAL (engine ON) unless instructed oth­ erwise for a specific service operation • Operate the engine only in a well­ventilated area to avoid the danger of carbon monoxide • 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 hang­ ing 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 • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts 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 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 © 2009 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION INTRODUCTION Engine Performance Operation and Diagnosis Intro ­ August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION ENGINE PERFORMANCE OPERATION AND DIAGNOSIS Course Description This is a 4–day course facilitated by an instructor This course is designed to provide you a hands­on opportunity to apply knowledge learned in previous curriculum courses and improve your skills using various tools and equipment Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All activities and workstation worksheets are designed to complement the hands­on activities and are identified by number and by name Students will complete the worksheets as they perform each Vehicle, Bench or CMT Workstation Course Requirements Each technician attending this course will be required to pass a combination of hands­on and written evaluations These will be administered on the afternoon of the fourth day • The hands­on evaluation is pass/fail type It will be conducted with exercises in PID review/evaluation and concern diagnosis and will cover: — PID monitoring — Diagnosis with DTCs — Using a pinpoint test to diagnose an engine performance concern In order to pass the course, you must demonstrate mastery of the skills covered at an evaluated hands­on exercise AND you must answer at least 80% of the written post­test questions correctly Course Objectives Upon successful completion of this course, you will be able to: • Use a scan tool to select PIDs and monitor normal system operation • Identify faults and monitor changes in system operation using a scan tool • Use PC/ED, wiring diagrams, and workshop manuals to diagnose an engine performance concern • Use the SSCC diagnostic process to diagnose an engine performance concern • Follow a pinpoint test to perform various tests on engine performance related components • Identify the root cause of an electronic engine performance concern Engine Performance Operation and Diagnosis Intro ­ August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION Course Agenda LESSON ONE: • Prerequisite Review • Workstation One: Secondary Ignition Operation and Testing • Workstation Two: Evaporative Emission (EVAP) Operation and Testing • Workstation Three: Fuel Delivery System Operation and Testing • Workstation Four: Electronic PC/ED and VCT LESSON TWO: • Workstation One: Exhaust Gas Recirculation (EGR) System Operation • Workstation Two: Variable Camshaft Timing (VCT) System Operation • Workstation Three: Fuel Control System Operation • Workstation Four: Idle Air Systems Operation LESSON THREE: • Workstation One: Vehicle: MIL ON, Hesitation • Workstation Two: MIL ON, Engine Runs Rough • Workstation Three: Vehicle: MIL ON • Workstation Four: MIL ON, Hesitation LESSON FOUR: • Workstation One: Vehicle: MIL ON • Workstation Two: MIL ON, Engine Runs Rough • Workstation Three: Vehicle: MIL ON, Rough Idle • Workstation Four: MIL ON Engine Performance Operation and Diagnosis Intro ­ August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION NOTES Engine Performance Operation and Diagnosis Intro ­ August, 2009 LESSON ONE PREREQUISITE REVIEW LESSON ONE Engine Performance Operation and Diagnosis 1­1 August, 2009 LESSON ONE PREREQUISITE REVIEW NOTES Engine Performance Operation and Diagnosis 1­2 August, 2009 LESSON FOUR WORKSTATIONS LESSON FOUR WORKSTATIONS Engine Performance Operation and Diagnosis 4­3 August, 2009 LESSON FOUR WORKSTATIONS NOTES Engine Performance Operation and Diagnosis 4­4 August, 2009 LESSON FOUR WORKSTATION ONE WORKSTATION ONE MIL ON SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern Use the steps in this worksheet to determine possible causes, separate those causes into a list of systems and components, then systematically eliminate each to come up with the root cause(s) of the concern DIRECTIONS: Read the information in the repair order* to start your diagnosis Diagnose the concern