-NOTEIF CONCERN IS FOUND, SERVICE AS REQUIRED. IF THIS CORRECTS THE CONDITION, IT IS NOT NECESSARY TO COMPLETE THE REMAINDER OF THE DIAGNOSTIC PROCEDURE. F-Super Duty/Excursion/Econline 2004 - Late Build 6.0L Power Stroke Diesel Engine Hard Start/No Start Diagnostic Guide DEALER NAME CUSTOMER NAME MODEL YEAR P&A CODE VEHICLE SERIAL N0.(VIN) CHASSIS STYLE VEHICLE GVW ODOMETER ENGINE SERIAL NUMBER TRANSMISSION 1863 CLAIM NUMBER AMBIENT TEMP. DATE CUSTOMER CONCERNS (Please list in this box) TYPE OF SERVICE 6005E 6005E » FICMLPWR FICMVPWR RPM • Check if the WATER IN FUEL lamp has been seconds Wait to Start Lamp "on" time is independent from g/p "on" time Glow Plug Resistance • Disconnect the 4-pin connector at front of valve cover • Measure each Glow Plug resistance to Bat. ground. • Measure engine harness resistance to GPCM 8 volt min. 100 RPM minimum ICP 3.5 mPa min. (500 PSI) ICP volts .80 V min. FUEL PW 500 µS - 2 mS FICMSYNC Yes/No A - B+ - If low voltage condition is present, check battery, sample from fuel control module. • Cetane rating between 40-50 is recommended for Check 6005E7 • Verify that the fuel pump has voltage and gnd. At key on. • Measure fuel pressure at engine fuel filter housing test port with a (0-160 PSI) gauge at key on. Fuel pump runs for 20 sec. at key on and pressure falls after key off. Instrument Spec. Measurement 0-160 PSI 45 PSI min. Gauge charging system, or power/gnd circuits to the PCM. B - FICMLPWR - No/low voltage indicated could be caused by 12-way connector issue or logic power fuse. Refer to Pinpoint S for detailed 12-way conn. diagnostics C - FICMVPWR - No or low voltage indicated could be caused by 12-way connector issues. D - RPM - Low RPM can be caused by starting/charging system issues. No RPM indicated while cranking could be CMP or CKP faults. E - ICP - A minimum of 500 PSI (3.5 mPa) is required for If pressure fails low go to next step to verify no restriction 6005E8 the injectors to be enabled. No or low oil in the system, system leakage, injector O-Rings, faulty IPR, or high pressure pump could cause low pressure. • Measure restriction at fuel pump inlet. Measurement IPR duty cycle defaults to 14 % (300 PSI) w/o CKP signal. If > 6" Hg restriction, check lines between pump and fuel tank. If < 6" Hg, inspect both fuel filters. If filters are OK, check fuel regulator. If regulator and filters are OK, replace fuel pump. Glow Glow Plug Harness to Plug Number #1 #3 #5 #7 #2 #4 #6 #8 to Ground .1 to 2 ohms GPCM connector 0 to 1 ohms 140 120 Time (seconds) illuminated. • After verifying that there is fuel in the tank, drain a » » 6005E4 parameter list and monitor while cranking engine. Parameter Spec. Measurement B+ 6005E6 Spec. 6" Hg MAX (Dependent on oil temperature and altitude) Relay on time Spec. Measurement 1 to 120 B+ • Scan tool may reset below 9.5 volts. • Select the parameters indicated from the scan tool 4. Sufficient Clean Fuel 6. Electric Fuel Pump Inlet Restriction glow plug "on" time . • Turn key to run position, measure voltage ("on"time) If self test codes are retrieved, go to appropriate PPT test. 10. Scan Tool - Data List Monitoring Check 5. Electric Fuel Pump Pressure • Using the scan tool GPCTM and EOT pids, verify click in sequence 1-8. Sequence repeats three times. Injector Trouble Codes • Inspect air filter and inlet ducts. • Inspect exhaust system. • Check if air filter minder indicator has been illuminated Instrument 0-30 " Hg vacuum 6005E3 • Use scan tool. Injector DTC's will be displayed at test end. • All injectors will momentarily click, then each injector will 3. Intake/Exhaust Restriction optimum start. Method Visual comes on between 1 and 120 sec., and does not come on at all if oil temp is above 131°F. • Using a scan tool , check Continuous and KOEO DTC's. If codes are present go to Pinpoint Test AF. • Verify B+ voltage is being supplied to GPCM. Trouble Codes 9. KOEO Injector Self Test (Click Test) Check Method Visual 6005E3 • Use the scan tool. • DTC's retrieved during this test are historical faults. Diagnostic • Check for contaminants (fuel, coolant). • Correct Grade/Viscosity. • Miles/Hours on oil ,correct level. Method Visual and altitude. The Glow Plug Control Module (GPCM) Trouble Codes 8. Retrieve Continuous Trouble Codes 2. Check Engine Oil Level 6005E5 GPCM Operation • Glow Plug ON time is dependent on oil temperature Diagnostic Fuel Oil Coolant Electrical Hoses Leaks Method Check Visual COMMERCIAL 11. Glow Plug System Operation • Use scan tool. DTC's set during this test are current faults 6005E 1. Visual Engine/Chassis Inspection 6005E2 7. Perform KOEO On-Demand Self Test NOTE: A hard start/no start concern with EOT Temp. below 60°F perform step 11 first. PERSONAL 100 80 60 40 20 0 0 20 40 60 80 100 120 140 EOT (F) • Add 5 seconds to glow plug on time when above 7000 feet in altitude, but not to exceed 120 seconds. F - ICP V - Voltage reading below spec indicates low ICP during crank. G - FUEL PW - Pulse width defaults to 0 w/o CKP signal H - FICMSYNC- No sync could be caused CMP or CKP faults. » Refer to PC/ED section 4 for detailed test procedures. See PC/ED manual, Section 4 for more detail on all of the above test steps. When troubleshooting a Hard Start / No Start or Performance concern, this form must be filled out to the point of repair and returned, to receive warranty credit for diagnostic time for the parts listed below. Fuel Injectors (9E527), regulator-injection control pressure (9C968), pump assembly-high pressure oil (9A543), turbo charger assembly (6K682), fuel control module (9G282), FICM (12B599), PCM (12A650), EGR valve (9P452), CKP sensor (6C315), CMP sensor (12K073), GPCM (12B533), and Glow Plugs (12A342). Some labor operations are listed in more than one test step. Those operations include time for all occurrences and can be claimed only once. What problems were found and what repairs were performed? List Part Name, Number and Serial Number of parts replaced.
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