Page 1 of 5 On Board Diagnostics 6.0L Diesel PCED 12/28/2010 http

Page 1 of 5 On Board Diagnostics 6.0L Diesel PCED 12/28/2010 http
On Board Diagnostics 6.0L Diesel PCED
Page 1 of 5
10e. Monitor the ICP and IPR Duty Cycle While Cranking
Note: If the IPR screen is damaged or debris is present, clean or install a new screen as necessary and retest the system. Do not install a new high pressure oil pump due to debris being
present on the screen.
Note: A complaint of engine stalls when warm followed by a crank no start indicates a high pressure oil system concern. This may be accompanied by DTC P2290 with or without DTC
P2291. Follow this procedure to isolate the cause of the concern.
Note: Higher oil temperatures are more effective to diagnose high pressure oil system leaks.
Purpose:
The purpose of this test is to determine if the injection control pressure (ICP) system can supply sufficient injection control pressure to sustain starting and to determine if oil leaks are
present in the high pressure oil system.
Data List
The diagnostic tool may reset below 9.5 volts.
Select the parameters indicated from the diagnostic tool parameter list and monitor while cranking the engine.
Parameter
Specification
ICPE
3.5 MPa (500 psi) Minimum (Engine Cranking)
ICP_VF
0.80 Volts Minimum (Engine Cranking)
IPR
30% [email protected] RPM during Engine Idle with EOT greater than 80°C (176°F)
Measurement
E
A minimum of 3.5 MPa (500 psi) is required before the injectors are enabled. No or low oil in the system, system leakage, injector O-rings, damaged IPR or high pressure pump could
cause low pressure. IPR duty cycle defaults to 14% [2.1 MPa (300 psi)] without a CKP signal.
Voltage reading below specification indicates low ICP during crank.
F
Recommended Procedure:
Connect the diagnostic tool.
Ignition ON, engine OFF.
Access and monitor the ICP, ICP_V, IPR, EOT and RPM PIDS.
If the ICP voltage is not between 0.15 and 0.35 volts with the ignition ON, engine OFF, GO to Pinpoint Test Q .
If the engine does not start, disconnect the ICP sensor connector and attempt to start the engine. If the engine starts with the ICP sensor disconnected, GO to Pinpoint Test Q .
If the engine does not start with the ICP sensor disconnected, carry out the High Pressure Oil System Air Pressure Check in this section.
If the engine starts, warm the engine up until the EOT temperature is greater than 80°C (176°F), then turn the ignition to the OFF position.
If the ICP sensor connector is disconnected, connect the ICP sensor connector.
Crank the engine and attempt to restart.
Compare the PID data to the specification and the graphs during engine start-up.
Note: A CKP signal is required before the IPR is commanded above 14%.
If the ICP does not meet the minimum specification of 3.5 MPa (500 psi), the injectors are not enabled by the PCM because of insufficient rail pressure.
If the IPR duty cycle is greater than the specification at warm idle, a leak in the high pressure oil system is suspect. Carry out the High Pressure Oil System Air Pressure Check in this
section.
If the IPR duty cycle is greater than 14%, ICP pressure should increase above 3.5 MPa (500 psi) provided that the IPR valve is not stuck open, the high pressure pump is building pressure
and there is not an injection control pressure system leak between the high pressure pump and the injectors.
Not all high injection control pressure oil system issues result in a no start condition. Intermittent hard start or slow start conditions may be the result of a small leak in the injection control
pressure system.
If the oil is leaking from the ICP system or if air is trapped in the ICP system, the IPR valve may be commanded fully closed (85% duty cycle) while the starter is engaged in an attempt to
exceed 3.5 MPa (500 psi). Monitoring RPM, IPR duty cycle, and ICP while cranking the engine, after 5 minute soak, may assist in ICP system diagnosis. ICP system leaks results in no
start, hard start, slow start or intermittent hard start conditions. The symptoms caused by small leaks are present only with excessive ICP after engine start and are more prevalent on warm
engines when the oil viscosity is lower.