and complete the necessary information on the pages that follow Repair Order Year Model Engine Trans Other Customer Concern MIL is ON Vehicle History/ OASIS results/ TSBs REPAIR HISTORY No related history SPECIAL SERVICE MESSAGES N/A EFFECTIVE DATE: TECHNICAL SERVICE BULLETINS No related TSBs IMPORTANT NOTES: DTC P0455 Evaporative Emissions System Leak Detected (Gross Leak) * OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual concern Engine Performance Operation and Diagnosis 4­5 August, 2009 LESSON FOUR WORKSTATION ONE Part A: IDS EVAP Leak Test What description is given for the P0455 code? • Use the IDS to perform the EVAP test and answer the following questions If the difference between the engine coolant temperature and the intake air temperature is greater than 45 degrees F, the test may be invalid Why? • Continue with the test If the temperature difference in Question is more than 45 degrees make a note of it Does the vehicle pass the IDS EVAP test? Yes • No The IDS EVAP test may not be able to detect a leak Proceed to Part B, and perform a smoke machine leak detection test Part B: Smoke Machine EVAP Leak Test • Calibrate the smoke machine with the 0.040” orifice • Use the Output State Control function of the IDS to energize the canister vent valve (CVV) to command it closed • Using the smoke machine instructions, perform a Phase I pressure test with the smoke machine Was a leak detected? Yes No What action should you take next? Engine Performance Operation and Diagnosis 4­6 August, 2009 LESSON FOUR WORKSTATION TWO WORKSTATION TWO MIL ON, Engine Runs Rough SUMMARY: In this activity, you are diagnosing a 2008 Ford Edge with a rough idle concern DIRECTIONS: Read the information in the repair order* to start your diagnosis Diagnose the concern and complete the necessary information on the pages that follow Repair Order Year 2008 Engine 3.5L Model Edge Trans 6F50 Other Customer Concern MIL is ON Vehicle History/ OASIS results/ TSBs REPAIR HISTORY No related history SPECIAL SERVICE MESSAGES No related SSMs TECHNICAL SERVICE BULLETINS No related TSBs IMPORTANT NOTES: * OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual concern Engine Performance Operation and Diagnosis 4­7 August, 2009 LESSON FOUR WORKSTATION TWO DIRECTIONS: When directed, use the wiring diagram below to identify the types of fault(s) that COULD be the cause of this concern As you go through your diagnosis, indicate your results for each step by crossing off component(s) and fault(s) that are eliminated by that step What description is given for the DTC(s)? What is the cause of the concern? • Call the instructor to the workstation • Team score Engine Performance Operation and Diagnosis 4­8 August, 2009 LESSON FOUR WORKSTATION THREE WORKSTATION THREE MIL ON, Rough Idle SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern Use the steps in this worksheet to determine possible causes, separate those causes into a list of systems and components, then systematically eliminate each to come up with the root cause(s) of the concern DIRECTIONS: Read the information in the repair order* to start your diagnosis Diagnose the concern and complete the necessary information on the pages that follow Repair Order Year Model Engine Trans Other Customer Concern MIL is ON, rough idle Vehicle History/ OASIS results/ TSBs REPAIR HISTORY No related history SPECIAL SERVICE MESSAGES EFFECTIVE DATE: TECHNICAL SERVICE BULLETINS No related TSBs IMPORTANT NOTES: DTC P0402 Excessive EGR Flow * OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual concern Engine Performance Operation and Diagnosis 4­9 August, 2009 LESSON FOUR WORKSTATION THREE What description is given for the DTC? What component(s) were tested in this step? What component(s) were tested in this step? What component(s) were tested in this step? What is the cause of the concern? • Call the instructor over to the workstation Engine Performance Operation and Diagnosis ­ 10 August, 2009 LESSON FOUR WORKSTATION FOUR WORKSTATION FOUR MIL ON SUMMARY: In this activity, you are diagnosing a 2008 Focus with a Check Engine Light ON DIRECTIONS: Read the information in the repair order* to start your diagnosis Diagnose the concern and complete the necessary information on the pages that follow Repair Order Year 2008 Engine 2.0L Model Focus Trans 4F27E Other Customer Concern MIL is ON Vehicle History/ OASIS