Advanced Engine Performance ­ Diagnosis and Testing 31 ­ Engine Performance FCS21049REF Student Guide FCS­21049­REF Course Code: 31S28T0 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 ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION INTRODUCTION Advanced Engine Performance ­ Diagnosis and Testing Intro ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION ADVANCED ENGINE PERFORMANCE DIAG & TESTING Course Description This is a day course facilitated by an instructor This course is designed to provide hands­on opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previous curriculum courses Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All activities and workstations have an accompanying worksheet 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 a pass/fail type It will be conducted with exercises in PID review/evaluation and intermittent concern diagnosis and will cover: — PID monitoring — intermittent diagnostics — diagnosis without DTCs In order to pass the course, you must demonstrate mastery of the skills covered at the 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: • Identify types of DTCs (Condition and component generated) • Perform data analysis (Mode 6, PID) during diagnosis • Perform diagnosis using the scan tool, oscilloscope, breakout box and other tools • Perform intermittent concern diagnosis • Perform diagnosis using the symptom chart Advanced Engine Performance ­ Diagnosis and Testing Intro ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION Course Agenda LESSON ONE: • Prerequisite Review • Workstation One: MIL ON, Engine Misfire (On Vehicle) • Workstation Two: MIL ON, Wrench Light On, No Throttle Control (Bench) • Workstation Three: No Crank (On Vehicle) • Workstation Four: E85 Bench Calculation and DTC P0133 (CMT) • Lesson One Written Activity LESSON TWO: • Workstation One: MIL On (On Vehicle) • Workstation Two: IDS Recordings (Bench) • Workstation Three: Engine Misfire (On Vehicle) • Workstation Four: IDS Recordings (Bench) • Lesson Two Written Activity LESSON THREE: • Workstation One: Intermittent Stall (On Vehicle) • Workstation Two: Intermittent Rough Idle (CMT) • Workstation Three: Intermittent Buck/Jerk (On Vehicle) • Workstation Four: Intermittent Misfire/Skip LESSON FOUR: • Workstation One: MIL ON, Hesitation (On Vehicle) • Workstation Two: Intermittent Misfire (Bench) • Workstation Three: MIL ON, Hesitation (On Vehicle) • Workstation Four: Intermittent Misfire (Bench) • Lesson Four Written Activity Advanced Engine Performance ­ Diagnosis and Testing Intro ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION NOTES Advanced Engine Performance ­ Diagnosis and Testing Intro ­ August, 2009 LESSON ONE PREREQUISITE REVIEW LESSON ONE Advanced Engine Performance ­ Diagnosis and Testing 1­1 August, 2009 LESSON ONE PREREQUISITE REVIEW NOTES Advanced Engine Performance ­ Diagnosis and Testing 1­2 August, 2009 LESSON FOUR WORKSTATION TWO • The start of the diagnosis is completed and the results are listed in the “TECHNICIAN NOTES” Table • When directed, use the ”SSCC Table” to identify the type 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 In the SSCC table, document the system(s) that could cause the concern SSCC Table Symptom: Intermittent Misfire System: Ignition, Fuel control, EGR, Base engine, Fuel delivery Component: Cause: Use the L4WS2 CMT on the desktop and fill in the result column of the table • Test Result Retrieve DTCs No DTCs Mode Mode Data does not indicate a fault Power Balance Power Balance does not indicate a fault Relative Compression Relative Compression does not indicate afault Relative Injector Flow Relative Injector Flow does not indicate a fault Load and review the L4WS2 IDS recording Based on the results of the tests, what systems can be eliminated? Advanced Engine Performance ­ Diagnosis and Testing ­ 11 August, 2009 LESSON FOUR WORKSTATION TWO Based on the knowledge you have gained, what other system may cause a perceived engine misfire? A Driveline B Brakes C Air Conditioning D Transmission What component in the transmission could give the sensation of an engine miss? • Review the L4WS2 IDS recording and analyze the data Change each of the digital fault PIDs to display as graphs Do any of the PIDs indicate a fault while playing the recording back? What is the cause of this concern? • Use the “Menu” button to exit datalogger, then place the IDS session on HOLD Advanced Engine Performance ­ Diagnosis and Testing ­ 12 August, 2009 LESSON FOUR WRITTEN ACTIVITY LESSON FOUR WRITTEN ACTIVITY Advanced Engine Performance ­ Diagnosis and Testing ­ 13 August, 2009 LESSON FOUR WRITTEN ACTIVITY NOTES Advanced Engine Performance ­ Diagnosis and Testing ­ 14 August, 2009 LESSON FOUR WRITTEN ACTIVITY LESSON FOUR WRITTEN ACTIVITY On the schematic in the SSCC Table, draw the faults that would cause the output device to not operate SSCC Table Advanced Engine Performance ­ Diagnosis and Testing ­ 15 August, 2009 LESSON FOUR WRITTEN ACTIVITY NOTES Advanced Engine Performance ­ Diagnosis and Testing ­ 16 August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX STUDENT GUIDE APPENDIX Advanced Engine Performance ­ Diagnosis and Testing Appendix ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX NOTES Advanced Engine Performance ­ Diagnosis and Testing Appendix ­ August, 2009 Appendix ­ ADVANCED ENGINE PERFORMANCE DIAG & TESTING Advanced Engine Performance ­ Diagnosis and Testing APPENDIX August, 2009 Appendix ­ ADVANCED ENGINE PERFORMANCE DIAG & TESTING NOTES Advanced Engine Performance ­ Diagnosis and Testing APPENDIX August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX Misfire Diagnosis Chart NOTE: On some vehicles, the Misfire Profile can be reset by clearing the Keep Alive Memory (KAM) On some newer vehicles, use the IDS to reset the Misfire Profile by selecting: TOOLBOX>POWERTRAIN>SERVICE FUNCTIONS>MISFIRE MONITOR NEUTRAL PROFILE CORRECTION CAUTION: Operating the vehicle for an extended period of time after resetting the Misfire Profile may cause catalyst damage Advanced Engine Performance ­ Diagnosis and Testing Appendix ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX NOTES Advanced Engine Performance ­ Diagnosis and Testing Appendix ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX System and Component Table 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 Coil Pack Ignition Wires 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 EGR Valve DPFE Vacuum Regulator 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 VCT VCT Solenoid Wiring Camshaft Phaser Other Base Engine Transmission Advanced Engine Performance ­ Diagnosis and Testing Brakes Appendix ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING APPENDIX NOTES Advanced Engine Performance ­ Diagnosis and Testing Appendix ­ August, 2009 Appendix ­ ADVANCED ENGINE PERFORMANCE DIAG & TESTING Advanced Engine Performance ­ Diagnosis and Testing APPENDIX August, 2009 ... Activity Advanced Engine Performance ­ Diagnosis and Testing Intro ­ August, 2009 ADVANCED ENGINE PERFORMANCE DIAG & TESTING INTRODUCTION NOTES Advanced Engine Performance ­ Diagnosis and Testing... Advanced Engine Performance ­ Diagnosis and Testing 1­7 August, 2009 LESSON ONE PREREQUISITE REVIEW NOTES Advanced Engine Performance ­ Diagnosis and Testing 1­8 August, 2009 LESSON... WORKSTATIONS Advanced Engine Performance ­ Diagnosis and Testing 1­9 August, 2009 LESSON ONE WORKSTATIONS NOTES Advanced Engine Performance ­ Diagnosis and Testing ­ 10 August, 2009 LESSON ONE