Good Start Expected Response
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On Board Diagnostics 6.0L Diesel PCED
Item
Number
Page 2 of 5
Description
1
—
ICP Pressure
2
—
ICP Voltage
3
—
IPR Duty Cycle
4
—
Engine RPM
A sharp increase in IPR duty cycle followed by a steep rise in ICP pressure is expected. If the ICP and IPR response resemble the Good Start Expected Response as shown, carry out the
Injection Pressure Regulator Test in this section.
Hard Start, Stall, No Start Engine Hot, Entrapped Air or Oil Leak Expected Response
Item
Number
Description
1
—
ICP Pressure
2
—
ICP Voltage
3
—
IPR Duty Cycle
4
—
Engine RPM
If the ICP and IPR response resemble the Hard Start, Stall, No Start Engine Hot, Entrapped Air or Oil Leak Expected Response as shown, carry out the High Pressure Oil System Air
Pressure Check in this section.
No Start or Oil Leak Expected Response
Item
Number
Description
1
—
ICP Pressure
2
—
ICP Voltage
3
—
IPR Duty Cycle
4
—
Engine RPM
If the ICP and IPR response resemble the No Start or Oil Leak Expected Response as shown, carry out the High Pressure Oil System Air Pressure Check in this section.
Possible Causes:
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On Board Diagnostics 6.0L Diesel PCED
Page 3 of 5
Low base engine oil pressure or level
ICP system leak
High pressure oil branch tube adapter leak
Damaged discharge tube
Damaged high pressure oil branch tube
Leaking high pressure tube assembly male and female fitting
Damaged stand-pipe or oil supply tube
Damaged or missing stand-pipe O-ring
Damaged or missing oil supply tube O-ring
Damaged high pressure oil rail plug
Damaged or missing high pressure oil rail plug O-ring
Damaged or missing O-ring between discharge tube and high pressure pump
Damaged or missing discharge tube O-ring that fits inside high pressure pump cover
Damaged or missing high pressure pump inlet O-ring
Damaged or missing O-ring between high pressure oil rail and the injector
IPR failure
Damaged high pressure pump
Possible Leak Locations
High Pressure Oil System
Item
Number
Description
1
—
ICP Sensor
2
—
High Pressure Oil Rail Plug
3
—
High Pressure Oil Branch Tube Adapter
4
—
High Pressure Oil Branch Tube
5
—
High Pressure Stand Pipe
6
—
High Pressure Oil Rail
7
—
IPR Valve
8
—
High Pressure Pump
9
—
High Pressure Pump Cover
10
—
Injector
10f. High Pressure Oil System Air Pressure Check
Note: An air leak on the high pressure oil pump shaft lip seal is normal while carrying out this procedure. This is not an indication of a high pressure oil leak and the high pressure oil pump
should not be replaced for this condition. If the pump is suspect, carry out the High Pressure Oil Pump Test to verify the pump generates sufficient pressure to start the engine.
Note: The replacement parts may leak if all the surfaces are not oil saturated under system pressure and the seals are not correctly seated during installation.
Note: Never replace the high pressure oil pump until all high pressure oil system leaks have been repaired and the high pressure oil system is retested.
Note: A complaint of engine stalls followed by a crank no start while the engine is warm indicates a leak in the high pressure oil system. This may or may not be accompanied by DTCs
P2290 or P2291. Follow this procedure to isolate the leak.
Note: If an intermittent no start condition or delayed ICP pressure rise during restart after a 15-minute soak exists, a small leak is suspect. Refer to the Hard Start illustration of the previous
test. Remove the valve covers to inspect for leaks.
Note: Higher oil temperatures are more effective for diagnosis of high pressure oil system leaks.
Purpose:
The purpose of this test is to verify IPR valve operation and to isolate leaks in the high pressure oil system.