results/ TSBs REPAIR HISTORY Vehicle was at an aftermarket repair facility days ago for tire rotation SPECIAL SERVICE MESSAGES 20377 VEHICLES EQUIPPED WITH 2.0L/2.3L I4 ENGINE LEAN CODES DUE TO VACUUM LEAK SOME FOCUS,ESCAPE,MARINER (INCLUDING HYBRID),RANGER, FUSION, MILAN EQUIPPED WITH A 2.0L/2.3L I­4 ENGINE MAY EXHIBIT A MIL ON WITH DTC’S P0171 AND P2195 AND ROUGH IDLE THE CONDITION MAY BE CAUSED BY A VACUUM LEAK AT THE PCV VALVE AT THE OIL SEPARATOR OUTLET HOSE BETWEEN THE INTAKE MANIFOLD AND THE CYLINDER HEAD AREA, UNDER THE #3 AND #4 INTAKE RUNNERS THE HOSE IS HARD TO SEE AND MIGHT BE LEAKING, PERFORMED FOLLOWING PRIOR TO ANY PART REPLACEMENT INTRODUCE PROPANE UNDER THE #3 AND #4 INTAKE RUNNERS IF THE OXYGEN SENSOR STARTS TO SWITCH NORMALLY WITH ENRICHMENT, REMOVE INTAKE MANIFOLD FOR FURTHER INSPECTION IF NOT FOLLOW NORMAL DIAGNOSTICS AFTER IDENTIFYING THE ROOT CAUSE (VACUUM LEAK) RESET THE KEEP ALIVE MEMORY AND PERFORM CONSECUTIVE DECELS FROM 60­40 MPH WITH NO BRAKING EFFECTIVE DATE: 08/12/2008 20555 FOCUS ­ CLOSELY INSPECT AIR INTAKE SYSTEM FOR LEAKS BEFORE ELECTRONIC THROTTLE BODY (ETB) REPLACEMENT SOME FOCUS VEHICLES MAY EXHIBIT SYMPTOMS AND/OR DIAGNOSTIC TROUBLE CODES (DTC’S) WHICH LEAD TO ELECTRONIC THROTTLE BODY (ETB) REPLACEMENT THIS MAY ALSO BE DUE TO AIR INTAKE SYSTEM LEAK(S) BEFORE REPLACING THE ETB, CLOSELY INSPECT THE ENTIRE AIR INTAKE SYSTEM FOR ANY SIGNS OF LEAKS PAY PARTICULAR ATTENTION TO THE SEAL AT THE MASS AIR FLOW (MAF) SENSOR AND THROTTLE BODY ­ LISTEN FOR ANY AIR NOISE WITH THE ENGINE RUNNING IF PRESENT, REPAIR AS NECESSARY, AND RETEST BEFORE REPLACING ETB EFFECTIVE DATE: 11/18/2008 TECHNICAL SERVICE BULLETINS No related TSBs IMPORTANT NOTES: DTC P0148 Fuel Delivery Error * OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual concern Engine Performance Operation and Diagnosis ­ 11 August, 2009 LESSON FOUR WORKSTATION FOUR DIRECTIONS: As you go through your diagnosis, use the chart below to cross off component(s) that are eliminated by that step Primary Inputs and PCM Ignition switch CKP CMP BPP MAF TP APP A/C Sensors ECT CHT IAT PSP Switch/Sensor VSS FLI PCM PCM Power Relay Ignition System COP Boot Spark Plug Knock Sensor Fuel Delivery System Fuel Pump Inertia Switch/RCM Fuel Damper Regulator Fuel Tank/Lines Fuel Filter Fuel Control System O2 Sensors Injectors MAP EGR System EEGR Valve EVAP System VMV/Canister Purge Valve Canister Vent Solenoid FTP Sensor Fuel Cap Fuel Tank Rollover Vent Valve Canister EVAP Lines PCV System PCV Valve PCV Hoses Intake System Intake Gaskets Intake Manifold/Tubes ETC Motor Throttle Body Air Filter Hoses Exhaust System Upstream Pipes Catalyst Muffler Tailpipe Other Base Engine Transmission Brakes What is the minimum fuel pressure specification for this vehicle? What type of fuel system does this vehicle have? Engine Performance Operation and Diagnosis ­ 12 August, 2009 LESSON FOUR WORKSTATION FOUR If the fuel pump ground circuit was open, would there be fuel pressure? Yes No If the fuel pump power circuit was open, would there be fuel pressure? Yes No What components could cause the fuel pressure to leakdown during this test? How much air pressure should be applied during this test? What is the root cause of the concern? Engine Performance Operation and Diagnosis ­ 13 August, 2009 LESSON FOUR WORKSTATION FOUR NOTES Engine Performance Operation and Diagnosis ­ 14 August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS APPENDIX STUDENT GUIDE APPENDIX Engine Performance Operation and Diagnosis Appendix ­ August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS APPENDIX NOTES Engine Performance Operation and Diagnosis Appendix ­ August, 2009 Appendix ­ ENGINE PERFORMANCE OPERATION AND DIAGNOSIS Engine Performance Operation and Diagnosis APPENDIX August, 2009 ... ON Engine Performance Operation and Diagnosis Intro ­ August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION NOTES Engine Performance Operation and Diagnosis Intro ­ August, 2009. .. Support Operations Ford Customer Service Division August, 2009 ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION INTRODUCTION Engine Performance Operation and Diagnosis Intro ­ August, 2009 ENGINE. .. PREREQUISITE REVIEW LESSON ONE Engine Performance Operation and Diagnosis 1­1 August, 2009 LESSON ONE PREREQUISITE REVIEW NOTES Engine Performance Operation and Diagnosis 1­2 August, 2009 LESSON ONE PREREQUISITE