Recommended Procedure:
Verify the base engine oil pressure. Refer to the Workshop Manual Section 303-01C, Engine, Inspection and Verification.
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On Board Diagnostics 6.0L Diesel PCED
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If the engine will start, warm the engine until the EOT is greater than 80 °C (176 °F).
For E-series vehicles, install the Adapter, High Pressure Pump Test 303-765 or equivalent by removing the test port plug on the top of the high pressure oil pump. For F-Super Duty
and Excursion vehicles, install the Adapter, High Pressure Pump Test 303-765 or equivalent by removing the ICP sensor.
Note: It is easier to find small leaks with higher pressure.
Pressurize the high pressure oil system up to 1379 kPa (200 psi) using a suitable tool.
Key ON, engine OFF.
Using the diagnostic tool, open the IPR valve by decreasing the IPR duty cycle to 0%.
Allow oil to drain through the IPR valve for two (2) minutes. An air leak should be heard.
Using the diagnostic tool, close the IPR valve by increasing the IPR duty cycle to 85%.
Listen for an air noise change.
Use a stethoscope through the oil fill tube or left valve cover crankcase vent hole to isolate the location of the air noise change.
Cycle the IPR valve open (IPR duty cycle 0%) and closed (IPR duty cycle 85%) as needed to help isolate the location of the air noise. An air noise at the base of the high pressure oil
pump with the IPR duty cycle at 0% is normal.
If no air noise change is heard, the IPR valve may not be functioning as commanded. GO to Pinpoint Test R to diagnose IPR circuit DTCs. If no DTCs are present and the engine will
start, carry out the Injection Pressure Regulator Test in this section to verify IPR function. If the engine will not start, install a new IPR valve and repeat the air pressure check. Refer
to the Workshop Manual Section 303-04C, Fuel Charging and Controls, Fuel Injection Pressure Regulator (IPR) Valve.
If no air noise change is heard and the IPR valve has already been replaced, carry out the High Pressure Oil Pump Test in this section.
If an air noise change is heard under a valve cover, remove the cover(s) to isolate the location of the leak. Refer to the Workshop Manual Section 303-01C, Engine, Valve Cover.
Listen for leaks around the fuel injector O-Rings, stand pipes, and oil rail plugs.
If an air noise change is heard at the back of the engine, a leak at the high pressure oil branch tube adapter or the high pressure oil branch tube is suspect. Refer to the Workshop
Manual Section 303-04C, Fuel Charging and Controls, High Pressure Oil Branch Tube Adapter and High Pressure Oil Branch Tube.
After completing all repairs, verify the high pressure oil system integrity by re-pressurizing the system and listening again for any remaining leaks while cycling the IPR valve duty
cycle. Repeat the Monitor the ICP and IPR Duty Cycle While Cranking test to verify the repair.
Possible Causes:
Low base engine oil pressure or level
ICP system leak
High pressure oil branch tube adapter leak
Damaged discharge tube
Damaged high pressure oil branch tube
Leaking high pressure tube assembly male and female fitting
Damaged stand-pipe or oil supply tube
Damaged or missing stand-pipe O-ring
Damaged or missing oil supply tube O-ring
Damaged high pressure oil rail plug
Damaged or missing high pressure oil rail plug O-ring
Damaged or missing O-ring between discharge tube and high pressure pump
Damaged or missing discharge tube O-ring that fits inside high pressure pump cover
Damaged or missing high pressure pump inlet O-ring
Damaged or missing O-ring between high pressure oil rail and the injector
IPR failure
Damaged high pressure pump
Possible Leak Locations
High Pressure Oil System
Item
Number
Description
1
—
ICP Sensor
2
—
High Pressure Oil Rail Plug
3
—
High Pressure Oil Branch Tube Adapter
4
—
High Pressure Oil Branch Tube
5
—
High Pressure Stand Pipe
6
—
High Pressure Oil Rail
7
—
IPR Valve
8
—
High Pressure Pump
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On Board Diagnostics 6.0L Diesel PCED
9
—
High Pressure Pump Cover
10
—
Injector
Page 5 of 5
Tools Required:
Diagnostic tool
Stethoscope
Adapter, High Pressure Pump Test 303-765 or equivalent
10g. High Pressure Oil Pump Test
Note: Never replace the high pressure oil pump due to debris on the IPR valve screen. Remove the debris and retest the system.
Note: Higher oil temperatures are more effective for diagnosis of high pressure oil system leaks.
Note: To maintain command of the IPR valve while cranking the engine, it is necessary to disconnect the crankshaft position (CKP) sensor.
Note: Make sure the battery voltage is greater than 12.5 volts at all times throughout this procedure. High pressure oil pumps will not pass the high pressure oil pump tests if the battery
voltage drops below 12.5 volts during the procedure. The high pressure oil pump is dependent on cranking speed to generate sufficient injection control pressure. If the battery voltage
drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to the Workshop Manual Section 414-00, Charging System, Symptom Chart
to continue diagnosis.
Purpose:
The purpose of this test is to isolate the high pressure oil branch tube and the high pressure oil pump from the rest of the high pressure oil system, and to verify pump function.
Data List
The diagnostic tool may reset below 9.5 volts.
Select the parameters indicated from the diagnostic tool parameter list and monitor while cranking the engine.
Parameter
Specification
B+
11.5 volts
G
IPR
Greater than 60%
ICPG
10.5 MPa (1500 psi) minimum
Measurement
After the ICP signal has stabilized and is not changing.
No or low oil in the system, system leakage, damaged IPR or high pressure pump could cause low pressure.
Recommended Procedure:
Remove the left and right hand valve covers. Refer to the Workshop Manual Section 303-01C, Engine, Valve Cover.
Remove both upper crankcase to head tubes (stand pipes).
Remove the ICP sensor.
Install the ICP sensor into the Adapter, ICP Test 303-1163/1 and into the rear of the right high pressure oil rail where the upper stand pipe was removed.
Install the Adapter, ICP Test 303-1163/2 into the rear of the left high pressure oil rail where the upper stand pipe was removed.
Install the Adapter Cable, ICP/EBC 418-D003 (D94T-50-A) or equivalent to the existing ICP sensor connector.
Remove the FICM relay.
Disconnect the crankshaft position (CKP) sensor.
Connect the diagnostic tool.
Access and monitor the ICP, ICP_V, IPR and B+ PIDS.
Using the diagnostic tool, command the IPR duty cycle above 60%.
Crank the engine until the ICP PIDs are stable and not changing.
Compare to the specification.
If the minimum ICP specification is achieved, a leak in the high pressure oil system is suspect. Remove both oil rail plugs and head tubes (stand pipe front plugs and both stand pipes) from
the oil rails, as equipped, and inspect the seals as a possible leak source. Replace the damaged components as necessary. Refer to the Workshop Manual Section 303-01C, Engine. Carry
out the High Pressure Oil System Air Pressure Test in this section to verify the repair.
If the minimum ICP specification is not achieved, a leaking high pressure oil branch tube, high pressure oil branch tube adapter, or damaged high pressure oil pump is suspect. Remove the
pump cover and inspect for leaks. Repair any leaks and repeat the test or replace the pump if no leaks are present. Refer to the Workshop Manual Section 303-04C, Fuel Charging and
Controls, Oil Pump.
If the high pressure oil branch tube adapter is leaking, replace the fitting, reinstall the pump, and verify that the pump pressure meets the specification.
Possible Causes:
High pressure oil branch tube
High pressure oil branch tube adapter
High pressure oil pump
Tools Required:
Diagnostic tool
Adapter, ICP Test 303-1163 or equivalent
Adapter Cable, ICP/EBC 418-D003 (D94T-50-A) or equivalent
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